“UNIT PROCESS”

(Semester Project Report)

Topic: Production of Formaldehyde From Oxidation of Mehanol
Submitted to:
Ms. Rabia Sabir
Semester 5th
(Wednesday, 10-January-2018)
Group Members

1. Ahmer Sohail Uw-15-ChE-BSc-007

2. Kamran Ahmad Uw-15-ChE-Bsc-009
3. Waseem Abbas Uw-15-ChE-BSc-013
4. Uzair Hafeez Uw-15-ChE-BSc-022
5. M. Zaid Lateef Uw-15-ChE-BSc-028
6. Tehmina Habib Uw-15-ChE-BSc-036

7. M. Aqib Uw-15-ChE-BSc-040

DEPARTMENT OF CHEMICAL ENGINEERING

WAH ENGINEERING COLLEGE
 semester Project Report Unit Process

Acknowledgement:

My deepest thanks to our Unit Process lecturer Ms. Rabia Sabir, for her incessant co-operation
and suggestions towards the completion of this project report.

My deep sense of gratitude to my class fellows for their support and guidance.

Abstract:
Formaldehyde, one of the important industrial chemicals, finds its applications in polymeric
resins like phenol formaldehyde, adhesives, alkali resins for paints and coatings etc.
Manufacture of formaldehyde (as formalin) is done by oxidation of methanol, mainly by metal
oxide process involving Fe/Mo catalyst with 95-99mol% conversion of methanol.

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Table of Contents:
1 Introduction: ............................................................................................................................1
2 Literature Review: ..................................................................................................................1
2.1.1 History: .....................................................................................................................1
3 Physical Properties: .................................................................................................................2
4 Thermal Properties: .................................................................................................................2
5 Chemical Properties: ...............................................................................................................3
5.1 Decomposition: ................................................................................................................3
5.2 Polymerization: ................................................................................................................3
5.3 Reduction and Oxidation:.................................................................................................3
5.4 Addition reactions: ...........................................................................................................3
5.5 Condensation reactions: ...................................................................................................3
5.6 Resin formation: ...............................................................................................................3
6 Different Manufacturing Processes: .......................................................................................4
6.1 Silver Catalyst Process: ....................................................................................................4
6.2 Production from Methane and other Hydrocarbons gases: ..............................................4
6.3 Metal Oxide Process: .......................................................................................................4
6.3.1 Advantages of Metal oxide process: .........................................................................6
6.3.2 Drawback of Metal oxide Process: ...........................................................................7
7 Applications: ...........................................................................................................................7
8 Market Survey of Formalehyde: .............................................................................................7
9 Factors affecting location of plant: .........................................................................................8
9.1 Location with respect to marketing area: .........................................................................8
9.2 Raw materials supply: ......................................................................................................8
9.3 Transportation facilities: ..................................................................................................8
9.4 Availability of utilities: ....................................................................................................8
10 Hazards: ..................................................................................................................................8
10.1 Acute Toxicity: .............................................................................................................8
10.2 Flammability:................................................................................................................8
10.3 Skin Corrosion: .............................................................................................................8
10.4 Environmental impact and effluent disposal: ...............................................................9
11 Safety and Handling:...............................................................................................................9
11.1 Handling: ......................................................................................................................9
12 Storage And Transportation: ...................................................................................................9
13 Commercial Uses Of Formaldehyde:....................................................................................10
14 Conclusion: ...........................................................................................................................10
15 References: ............................................................................................................................11

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List of Figures:
Figure 1: Structure of formaldehyde. ..............................................................................................1

Figure 2: Process Flow Diagram of Oxydation of Methanol to Formaldehyde .............................6

List of Tables:

Table 1: Physical properties……………………..………………………………………………. 2

Table 2: Comparison of various processes and catalysts………………………..………………. 5

Table 3: Storage temperatures for commercial formaldehyde solutions……….………………. 9

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Production of Formaldehyde From

