Properties of Formaldehyde PDF

Formaldehyde 2014
CONTENTS
1. Acknowledgement
2. Summary
3. Introduction
4. Properties of Formaldehyde
Physical properties
Chemical properties
Method of analysis
5. Manufacturers and economics

6. Usage and applications
7. Different processes for the manufacture of Formaldehyde
Silver Catalyst process
Oxide process
Reason for choosing silver process
8. The Silver process
Process description
Controlling Parameters
Equipment description
Stream description
9. Material Balance
General information
Material balance around different equipments
Overall material balance
10. Energy Balance
Air preheater
Energy balance around methanol before evaporation
Methanol Evaporator.
Reactor effluent gases cooling
B.TECH Project IIT (BHU) Varanasi
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11. Process design
Reactor
Absorption Column
Process design of few other equipments
12. Mechanical Design
Reactor
Absorption Column
13. Process utilities

14. Control and Instrumentation
15. Plant Safety
16. Effluent Treatment
Design of Deionizer
17. Plant location and layout
Plant location
Plant layout
18. Plant Economics

19. Bibliography
20. Bibliography
21. Nomenclature
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ACKNOWLEDGEMENT
This project is the result of the continuous guidance and encouragement of the
teachers of The Department of Chemical Engineering and Technology, IIT-BHU.
I express my deep sense of gratitude and reverence to Prof. A.S.K. Sinha, Head of
Department, Department of Chemical Engineering and Prof. P. Ahuja, Prof. KK
Singh, Dr. VL Yadav and Dr. Pradeep Kumar, Project Coordinators, for providing
us the opportunity to work in this project, for their scrupulous supervision and
being available for us to sort out any kind of trouble in the way.
It is my privilege to express indebtedness and deep sense of gratitude to all the
respected teachers of our department for their guidance throughout the duration
of the project. I also extend my gratitude to the library staff for their cooperation.
Finally, I would like to thank all my batch-mates for their unalloyed helping hands
which provided us with both material and moral support throughout the project.
Date: _____________
_______________
Shivam Singh
10102EN067
B.Tech. Part-IV
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SUMMARY OF THE PROJECT

The main objective of this project is to conduct a comprehensive study, from a
chemical point of view, that would ultimately lead to an integrated design of a
plant that produces 50 TDP of Formaldehyde.
During this study we will consider many aspects including the entire plants process
unit design, process flow diagrams, cost estimations, operation parameters,
equipment sizing, construction materials and environment/safety precautions.
This project requires the theoretical and practical application of mass transfer,
heat transfer, fluid dynamics, unit operations, reaction kinetics and process
control. There are several tasks that are crucial to the completion of the project
outlines including mass and energy balances, design of the reactor, design of heat
exchangers, design of the absorber and distillation column, energy optimization,
economic analysis and hazard analysis.
Formaldehyde (CH2O), the target product of the projects plant, is an organic
compound representing the simplest form of the aldehydes. It acts as a synthesis
baseline for many other chemical compounds including phenol formaldehyde, urea
formaldehyde and melamine resin. The most widely produced grade is formalin (37
wt. % formaldehyde in water) aqueous solution.
In this projects study, formaldehyde is to be produced through a catalytic vapourphase oxidation reaction involving methanol and oxygen according to the following
reactions:
CH3OH + 1/2O2 HCHO + H2O

CH3OH HCHO +H2
(1)
(2)
First reaction is desirable which is exothermic with a selectivity of 9, while the

second is an endothermic reaction. The projects target is to design a plant with a
capacity of 50Tons/day. This plant is to include three major units; a reactor, an
absorber and a distillation column. Also it includes pumps, compressors and heat
exchangers. All are to be designed and operated according to this production
capacity.
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PROBLEM INFORMATION
Formaldehyde is to be commercially manufactured on an industrial scale from
methanol and air in the presence of a sliver catalyst or the use of a metal oxide
catalyst. The former of these two gives a complete reaction of oxygen. However
the second type of catalyst achieves almost complete methanol conversion. The
silver catalyzed reactions are operated at atmospheric pressure and very high
temperatures (600oC 650oC) presented by the two simultaneous reactions above
(1) and (2).
The standard enthalpies of these two reactions are Ho1 = -156 KJ and Ho2 = 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 by-products such as
Carbon Monoxide (CO), Carbon Dioxide (CO2), Methyl Formate (C2H4O2) and Formic
Acid (CH2O2). Below is table of these side reactions that may take place in the
process:
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The reactor in this projects problem is to receive two streams; the first is a
mixture of fresh methanol and recycled methanol. The second stream to the
reactor mixed with the first is compressed fresh air.
The absorber receives the reactors outlet and afresh stream of water. Absorption
of 99% is expected. The distillation column receives the liquid then separates the
overhead methanol stream then recycles it back to methanol fresh feed mixing
point.
The bottom formaldehyde stream is pumped and mixed with deionized water
forming (37 wt. % formaldehyde) formalin stream which sent for storage. The
mixing is presented as follows:
The catalyst to be implemented in the reactors design is silver wired gauze layers
or catalyst bed of silver crystals. 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 usual life span of this catalyst is three to eight months, where the silver can
be recovered. The purity of the feed flow rates is very crucial due to the fact that
the catalyst is very receptive to poisoning that would kill the reaction and reduces
the production to zero if traces of sulfur or a transition metal are present.
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PHYSICAL & CHEMICAL PROPERTIES
This section includes all the major participating materials to the production plant.
These properties are based upon operating conditions of the plants design:
INITIAL BLOCK FLOW DIAGRAM
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LITERATURE REVIEW OF PRODUCTION PROCESS
Formaldehyde was discovered in 1859 by a Russian chemist named Aleksandr
Butlerov. Then in 1869, it was ultimately identified by the German chemist August
Hofmann. The manufacture of formaldehyde started in the beginnings of the
twentieth century. Between 1958 and 1968, the annual growth rate for
formaldehyde production averaged to 11.7%.
In the mid-1970s, the production was 54% of capacity. Annual growth rate of
formaldehyde was 2.7% per year from 1988 to 1997. In 1992, formaldehyde ranked
22nd among the top 50 chemicals produced in the United States. The total annual
formaldehyde capacity in 1998 was estimated by 11.3 billion pounds. Since then
and the production capacity around the globe is expanding exponentially reaching
a worlds production of 32.5 million metric tons by 2012.
Due to its relatively low costs compared to other materials, and its receptivity for
reaching high purities, formaldehyde is considered one of the most widely
demanded and manufactured materials in the world. It is also the centre of many
chemical researches and alternative manufacture methods.
This also explains the vast number of applications of this material including a
building block for other organic compounds. Formaldehyde is a very versatile
chemical and it is used in many industries, including
Antiseptic, Germicide and Fungicide

