Formaldehyde-Plant

Brief Overview

The plant ran for upto six consecutive months before the catalyst charge needed replacement. A high monthly production rate, (highest monthly production rate demonstrated was 4,189 MT) and a conversion factor methanol to formaldehyde above. Industrial standard proves that this plant met requirements for reliability and cost efficient operation.

Capacity:

50,000+ Metric Tons/Year
 

Built:

1987
Start up of production was in the first quarter 1988
 

Major Upgrades:

Took place in in 1997, and a new distillation column and saturator column, and replacing sections of the absorption columns (to allow for higher throughput).
 

Raw Materials:

Methanol (100%)
1.19 pounds of methanol to produce 1.0 pound of formaldehyde
 

Products Produced:

50% formaldehyde with 0.7% Methanol and 0.010 PPM Formic Acid.
Dilution to other concentrations is possible.

Documentation:

Foot print
- PLANT 60'6" X 38'6"
- BLOWERS 25' X 13'

Construction
- 304 STAINLESS STEEL
 

Major Equipment:

Number of Instrument Control loops: 243

- (2) AIR BLOWERS
- (9) PLATE EXCHANGERS
- (1) SHELL/TUBE EXCHANGER
- (18) PUMPS
- (3) VACUUM PUMPS
- (1) REACTOR
- (2) DISTILLATION COLUMNS
- (1) ABSORBER COLUMN
- (1) SATURATOR COLUMN
- (1) INTERMEDIATE VESSEL
- (1) NITROGEN VESSEL
- (1) FLAME TRAP
- (1) GAS SUPER HEATER
- (1) STEAM CYLINDER
- (1) CONDENSATE VESSEL
- (2) REBOILERS
- (1) EXCESS METHANOL VESSEL
- (1) CIRCULATION VESSEL ON VACUUM SYSTEM

 

Process Description

- Silver Catalyst based conversion of methanol
- Steam (at maximum rates the total steam consumed is approx. 12,600 KG/HR of 75# steam. 80% is used in the distillation column. The remaining is used in the super heater and the heating coil in the top of the reactor. Approximately 7600 KG/HR of the steam used was produced by the reactor).
- Cooling water (2500 M3/HR at 100% capacity)
- Instrument Gas
- Nitrogen Demineralized water
- Stream Factor: 98%