Oxidation of Mehanol
1 Introduction:
Formaldehyde is the first aliphatic aldehyde (H2C=O). At ordinary temperature pure
formaldehyde is colorless having a strong pungent, suffocating odor and is readily soluble in
water. Commercially 37 % (by weight and 40 % by volume) formaldehyde dissolved in water is
sold as formalin. Also, a small amount of 1-2 % methanol is added as a stabilizer to prevent
oxidation and polymerization.
Formaldehyde has disinfectant properties due to which it is used in soap as a disinfectant.
Formaldehyde in hydro alcoholic solution is used widely in the sterilization of surgical goods. It
is also used as a preservative in cosmetic products to increase their effectiveness against
different micro-organisms. Smaller amounts of formaldehyde are also used to make lubricants,
in leather tanning, paper coating and laminating, photographic chemicals, dyes, well-drilling
muds, and to impart wrinkle resistance to fabrics. Formaldehyde is mainly used in plywood,
paint and pharmaceutical industries.

Figure 1: Structure of formaldehyde.

2 Literature Review:
2.1.1 History:
The ease with which methanol passes on oxidation from formaldehyde to formic acid and thence
to carbon dioxide and water made the isolation of formaldehyde difficult. Therefore, aldehydes
like propionaldehyde, butyraldehyde etc. were discovered first. Formaldehyde was first prepared
by Alexander Mikhailovich Butlerov in 1859 as the product of an attempted synthesis of
methane diol (CH2 (OH) 2). The preparation was carried out by hydrolyzing methylene acetate
previously obtained by the reaction of methylene iodide with silver acetate, but he did not isolate
formaldehyde. It was done in 1869 by August Wilhelm von Hoffman by passing a methanol
vapor along with oxygen over spiral platinum catalyst. This procedure was the direct forbear of
modern methods of formaldehyde manufacture.
Today, formaldehyde is manufactured principally from methanol; limited amounts are also
produced by the oxidation of natural gas and the lower petroleum hydrocarbons. The formation
of formaldehyde by the passage of methanol and air over a heated metallic catalyst was first
believed to be a gas-phase oxidation process, as indicated in the following equation:

CH3OH + 0.5O2  HCHO + H20

Industrial production of formaldehyde became possible in 1882, when TOLLENS discovered a
method of regulating the methanol vapour: air ratio and affecting the yield of the reaction.

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In 1905, Badische Anilin and Soda-Fabrik (BASF) started to manufacture formaldehyde by a

continous process employing a crystalline catalyst. Formaldehyde output was 30 kg/day in the
form of an aqueous 30 wt% solution. The methanol required for the production of formaldehyde
was initially obtained from the timber industry by carbonizing wood. The development of high-
pressure synthesis of methanol by Badische Anilin and Soda-Fabrik (BASF) in 1925 allowed the
production of formaldehyde on a true industrial scale.
Formaldehyde is more complicated than many simple carbon compounds in that it adopts
several different forms. As a gas, formaldehyde is colorless and has a characteristic pungent,
irritating odor. Upon condensation, the gas converts to various other forms of formaldehyde
(with different chemical formulas) that are of more practical value.

3 Physical Properties:
Formaldehyde is a colorless gas at ambient temperature that has a pungent, suffocating odor. At
ordinary temperatures formaldehyde gas is readily soluble in water, alcohols and other polar
solvents.
Table 1: Physical properties

4 Thermal Properties:
Heat of formation at 25oC = -115.9 + 6.3 kJ/mol
Heat of combustion at 25oC = 561.5 kJ/mol
Heat of vapourisation at –19.2oC = 23.32 kJ/mol
Specific heat capacity at 25oC = 35.425 J/mol K
Heat of solution at 23oC
In water = 62 kJ/mol
In methanol = 62.8 kJ/mol
In 1-propanal = 59.5 kJ/mol
In 1-butanol = 62.4 kJ/mol

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Entropy at 25oC = 218.8 + 0.4 kJ/mol K