Purifier in Sugar Industry
Leather Tanning
Photograph Washing
Wood Working
Cabinet Making Industries
Glues and Adhesives
Paints
Explosives
Tissue Preservation
One of the main use of Formaldehyde is formaldehyde based resins. Most of the
formaldehyde produced in the world is used for this. Different resins are made
from formaldehyde using different substrates. One of the most popular is UreaFormaldehyde resin. Its major use is as adhesives and it is also used as a binder for
glass fibre roofing materials. We will now discuss the various productions methods
available.
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DIFFERENT PROCESSES FOR MANUFACTURE
In general two types of processes are used today.
THE SILVER CATALYST PROCESS

This process is based on partial oxidation and reduction process at 600 C on silver
grains, works with the excess of methanol above the upper explosion limit of the
mixture methanol-air.
In this process, formaldehyde is formed both by oxidation and by dehydrogenation
reactions:
+ 37 KCal/g-mol
CH3OH HCHO+H
-20.3 KCal/g-mol
.
The other minor reactions that are taking place are:

CH3OH+ O2
H2 + O2
HCHO+ O2
H2O
CO + H2O
HCHO
CO + 2 H2O -162 KCal/g-mol

-241.82 KJ/g-mol
-563.46 KJ/g-mol
CO + H2
The reaction occurs over a silver catalyst at typical conditions of (560620oC) and pressure slightly over atmosphere. Methanol conversion is 65- 75
% per pass.
THE OXIDE PROCESS
This process is based on the air oxidation of the methanol under Lean, i.e. low
methanol concentration, conditions to avoid the explosive range.
In this process the methanol is produced only by the oxidation reaction:
CH3OH + 1/2O2
HCHO + H2O
+ 37 KCal/g-mol
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A small portion of formaldehyde gets oxidized further:
HCHO+1/2O2
CO + H2O
-563.46 KJ/g-mol
The reactions occur over a mixed oxide catalyst containing molybdenum oxide and
iron oxide in the ratio 1.5 to 3. The reaction temperature is around 550o F and the
reaction is slightly over atmospheric pressure. An excess air is used to ensure a
near complete and to avoid the explosive range for methanol.
Fresh methanol is mixed with air plus recycled gas in a steam-heated vaporizer.
The effluent from this device is fed to the reactor, which is of the vertical packedtubular type. The reacting gas mixture flows downward through the tubes and
transfers its heat of reaction to a circulating heat transfer medium on the shell
side of the reactor.
The heat transfer medium in turn vaporizes the feed water to produce steam at
pressures up to about 25 atmosphere .The catalyst is granular or spherical
supported Fe/Mo and has aging characteristics such that over the period of its life
(12-15 months) the bed temperature must be increased from about 450 550 o F.
The exit gases from the reactor pass through a heat recovery exchanger, where
low pressure steam is generated, and thence to the absorption column where
water is used as the scrubber column.
The absorber can be either of the packed or the tray type. The top of the absorber
is kept at a low temperature in order to ensure adequate removal of formaldehyde
from the overhead gases. The bottom stream from the absorber represents the
final product. Because the reaction conditions promote more formic acid than do
those for the silver process, it is necessary to remove this acid by ion exchange
method.
A large portion of the absorber overhead is recycled back to the feed system. This
permits the methanol content of the reactor feed to be as high as 9.0 volume%
and causes a dilution of the gas from the absorber to the point that is not always
necessary to provide further treatment of the gas discharged from the system. For
this reason, the absorption column in this process is higher than that foe silver
catalyst process.
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REASON FOR CHOOSING SILVER CATALYST PROCESS
Studies of the two processes based on the nominal size of 100,000,000 lb/yr of 37%
formaldehyde solution showed that the silver process was far economical than the
oxide process. It was found that the capital cost of the silver process was about
20% lower than the oxide process with manufacturing cost essentially the same.
The conversion of methanol to formaldehyde in the improved silver process is
normally between 77% and 95%, while in the older it is about 55%. So, conversion is
also not a problem anymore.
The most radical improvements in the silver catalyst process have been made by
BASF and are now used commercially. A different form of the catalyst, a higher
reaction temperature, and changes in reactor feed composition have made
possible a high methanol conversion; thus, it is no longer necessary to recover
unreacted methanol. Maximum size of a production unit has also been increased by
these changes.
PROCESS DESCRIPTION OF SILVER CATALYST PROCESS

This process is based on partial oxidation and reduction process at 600 C on silver
grains, works with the excess of methanol above the upper explosion limit of the
mixture methanol-air.
In this process, formaldehyde is formed both by oxidation and by dehydrogenation
reactions:
+ 37 KCal/g-mol
CH3OH HCHO + H2
-20.3 KCal/g-mol
The other minor reactions that are taking place are:
CH3OH + O2
CO + 2 H2O
-162 KCal/g-mol
H2 + O2
H2O
-241.82 KJ/g-mol
HCHO+ O2
-563.46 KJ/g-mol
CO + H2O
HCHO
CO + H2
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The reaction occurs over a silver catalyst at typical conditions of (560-620oC) and
pressure slightly over atmosphere. Methanol conversion is 65- 75 % per pass. Since
the reactor feed is kept on the rich side of the explosive limit, all the oxygen is
converted .Unreacted methanol is separated from the reaction mixture and
recycled.
A flow diagram is shown. Fresh Methanol, which must be free from iron carbonyls
and sulphur compounds (catalyst poison), is combined with recycle methanol and
pumped through a steam-heated vaporizer. An additional heat exchanger for super
heating the methanol may also be used. Air is drawn through a filter and
compressed in a blower for feed to the process. An air washer is provided for
removal of possible catalyst poisons, and while water is usually sufficient for the
scrubbing liquid, caustic solutions are sometimes needed. The washed air is pre
heated and mixed with fresh feed methanol to give a combined feed temp. of
about 150o C. Provision is made for the addition of up to 0.75 lb steam /lb
methanol to serve as thermal ballast for reaction control.
The converter consists of a feed distribution chamber, a shallow bed of catalyst,
and a waste heat boiler. The catalyst is in the form of silver crystals or gauge and
the catalyst bed typically is 0.5-1.0 in deep and up to 6-7 ft. in diameter. To avoid
undesirable reactions it is necessary to quench the reaction product in less than
about 0.02 s.
Quenching is accomplished in a directly connected shell-and-tube heat exchanger
where the net exothermic heat of reaction is used to generate steam. Typically
the catalyst is contained in a basket resting on top of the waste heat boiler upper
tube sheet, and the gases flow downward through the tubes. These gases then pass
to the absorber where formaldehyde and methanol are recovered from bottom
liquid.
The absorber typically comprises two absorption/cooling sections with
recirculating liquid (thus providing a maximum of two theoretical stages). Either
packing or trays can be used for the absorber column. the heat of solution and the
residual sensible heat in the gases is removed by heat exchangers. Uncondensed
material from the circulating sections flows upward through a water contracting
zone for further absorption and finally leaves the top of the column and flows to a
suitable device for removing residual organics and carbon monoxide. Since the
gases have heating value, it is usually appropriate to add it to the fuel used for
steam generation boilers.
The absorber bottoms stream is pumped to the still where methanol is separated
overhead and the product formaldehyde solution is the bottom stream. The water
content of the bottoms is controlled by the amount of makeup water added at the
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top of the absorption column, and thuds there are definite upper limit for the
water content in the bottoms.
The methanol still typically is a tray column with conventional refluxing and reboiling. For reduction of the bottom to 1.0 wt% methanol, 40 bubble cap trays are
used. Residence time distribution can depend on the shifting equilibrium
composition of the liquid, and the controlled residence time characteristics of the
bubble cap tray appear advantageous. The methanol net distillate is recycled back
to the fresh feed of methanol. The recycle is done in vapor phase to conserve
energy. Also, some design employs vacuum distillation of methanol still to
discourage the formation of higher products like acetaldehyde.
If the formic acid content is higher then the distillate bottom is passed through
deionizer. Also a certain amount of product is left in distillation column for
stabilization.
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LIST OF EQUIPMENTS
The production plant contains following equipment
One (1) evaporator
One (1) air blowers (one with speed variator)
One (1) reactor with boiler tubes
One (1) gas/gas heat exchanger
Seven (7) liquid/liquid heat exchangers
One (1) condensers
One (1) packing absorption column
Two (2) tray absorption columns (bubble caps)
One (1) tray distillation column (bubble caps)
Vessels
Pumps (Sihi) doubled to secure the process
Pipes, valves, etc.
Steel : SS 316 L
Protection of electric motors : IP 55 Eexd II BT 4
CONTROLLING PARAMETERS:
1.
2.
Composition of the feed entering the evaporator: It is controlled by means

of automatic valves that control the inflow rate of methanol & water. The
composition is kept maintained at 64% methanol as it is crucial in deciding
the composition of the feed entering the reactor.
Temperature of the evaporator. It is kept around 70-72C by controlling the
rate of steam applied in the outer jacket. A temperature gage on the
evaporator indicates temperature continuously. It is important as it decides
the amount of methanol evaporating & thus the composition of the feed to
the reactor.
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3.
Pressure of the evaporator. Maintained at ~ 900 mm wc & monitored by

means of pressure gage.
4.
Level of the mixture in the evaporator. Maintained at 45% of total capacity

& monitored by a level indicator outside the evaporator. It is important as it
decides the rate of evaporation of the mixture & thus affects the yield.
5.
Composition of the feed entering the reactor. Maintained at 80% methanol &
controlled indirectly by controlling the composition of the feed entering the
evaporator. It is important as it controls the composition of formaldehyde
formed.
6.
Phase of the feed entering the reactor. No liquid should enter the reactor
dome as it could spoil the silver bed. To ensure this feed is passed through
superheater before it enters the reactor so that no condensation takes
place. In addition to this another separator is employed just before the feed
enters the reactor which filters out any liquid & send it back to the
evaporator.
7.
Temperature & pressure inside the reactor. The temperature should be

maintained at 680-700C. This is important as the reaction conditions affect
the yield.
8.
Composition of the formaldehyde leaving the absorption column. It is

maintained at 37% formaldehyde by means of controlling the flow rate of
the D.M. water added from the top of absorption column.
9.
Other gases present should be removed.
10.
Specific gravity of formaldehyde :The specific gravity of formaldehyde is