5 Chemical Properties:
Formaldehyde is one of the most reactive organic compounds known. The various chemical
properties are as follows:
5.1 Decomposition:
At 150oC formaldehyde undergoes heterogeneous decomposition to form methanol and CO2
mainly. Above 350oC it tends to decompose in to CO and H2.
5.2 Polymerization:
Gaseous formaldehyde polymerizes slowly at temperatures below 100oC, polymerization
accelerated by traces of polar impurities such as acids, alkalis or water. In water solution
formaldehyde hydrates to methylene glycol Which in turn polymerizes to polymethylene
glycols, HO (CH2O)nH, also called polyoxy methylenes.
5.3 Reduction and Oxidation:
Formaldehyde is readily reduced to methanol with hydrogen over many metal and metal oxide
catalysts. It is oxidized to formic acid or CO2 and H2O. In the presence of strong alkalis or
when heated in the presence of acids formaldehyde undergoes cannizzaro reaction with
formation of methanol and formic acid. In presence of aluminum or magnesium methylate,
paraformaldehyde reacts to form methyl formate.
5.4 Addition reactions:
The formation of sparingly water-soluble formaldehyde bisulphite is an important addition
reaction. Hydrocyanic acid reacts with formaldehyde to give glyconitrile. Formaldehyde
undergoes acid catalyzed Prins reaction in which it forms α-Hydroxymethylated adducts with
olefins. Acetylene undergoes a Reppe addition reaction with formaldehyde to form 2- butyne-1,
4- diol. Strong alkalis or calcium hydroxide convert formaldehyde to a mixture of sugars in
particular hexoses, by a multiple aldol condensation, which probably involves a glycolaldehyde
intermediate. Acetaldehyde, for example reacts with formaldehyde to give pentaerythritol, C
(CH2OH)4.
5.5 Condensation reactions:
Important condensation reactions are the reaction of formaldehyde with amino groups to give
schiff’s bases, as well as the Mannich reaction. Formaldehyde reacts with ammonia to give
hexamethylene teteramine and with ammonium chloride to give monomethylamine,
dimethylamine, or trimethylamine and formic acid, depending upon reaction conditions.
Aromatic compounds such as benzene, aniline, and toluidine combine with formaldehyde to
produce the corresponding diphenyl methanes. In the presence of hydrochloric acid and
formaldehyde, benzene is chloromethylated to form benzyl chloride. Formaldehyde reacts with
hydroxylamine, hydrazines, or semicardazide to produce formaldehyde oxime, the
corresponding hydrazones, and semicarbazone, respectively.
5.6 Resin formation:
Formaldehyde condenses with urea, melamine, urethanes, cyanamide, aromatic sulfonamides
and amines, and phenols to give wide range of resins.

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6 Different Manufacturing Processes:

6.1 Silver Catalyst Process:
The silver catalyzed reactions are operated at atmospheric pressure and very high temperatures
(600oC – 650oC) presented by the two simultaneous reactions below (1) and (2). The standard
enthalpies of these two reactions are ΔHo1 = -156 KJ and ΔHo2 = 85 KJ respectively. The first
exothermic reaction produces around 50 % -- 60 % of the total formed formaldehyde. The rest is
formed by the second endothermic reaction. These reactions are usually accompanied by some
undesired byproducts such as Carbon Monoxide (CO), Carbon Dioxide (CO2), Methyl Formate
(C2H4O2) and Formic Acid (CH2O2). The catalyst to be implemented in the reactor’s design is
silver wired gauze layers or catalyst bed of silver crystals(to be decided) with a bulk density of
1500 kg catalyst/ m3 of reactor’s volume. The catalyst is spherical with 1mm diameter and a
void fraction or porosity of 0.5. The common design of the silver catalyst is a thin shallow
catalyzing bed with a thickness of 10 to 55 mm. The capacity that the catalyst can handle could
reaches up to 135,000 ton/year. The usual life span of this catalysis three to eight months, where
the silver can be recovered. The purity of the feed flowrates is very crucial due to the fact that
the catalyst is very receptive to poisoning that would kill there action and reduces the production
to zero if traces of sulfur or a transition metal are present.
Following reactions take place