1.12.
I NFLUENCE
OF REACTION TEMPERATURE
Conversions and yields vary as a function of temperature. A light-off temperature

was observed at about 570 K. CO2 displayed a maximal yield at the relatively low
temperature of 575 K and then dropped off with temperature. The yield of
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formaldehyde increased gradually with temperature and reached a maximum at
about 923 K, which corresponds well with the commercial operation temperature.
The abrupt decrease of the formaldehyde yield above 923 K was accompanied by a
yield increase of CO and H2, suggesting a gas phase decomposition of formaldehyde
to CO and H2 at the high temperature. Formic acid appeared only in a limited
temperature region (approximately 570850 K) and could not be observed in the
high temperature region before the deactivation of catalyst
I NFLUENCE
OF RESI DENC E TIME
Methanol conversion and the selectivity to formaldehyde and hydrogen were

determined at different residence times (0.060.45 s). The higher the residence
time was, the more methanol was converted.
However, the longer residence time was not beneficial for the formaldehyde
formation: its selectivity decreased apparently under the longer residence time,
which may be partly due to the fast decomposition of formaldehyde in the gas
phase to H2 and CO at high operation temperatures. The H2 selectivity did increase
with residence time, albeit not to the extent that the formaldehyde selectivity
decreased.
I NFLUENCE
OF MOLAR RATIO OF
H 2 O / CH 3 OH
IN THE FEED
The influence of water vapor in the reaction gas on the formaldehyde selectivity
was estimated. Water vapor content was varied in the region of H 2O/CH3OH molar
ratio of 02.0. The space velocity was kept constant by varying the N2 flow
accordingly. This led to a constant CH3OH/O2 molar ratio. Each result was an
average over a 15 h lasting stationary test.
The conversion of methanol increased with the H2O/CH3OH molar ratio, however,
the selectivity to formaldehyde passed through a maximum around a H2O/CH3OH
molar ratio of about 0.75, which corresponds basically well with the abovementioned molar ratio of 0.67 in industrial formaldehyde manufacture (indicated
by the vertical dashed line). Because of the experimental error in the
formaldehyde detection, the experiment was reproduced at different feed
concentrations, supporting the conclusions reported above.
It is also show that the selectivity to CO2 decreased with the molar ratio of
H2O/CH3OH. The more water vapor was fed in the reaction gas, the less CO2 was
detected.
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SAFETY & ENVIRONMENT PRECAUTIONS
The main concern is mainly with precautions and protocols that are to be followed
while handling materials in the plant. Safety equipment includes: splash goggles,
protective coats, gloves and safety shoes are all required in dealing with these
materials regardless of the their reactivity and stability. These documentations
will include the two target materials and compounds encountered and utilized in
the plant as follows:
METHANOL
Its a light, volatile, colorless, clear and flammable liquid. It has a

distinctive sweetish smell and close to alcohol in odor and colorlessness.
Methanol is very toxic to humans if ingested. Permanent blindness is caused
if as little as 10 mL of methanol is received and 30 mL could cause death.
Even slight contact with the skin causes irritation .
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EXPOSORE
Exposure to methanol can be treated fast and efficiently. If the contact was
to the eyes or skin, flushing with water for 15 minutes would be the first
course of action. Contaminated clothing or shoes are to be removed
immediately. If the contact is much more series, use disinfectant soap, then
the contaminated skin is covered in anti-bacteria cream. Inhalation of
methanol is much more hazardous than mere contact. If breathing is
difficult, oxygen is given, if not breathing at all artificial respiration
REACTIVITY
Methanol has an explosive nature in its vapor form when in contact with
heat of fires. In the case of a fire, small ones are put out with chemical
powder only. Large fires are extinguished with alcohol foam. Due to its low
flash point, it forms an explosive mixture with air. Reaction of methanol and
Chloroform + sodium methoxide and diethyl zinc creates an explosive
mixture. It boils violently and explodes.
STORAGE
The material should be stored in cooled well-ventilated isolated areas. All

sources of ignition are to be avoided in storage areas.
FORMALIN( FORMALDEHYDE 37
WT % SOLUTION )
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This material is a highly toxic material that the ingestion of 30 ml is

reported to cause fatal accidents to adult victims. Formaldehyde ranges
from being toxic, allergenic, and carcinogenic. The occupational exposure
to formaldehyde has side effects that are dependent upon the composition
and the phase of the material. These side effects range from headaches,
watery eyes, sore throat, difficulty in breathing, poisoning and in some
extreme cases cancerous. According to the International Agency for
Research on Cancer (IARC) and the US National Toxicology Program: known
to be a human carcinogen, in the case of pure formaldehyde.
FIRE HAZARDS
Formaldehyde is flammable in the presence of sparks or open flames.
EXPOSURE
Exposure to methanol can be treated fast and efficiently. If the contact was
to the eyes or skin, flushing with water for 15 minutes would be the first
course of action. If the contact is much more series, use disinfectant soap,
then the contaminated skin is covered in anti-bacteria cream. Inhalation of
methanol is much more hazardous than mere contact. The inhalator should
be taken to a fresh air.
STORAGE AND HALDLING
Pure Formaldehyde is not stable, and concentrations of other materials
increase over time including formic acid and para formaldehyde solids. The
formic acid builds in the pure compound at a rate of 15.5 3 ppm/d at 30
oC, and at rate of 10 20 ppm/d at 65 oC. Formaldehyde is best stored at
lower temperatures to decrease the contamination levels that could affect
the products quality. Stabilizers for formaldehyde product include
hydroxypropylmethylcellulose, Methyl cellulose, ethyl cellulose, and poly
(vinyl alcohols).
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MATERIAL BALANCE
In this section, material balance over some important units has been performed
manually. The final stream tables give the composition in all streams.
Equation used
Inlet outlet + generation consumption = accumulation
as accumulation = 0
equation given above can be applied for mass balance.
M ASS
BALANCE FOR REAC TOR :
Main reactions in reactor are CH3 OH + O2

=
HCHO + H2O
CH3 OH
=
HCHO + H2
CH3 OH + O2
= CO + 2H2O
.(1)
.(2)
.(3)
ASSUMPTIONS
Total molar conversion of methanol is 81%.

60% of formaldehyde is formed via reaction 1 and remainder is formed
by reaction 2.
Conversion values for reaction 1 and 2 are obtained by using literature
survey on the formaldehyde production process.
Formaldehyde produced = 50 TPD

= (50*1000)/30 = 1666.66 Kmol/day
= 69.44 Kmol/hr (approx. 70 Kmol/hr)
From reaction 1, formaldehyde produced = (0.6*70) Kmol/hr = 42 Kmol/hr
From reaction 2, formaldehyde produced = (0.4*70) Kmol/hr = 28 Kmol/hr
By stoichiometry, kmols of methanol converted = 42+28= 70 Kmol/hr
Now, 1% of methanol total is consumed in reaction 3.
So, total methanol taken in feed stream = (70*100)/80 = 87.5 Kmol/hr
Since,the ratio of methanol to oxygen for this process in industrial reactors is 2.5.
Amount of oxygen required = 87.5/2.5 = 35 Kmol/hr
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Hence,nitrogen in feed stream = 140 Kmol/hr
Amount of methanol consumed in reaction 3 = 87.5/100 = 0.875 Kmol/hr
Total amount of water produced in reaction 1&3 = (2*0.875)+42 = 43.75 Kmol/hr
Hydrogen in exit stream = 28 Kmol/hr
Carbon monoxide in exit stream = 0.875 Kmol/hr
Amount of oxygen consumed in reaction 1&3 = (0.5*42)+0.875 = 21.875 Kmol/hr
Oxygen remaining = 35-21.875 = 13.125 Kmol/hr
Unreacted methanol = 87.5-70-.875 = 16.625 Kmol/hr
REACTOR
Components
Stream 9
(kmol/hr)
Stream 10
(kmol/hr)
Methanol
87.5
16.625
Formaldehyde
70
Water
43.75
Oxygen
35
13.125
Nitrogen
140
140
Hydrogen
28
Carbon monoxide
0.875
M ASS B ALANCE F OR A BSORBER :

As more than 90% formaldehyde is absorbed in absorption column
In inlet stream, amount of formaldehyde = 70 Kmol/hr
Fresh water is added in stream 12
= 70 Kmol/hr (approx.)
Assuming 99.9% formaldehyde is absorbed

Amount of formaldehyde in stream 14 =69.93 Kmol/hr
Methanol in exit stream = 16.625 Kmol/hr
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F ORMALIN ABSORBER
Components
Stream 11
(kmol/hr)
Stream 12
(kmol/hr)
Stream 13
(kmol/hr)
Stream 14
(kmol/hr)
Methanol
16.625
0.09
16.625
Formaldehyde
70
0.07
69.93
Water
43.75
70
0.5
113.75
Oxygen
13.125
13.120
0.005
Nitrogen
140
139.5
0.5
Hydrogen
28
27.95
0.05
Carbon monoxide
0.875
0.879
0.001
F ORMALIN D ISTILLATION C OLUMN

Components
Stream 15
(kmol/hr)
Stream 16
(kmol/hr)
Stream 17
(kmol/hr)
Methanol
16.625
16.620
0.005
Formaldehyde
69.93
0.03
69.90
Water
113.75
7.915
105.33
Oxygen
0.005
0.005
Nitrogen
0.5
0.5
Hydrogen
0.05
0.05
Carbon monoxide
0.001
0.001
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REACTOR
The reactor used in the formaldehyde plant utilizes catalyst bed and has the shell
and tube heat exchanger located in it. The catalyst bed actually lies on the shell
and tube heat exchanger. The reaction takes place on the exchanger and as can be
seen from the rate equation is actually very fast. So, the diffusion or mass transfer
resistance is not considered in the reaction.
The use is made of rate equation in terms of moles of methanol consumed.
The reactor is made up of copper material and it is about 0.992 m in diameter. It
consists of a silver bed in the form of granules weighing about 25 kg. The silver bed
has the following layers:
6 copper screens and two silver screens at bottom. 1 silver screen is kept at top.
The temperature of the catalyst bed is maintained at about 600C. The heat
evolved from the highly exothermic reaction raises the temperature to 670-700C.
Also initially passing steam in the outer jacket raises the temperature. Air required
for the reaction is provided from the air valve provided near the reactor.
Here, the methanol vapours are converted into formaldehyde by an oxidation
reaction in the presence of silver catalyst.
The methanol vapours enter the reactor dome at a temperature of about 120C.
The methanol vapours are then converted into vapours of HCHO in the reactor in
the presence of high-pressure air and the high temperature of about 700C. The
vapours go down into the steam generator and then to the condenser.
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REACTOR HEAT CALCULATIONS

I Method.
Using Heat Of Reactions for different Reactions
Reaction No.
Nature
Moles Reacted
Exothermic
8.559
37.3
Endothermc
5.706
20.3
3
4
Exothermic
Exothermic
1.538
162
Heat
1335.74
5
484.640
3
1042.46
9
5
6
Exothermic
Exothermic
0.14
0.14
51
29.8737
6
II Method.
Using Heat Of Reaction Cumulatively
heat of
reaction
Heat Of Reaction
116.6
1663.29
9
heat released
Kj/Kmol
Kj/sec
HEAT BALANCE FOR REACTOR EFFLUENT GASE

Species
Moles of Diff. Species
CH3OH
0.61
HCHO
H2
0.418
CO2
0.22
CO
0.13
H2O
0.842
O2
0.009
N2
3.118
Total
6.347
Fraction
0.09610
8
0.15755
5
0.06585
8
0.03466
2
0.02048
2
0.13266
1
0.00141
8
0.49125
6
Formulae Of Specific Heat