CH3OH + ½ O2  HCHO + H2O (1)

CH3OH  HCHO + H2 (2)
6.2 Production from Methane and other Hydrocarbons gases:
Another method of producing formaldehyde is through the oxidation of hydrocarbon gases. An
increase in the amount produced of formaldehyde is expected in this process. However, the
hydrocarbon formaldehyde is usually obtained as dilute solution which is not economically
concentrated accompanied by other aldehydes and by-products. However, improvements have
been effected by the use of special catalysts and better methods of control. Wheeler
demonstrated that methane is not oxidized at an appreciable rate below 600°C. The difficulty in
this method is in controlling the oxidation of reaction. Ethylene, ethane and propane oxidations
can be controlled to yield formaldehyde under similar conditions to methane. Higher
hydrocarbon gases can be oxidized at much lower temperatures than methane and ethane. These
methods have been described by Bibb also reported by Wiezevich and Frolich, who used iron,
nickel, aluminum, and other metals as catalysts and employed pressures up to 135 atmospheres.
The Cities Service Oil Company has developed a commercial process using this method.

6.3 Metal Oxide Process:

The Formox process developed by Reich hold chemicals to produce formaldehyde through
direct catalytic oxidation of methanol and some other by-products such as carbon monoxide and
dimethyl ether forms. In 1921, the oxidation of methanol to formaldehyde with vanadium
pentoxide catalyst was introduced to and patented. Then in 1933, the iron molybdenum oxide
catalyst was also patented and used till the early 1990’s. Improvements to the metal oxide
catalyst were done through the metal composition, inert carriers and preparation methods. The
first commercial plant for the production of formaldehyde using the iron molybdenum oxide

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catalyst was put into action in 1952. Unlike the silver based catalyst in this project, the iron-
molybdenum oxide catalyst makes formaldehyde from the exothermic reaction (1) entirely.
Under atmospheric pressure and 300 – 400 oC, methanol conversion inside the reactor could
reach 99% and a yield of 88% - 92%. The process begins by mixing of vaporized methanol and
air prior to entering the reactors. Inside the heat exchanger reactor, the feed is passed through the
metal oxide catalyst filled tubes where heat is removed from the exothermic reaction to the
outside of the tubes. Short tubes (1 – 1.5 m) and a shell diameter 2.5 m is the expected design of
typical reactors. The bottom product leaving the reactors is cooled and passed to the absorber.
The composition of formaldehyde in the absorber outlet is controlled by the amount of water
addition. An almost methanol-free product can be achieved on this process design. The
advantage of this process over the silver based catalyst is the absence of the distillation column
to separate unreacted methanol and formaldehyde product. It also has a life span of 12 to 18
months, larger than the sliver catalyst. However, the disadvantage of this process design is the
need for significantly large equipment to accommodate the increased flow of gases (3 times
larger) compared to the original silver catalyst process design. This increase in equipment sizing
clashes with economic prospect behind the design costs. Around 70 % production of formalin is
made by this process. The main reactions occurring are:

CH3OH + ½ O2  HCHO + H20

HCHO + ½ O2  CO + H20
The temperature inside the reactor is maintained at 250-350°C.