Used
2
3
4
Specific Heat = a+b*T+c*T +c*T +d*T
Constants
a
b
c
CH3OH
21.37
0.070843
0.00002586
HCHO
3.094
0.00387
7
-3.1E-06
H2
28.9105
0.00102
-1.476E-07
CO2
21.3655
0.06428
1
-4.1E-05
CO
29.0277
-0.00282
1.16E-
H2O
32.4721
7.96E05
1.32E-
O2
23.3768
-0.00406
1.04EPage 24
Formaldehyde 2014
-2.8497E-08
1.01E09
7.69E-10
05
05
05
9.8E-09
-4.7E-09
-4.5E-09
-3.9E-09
CO2
0.74779
3
CO
0.58055
4
O2
0.02337
7
0.00225
-5.6E-05
2.33E07
H2O
4.31878
9
1.06E05
1.76E06
-4.1E-06
1.04E08
-9.4E-11
-6E-10
-3.9E-12
After Multiplying With

Fractions
Constants
a
b
c
d
Constants
a
b
c
d
CH3OH
2.053657
0.00680801
2
2.48515E06
-2.73856E09
Total
24.6490089
0.00716214
6
9.02241E06
-5.32758E09
HCHO
0.48761
4
0.00061
1
-4.9E-07
1.58E10
H2
1.908093
0.0000673
2
-9.7416E09
5.0754E11
-1.4E-06
3.43E10
Heat
5003.74
9
791.846
1
549.567
2
-180.783
Temperature Specifications of Inlet and Outlet reactor effluent gases

Inlet
Temperature
Outlet
Temperature
deg. C
373
in K
646.13
deg. C
170
in K
443.13
in K
in K
298.13
477.57
Energy Calculations
Heat Required
Flow Rate of
Gases
(Sp.
Heat.*
(flow Rate*Sp.
Heat Required Heat.*
Cooling Medium is Water
Inlet Temperature of Water
Outlet Temperature of Steam
Specific Heat Of Water
KJ/Kmol
Moles/sec
KW
deg. C
deg. C
KJ/KgK
Total Heat To Be Quenched

KW
(Total heat is equal to latent heat and sensible heat)
6164.37
9
90.5399
6
558.122
6
25
204.44
4.184
2221.42
2
Page 25
Formaldehyde 2014
Steam
Enthalpy
Steam
Enthalpy
Btu/lb
826
1920.00
6
KJ/Kg
Flow Rate of Water is calculated by dividing the heat load by the temp. difference of
water and
the specific heat of water
Flow Rate of
0.83174
Water
Kg/sec
9
Catalyst Calculations
Reaction Rate
where
Consatnts
a
b
mole/Kg catalyst hr.

K1*Pm/(1+K2Pm)
K1& K2
are constants
P
stands for pressure in atm.
m
stands for methanol
K1
K2
8.52
10.79
3810
7040
Temp. of Reaction
in deg. C=
Consatnts
log K1
log K2
600
2.727054
4.156389
in K =
K1
K2
873.13
533.4013
14334.7
Moles of Methanol Reacted

taking conversion into consideration for 1 mol formaldehyde
moles
1.13
Moles of Methanol Reacted taking conversion into consideration /hr
moles/hr
58030.02
Mole fraction of Meyhanol in gases coming to reactor

Moles of Methanol
Total Moles of Gase
fraction
0.644
1.487
0.433087
Reactor
Page 26
Formaldehyde 2014
Conditions
Temp.
Pressure
Partial Press. Of Methanol
Amount of Catalyst Required
TABLE 7:
873.13
1.1
0.476395
Kg
K
atm
25.32358
SHELL DIA CORRELATION DATA FOR DIFFERENT ALLOYS
Page 27
Formaldehyde 2014
HEIGHT AND DIAMETER

For the gases
Inlet Temperature
Outlet Temperature
in deg. C =
in deg. C =
373
170
in K =
in K =
646.13
443.13
For the water

Inlet Temperature
Outlet Temperature
Boiling Point
Total Heat to be Removed
in deg. C =
in deg. C =
in deg. C =
KW
25
204.44
204.44
2221.421577
in K =
in K =
in K =
298.13
477.57
477.57
Area Calculation
LMTD
R
S
Correction Factor (from graph)
Corrected LMTD
Taking U equals to
Area Outside
Reqd.
deg. C
W/m^2 deg. C
m
358.05
1.39
0.318
0.92
329.406
500
13.48743846
Tuibes Used are 20 mm OD 16 mm ID and 4.88 m length

2
Area of One tube

Number of Tubes
Triangular Pitch
(1.25*OD)
Bend Radius
(3*OD)
Tube Out Limit Dia.
Heat Flux (based on estimate area)
hnb
W/m^2
mm
mm
mm
KW/m^2
0.303
44.51299822
25
60
495.3846154
164.703
or
46
25873
Heat Transfer Coeff. Calculation

Air Mixture Condensing Coeff. Is taken as 400 W/m^2
1/hnb
3.86503E-05
1/fouling factor for reactor gases
0.0001
1/heat transfer coeff. For tube wall
4.05716E-05
For Steam Side
0.0015625
1/Uo
0.001741722
Uo
574.1444765
Uo cimes out too close to assumed from value of 500 and higher so is in safe side
Page 28
Formaldehyde 2014
Max. Allowable Heat Flux

surface Tension
Liq. density
Vap. Density
Number of Tubes
N/m
Kg/m^3
Kg/m^3
0.0352
960
7.725
184
For square arrangement, Kb

Heat Flux
Factor
Actual Max. Flux
So, Its safe
Tube Sheet Layout, Bundle Dia., Db
mm
Taking shell diameter to be 2 times bundle dia.
shell dia.
mm
Liquid level from base
mm
freeboard
mm
0.41
2055.62
0.7
1438.934
496
992
800
192
Height of Catalyst Bed

Weight of Catalyst
Density of Catalyst
Kg
lb/ft^3
25.32357959
100
Volume of Catalyst
Dia of Catalyst Bed
Height of Catalyst Bed
Lemgth of Tube
Total
Kg/m^3
m^3
mm
m
m
m
1601.85
0.015808958
992
0.204519026
4.88
5.084519026
inch
39.05512
taking a favtor of 1.5 to accommodate space on top and bottom

Total Height
m
7.626778539
Page 29
Formaldehyde 2014
ABSORPTION COLUMN
ABSORBER DESIGN
One of the most common unit operations in the industry is the absorption process.
Absorption is the mechanism of transporting molecules or components of gases into
liquid phase. The component that is absorbed is called the solute and the liquid
that absorbs the solute is called the solvent. Actually, the absorption can be either
physical where the gas is removed due to its high solubility in the solvent, or
chemical where the removed gas reacts with the solvent and remains in solution.
PACKED-BED ABSORBER
The packed-bed absorbers are the most common absorbers used for gas removal.
The absorbing liquid is dispersed over the packing material, which provides a large
surface area for gas-liquid contact. Packed beds are classified according to the
relative direction of gas-to-liquid flow into two types. The first one is co-current
while the second one the counter current packed bed absorber. The most common
packed-bed absorber is the counter-current flow tower. The gas stream enters the
bottom of the tower and flows upward through the packing material and exits from
the top after passing through a mist eliminator.
Liquid is introduced at the top of the packed bed by sprays or weirs and flows
downward over the packing. In this manner, the most dilute gas contacts the least
saturated absorbing liquid and the concentration difference between the liquid
and gas phases, which is necessary or mass transfer, is reasonably constant through
the column length. The maximum (L/G) in counter-current flow is limited by
flooding, which occurs when the upward force exerted by the gas is sufficient to
prevent the liquid from flowing downward. The minimum (L/G) is fixed to ensure
that a thin liquid film covered all the packing materials.
PACKING MATERIAL
The main purpose of the packing material is to give a large surface area for mass
transfer. However, the specific packing selected depends on the corrosiveness of
the contaminants and scrubbing liquid, the size of the absorber, the static pressure
drop, and the cost. There are three common types of packing material: Mesh,
Ring, and Saddles. In our project Ceramic Berl Saddles packed was selected since it
is good liquid distribution ratio, good corrosion resistance, most common with
aqueous corrosive fluids and Saddles are beast for redistributing liquids low cost.
Also we use 2 inches diameter packing.
Page 30
Formaldehyde 2014
S I ZI N G O F P A CK E D T O W E R
ASSUMPTIONS
Some assumptions and conditions were design calculation based on:
1. G and L are representing the gas and liquid flow rates.
2. x and y are for the mole fraction of Methanol in liquid and gas respectively.
3. Assuming the column is packed with (2 Ceramic Berl_ Saddle).
PACKED TOWER DIAMETER:

Gas velocity is the main parameter affecting the size of a packed column. For
estimating flooding velocity and a minimum column diameter is to use a
generalized flooding and pressure drop correlation. One version of the flooding and
pressure drop relationship for a packed tower in the Sherwood correlation, shown
in Figure 2.
Packing diameter calculation:
The gas flow rate G= 6670.781 kg/h
The liquid flow rate L= 1549.818
Calculate the value of the abscissa
Where: L and G = mass flow rates (kg/h)

_g = density of the gas stream
_l = density of the absorbing liquid
_g = 1.605 kg/m^3
_l = 995 kg/m^3
Fp = 150m^(-1)
= 0.000797 P
gc = 9.8 m/s^2
Flow factor = 0.013706
Page 31
Formaldehyde 2014
From the figure

using flooding line,
= 0.2
Where
G' = mass flow rate of gas per unit cross-sectional area of column, g/sm2
_g = density of the gas stream
_l = density of the absorbing liquid
gc = gravitational constant,
F = packing factor given
= ratio of specific gravity of the scrubbing liquid to that of water
= viscosity of liquid
Gflooding = 9.323643
G operating = 0.55 (G flooding) = 5.128
area of packing = 0.361348 (G/Goperating)
D_packing = 0.6784m
Packing diameter, D_tower =0.8480 (D_packing*1.25)
column diameter = 1.0m (roundoff)
Page 32
Formaldehyde 2014
PACKING HEIGHT
Page 33
Formaldehyde 2014
C ALCULATING N O G
AND
Z= HOG *NOG
NOG = number of transfer units based on an overall gas-film coefficient.
HOG = height of a transfer unit based on an overall gas-film coefficient, m
yA,in = mole fraction of solute in entering gas
YA,out = mole fraction of solute in exiting gas
yA,in = 0.27778
yA,out = 0.007
Y* A,in = 0.20
Y* A,out = 0.0001
NOG = 9.2540
HOG obtained from table 15-4 in Separation Process Engineering.
For ceramic packing with size 2 inch,

HOG = 3 ft = 0.9 m
Z= HOG *NOG = 8.32 m
Z_column = Z_packing*(1+0.25)
Z_column = 10.41m
Page 34
Formaldehyde 2014
DISTILLATION COLUMN
The
problem
of
determining
the
stages
and
reflux
requirements
for
multicomponent distillations is much mo4re complex than for binary mixtures.