Table 2: Comparison of various processes available for formaldehyde production and catalysts
used in the processes.
Catalyst Processes

Oxidation process Modified iron-oxide-molybdenum oxide catalyst 280400 o C

Partial oxidation and Silver based catalyst 450-720 o C

dehydrogenation

Silver catalyst process Bayer, Chemical construction, DuPont, Chemie process,

Iron-Molebdenum catalyst Formox process

Metal oxide (The Formox process) process is conversion of 99 % and yield of 93 % is taken. Air
in excess is mixed along with recycle stream (from absorber) and fed to a blower (at 30o C).
Fresh Methanol (liquid) is pumped to a vaporizer along with the mixed stream of air. The
temperature in the vaporizer is 300o C, superheated steam is used to achieve such higher
temperatures. The mixture turns in gaseous phase and enters an isothermal reactor, essentially a
shell and tube heat exchanger. The reaction mixture enters on the tube side containing Iron-
Molebdenum catalyst. Dowtherm oil is used to maintain the temperatures and to avoid runaway
reaction. Oil coming out from shell side is cooled using boiler feed water (BFW). The products
coming out of the reactor is at 300 oC is cooled to 110 oC in another heat exchanger using

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BFW. These cooled products enter to an absorber. Process water enters from the top and through
counter-current flow and proper monitoring desired strength of formalin is attained.
In market 37-55 % formaldehyde is commercially sold and some amounts of methanol (0.5- 1.5
% wt/wt %).
6.3.1 Advantages of Metal oxide process:
• Higher conversion than silver catalyst process (up to 99 %)
• As air is taken in excess, complete conversion of methanol takes place whereas in silver
catalyst process excess of methanol is taken which prevents its complete conversion.
• As conversion is higher, unreacted compounds are formed very less and thus purification
steps become simpler.
• In Metal Oxide process, a distillation column is excluded. The reaction products are
directly fed to the absorber while in silver process distillation column and an absorber is
required to achieve desired results.

Figure 2: Process Flow Diagram of Oxydation of Methanol to Formaldehyde

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6.3.2 Drawback of Metal oxide Process:

• The major drawback is that as air is in excess quantities, there is a formation of a
very dangerous
• reaction mixture so proper care has to be taken in operating the plant. Also the
equipment sizes
• have to be increased to accommodate the compounds. The Fixed capital cost is less
than silver
• process but the Operating cost is more.

7 Applications:
Large tonnage of formaldehyde is used in the manufacturing of various thermosetting resins and
plastics: urea-formaldehyde and phenol- formaldehyde. It also finds application in production of
pentaerythritol, hexamethylene tetra mine, disinfectants, biocides, preservatives, reducing
agents, and corrosion inhibitors for oil drilling and industrial sterliants, slow release fertilizer,
textile finishers. Some major intermediates derived are chelating agents, acetal resins, 1.4-
butanediol, polyols; methylene diisocyanate. It is also used in production of sealants, herbicides,
fertilizers, coatings and pharmaceuticals. It is also sold in the solid form as paraformaldehyde or
trioxane.

8 Market Survey of Formalehyde:

In 2012, the global production capacity of formaldehyde surpassed the 46.4 million tones mark.
In the same year, the Asian-Pacific region held a share of 56 % of the world’s total
formaldehyde capacity. It was followed by Europe and North America, accounting for 22% and
15.83 % shares, respectively. China was an unrivalled leader in terms of formaldehyde capacity,
accounting for over 51% of the total capacity. Momentive Specialty Chemicals, Dynea,
Perstorp, Georgia-Pacific Corp, Celanese, Ercros S.A, Kingboard Chemical Co, DB Western
Inc, BASF AG, Sadepan Chimica, Metafrax, Yunnan Yuntianhua Co, Tomskneftekhim and
Nantong Jiangtian Chemical Co are among the top companies operating in the world
formaldehyde market.
Asia-Pacific was the largest regional producer of formaldehyde, accounting for around 55% of
the world’s total formaldehyde production volume. China ranked first in the world in terms of
formaldehyde production volume, holding a 50% share of the global output. It was followed by
the USA, Russia and Germany, accounting for 14.47%, 6.68% and 5.12% shares, respectively.
During 2010-2012, the world formaldehyde consumption was following an upward trend, and in
2012 it exceeded 40.8 million tones. In 2012, the Asian-Pacific region consumed as much
formaldehyde as Europe, North America and Latin America together. Meantime, the share of
other regions was slightly over 3%. In 2012, the production of urea- and phenol-formaldehyde
resins was the major application area of formaldehyde, accounting for over half of the world’s
total formaldehyde consumption. The unfavorable economic climate in the mature markets is
expected to have a negative influence on the worldwide formaldehyde production; though, the
latter is poised to witness positive growth in the years ahead, increasing annually by around 5%.
In 2017, the global formaldehyde production is anticipated to exceed 52 million tone.

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9 Factors affecting location of plant:

9.1 Location with respect to marketing area:
For materials that are produced in bulk quantities, such as cement, mineral acids, and fertilizers
where the cost of product per tone is relatively low and the cost of transport a significant fraction
of the sales price, the plant should be located close to the primary product. This consideration
will be less important for low volume production, high-priced products, such as pharmaceutical.
9.2 Raw materials supply:
The availability and price of suitable raw materials will often determine the site location. Plants
producing bulk chemicals are best located close to the source of major raw materials, where this
is also close to the marketing area. For the production of formaldehyde the site should be
preferably near a methanol plant.
9.3 Transportation facilities:
Transport of raw materials and products is an important factor to be considered. Transport of
products can be in any of the four modes of transport. Generally there should be at least two
modes of transportation i.e. either rail/road or rail/sea or sea/road.
9.4 Availability of utilities:
Utilities required by the plant must be easily available. For example Formaldehyde plant
requires water in large quantities which can be drawn from local water body it a lake or river.
There hould also be arrangement of steam production inside the plant so that the plant can its
own electricity and it wouldn’t be dependent on foreign bodies.

10 Hazards:
10.1 Acute Toxicity:
Formaldehyde can be highly toxic if swallowed, inhaled or absorbed though skin. Ingestion of as
little as 30 ml (1 oz.) of a solution containing 37% formaldehyde has been reported to cause
death in adults.
10.2 Flammability:
According to the Occupational Safety & Health Administration (OSHA), a 37% formaldehyde
solution is classified as a Category 4 flammable liquid with a flashpoint of 64 °C (147 °F).
Formaldehyde becomes a fire or explosion hazard in the presence of heat, flames or other
sources of ignition. Upon ignition, the chemical decomposes into carbon oxides (i.e.carbon
monoxide, carbon dioxide), which can be hazardous to humans.
10.3 Skin Corrosion:
Formaldehyde can become irritating to the eyes at low concentrations.
Irreversible damage (i.e., corneal ulceration or cloudiness of the eye surface, death of eyesurface
cells, and permanent loss of vision) can occur after a single exposure, depending on dose and
level of sensitivity. Ingestion may cause corrosive injury to the gastrointestinal mucosa, with
nausea, vomiting, pain, bleeding and perforation. Corrosive injuries are usually mostpronounced
in the pharyngeal mucosa, epiglottis, esophagus and stomach.

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10.4 Environmental impact and effluent disposal:

All industrial processes produce waste products, and full consideration must be given to the
difficulties and cost of their disposal. The disposal of toxic and harmful effluents will be covered
by the local regulations and the appropriate authorities must be consulted during the initial
survey to determine the standards that must be met. Even the slightest violations of the policies
adopted by local/state body (in this case GPCB) will lead to shut down of the plant immediately.

11 Safety and Handling:

Formaldehyde is a common sensitizing agent found in laboratories that that can trigger an
allergic reaction in normal tissue after single or repeated exposures. It is also classified as a
known human carcinogen (cancer-causing substance) by the International Agency for Research
on Cancer and as a probable human carcinogen by the U.S. Environmental Protection Agency
(EPA). Researchers must understand the hazardous properties of formaldehyde so that control
measures can be taken to minimize exposure.
11.1 Handling:
• Keep containers closed when not in use.
• Open containers slowly to allow any excess pressure to vent.
• Keep away from heat, sparks, flame, or other sources of ignition.
• Use proper electrical grounding and bonding procedures when loading, unloading, and
transferring.
• Use spark-resistant tools.

12 Storage And Transportation:

Formaldehyde solutions can be stored and transported in containers made of stainless steel,
aluminum, enamel or polyester resins. Iron containers lined with epoxide resin or plastic may
also be used, although stainless steel containers are preferred, especially for higher
formaldehyde concentrations. Unprotected vessels of iron, copper, nickel and zinc alloys must
not be used. With a decrease in temperature and/or increase in concentration, aqueous
formaldehyde solutions tend to precipitate paraformaldehyde. On other hand, as the temperature
increases, so does the tendency to form formic acid. Trace metallic impurities such as iron can
boost the rate of formation of formic acid. Therefore, an appropriate storage temperature must
be maintained. Stabilizers can also be added to prevent polymerization. Methanol is generally
used as a stabilizer. Other compounds used as a stabilizer for formaldehyde are ethanol,
propanol, urea, melamine, hydrazine hydrate and bismelamines.
Table 3: Storage temperatures for commercial formaldehyde solutions

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13 Commercial Uses Of Formaldehyde:

Formaldehyde resins are one of the major applications of formaldehyde. Some of the
derivatives are given below.
i. Urea-formaldehyde resins are produced by the controlled reaction of urea and
formaldehyde. Their major uses are as adhesives for particleboard, fiberboard and
plywood. They are also used for compression molded plastic parts, as wet-strength
additives for paper treating, and as bonders for glass fiber roofing materials.
ii. Phenol formaldehyde is produced by the condensation of phenol with formaldehyde. The
use of these resins is as an adhesive in waterproof plywood. These resins are also used
for binding glass fiber insulation.
iii. Acetylenic chemical uses of formaldehyde involve the reaction with acetylene to form
butynediol, which in turn can be converted to butanediol, butyrolactone and
pyrrolidones. Their major applications are as specialty solvent and extractive distillation
agents.
iv. Polyacetyl resins are produced from the anionic polymerization of formaldehyde. These
resins are used in plumbing materials and automobile components.
v. Pentaerythritol is formed by the reaction of formaldehyde, acetaldehyde and sodium
hydroxide. Its largest use is in the manufacture of alkyd resins for paints and other
protective coatings.
vi. Hexamethylene tetramine is formed by the reaction between formaldehyde and
ammonia. It is used as a partial replacement for phosphates as a detergent builder and as
a chelating agent.
vii. Urea-formaldehyde concentrates are used as controlled release nitrogen fertilizers.
viii. Melamine resins are thermosetting resins produced from melamine and formaldehyde
and are primarily used for surface coatings.
ix. The direct use of formaldehyde is to impart wrinkle resistance in fabrics

14 Conclusion:
The metal oxide process was selected for the manufacture of formaldehyde.
Manufacture of formaldehyde (as formalin) is done by oxidation of methanol, mainly by metal
oxide process involving Fe/Mo catalyst with 95-99mol% conversion of methanol.
Formaldehyde, one of the important industrial chemicals, finds its applications in polymeric
resins like phenol formaldehyde, adhesives, alkali resins for paints and coatings etc.

The End

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15 References:

1. Shreve’s Chemical Process Industries,Fifth edition McGrawHill,1984

2. Mccabe, Smith and Harriot - Unit Operations in Chemical Engineering, seventh

edition,McGraw Hill,2001

3. “Coulson and Richardson’s Chemical Engineering Series, volume-6

4. R. H. Perry and Don W. Green, “Perry’s Chemical Engineers’ Hand Book”, 6th and 7th

Ed., Mc-Graw Hill International edition.

5. The OSHA Standard for Formaldehyde (29 CF1910.1048)

http://www.osha.gov/SLTC/formaldehyde/

6. Formaldehyde solutions, Product Handling Guide, Celanese Chemicals.

7. “Informally speaking”, 2015, a formaldehyde magazine from JM Formox.

8. Formaldehyde- Safe Work Practices, UCONN. Division of Environmental Health &

Safety Best Management Practices.

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