With a multicomponent mixture, fixing one component composition does not
uniquely determines the other component compositions and stage temperature.
Also when feed contains more than two components, it is not possible to specify
the complete composition of the top and the bottom products independently. The
separation between top and the bottom products is specified by setting limits on
two key components, between which it is deserved to make the separation.
KEY COMPONENTS
The light key will be the component that it is desired to keep out of the bottom
product, and the heavy key the component to be kept out of the top product.
Here the light component is Methanol while the heavy component being Water.
MULTICOMPONENT DISTILLATION FOR STAGE AND REFLUX

REQUIREMENT
Hengstebecks Method:
For any component i the Lewis-Sorel material balance equation and equilibrium
relation can be written in terms of individual component molar flow rates; in the
place of component composition:
vn+1,i = ln+1 + di
vn, i = Kn, i (V/L) ln,i
For the stripping section :
ln+1, i = vn, 1 + bi
vn, 1 = Kn, i (V/L) ln,i
Page 35
Formaldehyde 2014
where :
ln+1 = the liq. flow rate of any component i from the stage n,
vn, i = the vapour flow rate of any component i from the stage n,
di = the flow rate of the component i in the tops,
bi = the flow rate of the component i in the bottoms,
Kn, i = the equilibrium constant for component i at the stage n.
The subscript denotes the stripping section.
V and L being the total flow rates, assumed constant.
To reduce a multicomponent system to an equivalent binary system it is necessary
to estimate the flow rate of the key component throughout the column. This
method assumes that in a typical distillation the flow rates of each of the light
non-key components approaches a constant, limiting , rate in the rectifying
section; and the flow of each of the heavy non-key components approach limiting
flow rates in the stripping section.
Thus we have for the rectifying section :
Le = L - li
Ve = V - vi
And for the stripping section:
Le = L - li
Ve = V - vi
Where
Ve and Le are the estimated flow rates of the combined keys.
li and vi are the limiting liquid and vapour rates of the components lighter than the
keys in the rectifying section.
Li and vi are the limiting liquid and vapour rates of the components heavier than
the keys in the stripping section.
Page 36
Formaldehyde 2014
Then we have:
li = di/(i-1)
vi=li + di
vi = ibi/(LK-i)
li = vi + bi
where i = relative volatility of the component i, relative to to the heavy key HK
and LK = realtive volatility of the light key (LK), relative to the heavy key.
The equilibrium live was drawn using the relation
y= LKx / ( 1 + (LK-1)x )
where x and y refers to the liquid and vapour concentrations of the light key.
FINDING THE MINIMUM NUMBER OF STAGES

The Fenske equation have been used to estimate the minimum number of stages at
the total reflux condition. The equation is:
[ xi / xr ] = iNm [ xi / xr ]b
[ xi / xr ] = the ratio of the concentration of any component i to the concentration
of a reference component r and the suffixes b and d denote the distillate and the
bottoms respectively.
Nm = minimum number of stages at the total reflux condition.
i = average relative volatility of the component i with respect to the reference
component.
Page 37
Formaldehyde 2014
If the number of stages is known then the above equation can be used to estimate
the split of components between the top and the bottom at total reflux. Thus we
have:
di/ bi = iNm [ dr / br ]
Where di and
bi are the flow rates of the component i in the tops and the
bottoms.
And dr and br are the flow rates of the reference component in the tops and the
bottoms.
We also have di + bi = fi wher fi is the flow rate of the component i.
MINIMUM REFLUX RATIO

The equation is:
[i xi,d / (i - ] = Rm + 1
Where:
i = relative volatility of component i with respect to some reference component,
usually the heavy key.
Rm = the minimum reflux ratio.
xi,d = concentration of component i in the tops and bottoms.
root of the equation : [i xi,f / (i - ] = 1-q
where xi,f = the concentration of the component i in the feed and q depends upon
the condition of the feed.
FEED POINT LOCATION

The empirical relation used is :
log [ Nr / Ns] = 0.206log[ ( B/D)( xf,HK/ xf,LK ) (xb,LK/ xb,HK)2]
Nr = number of stages above the feed, including any partial condenser.
Page 38
Formaldehyde 2014
Ns = number of stages below the feed, including the reboiler.
B = molar flow of bottom product.
D = molar flow of top product.
xf, HK = concentrations of the heavy key in the feed
xf, LK = concentrations of the light key in the feed.
xb, LK = concentrations of the heavy key in the top product.
xb, HK = concentrations of the light key if in the bottom product.
EFFICIENCY
The overall column efficiency is obtained by O Connell correlation:
Eo = 51 32.5 log (aa)
Where a = molar average liquid velocity.
a = average molar volatility of the light key.
MATERIAL COMING FROM ABSORBER
FLOW RATE OF METHANOL

FLOW RATE OF
WATER
FLOW RATE OF FORMALDEHYDE (IN WATER)
TOTAL SOLUTION
PERCENTAGE OF FORMALDEHYDE IN WATER

PERCENTAGE OF METHANOL IN SOLUTION
MOLES/S
8.70165
MOL. WT.
32.06
G/SEC
278.9749
41.4659
14.265
64.43255
18
30.02
746.3862
428.2353
1453.5964
0.2213943
0.1350505
0.294604
0.1919205
OPERATING CONDITIONS AND VARIABLES

PRESSURE OF THE COLUMN
DEW
POINT
BUBBLE POINT
UNIT
atm.
deg C
deg C
1
66.5 deg
C
97.6 deg
C
K's VALUES AT 1 atm AND DIFFERENT TEMP.
Page 39
Formaldehyde 2014
Feed Specifications
COMPONENT
FEED
METHANOL
WATER
FORMALDEHYDE
8.70165
40.3559
14.265
8.151891
0.360068
0.014265
0.549759
40.78652
14.25074
63.32255
8.526224
55.58702
TOTAL
TOP
COMPONENT
Xd
Xb
METHANOL
WATER
FORMALDEHYDE
0.956096
0.042231
0.001673
LIGHT KEY
HEAVY KEY
METHANOL
WATER
0.00989
0.733742
0.256368
BOTTOM
Xf
0.137418
0.637307
0.225275
Page 40
Formaldehyde 2014
BUBBLE POINT CALCULATION
COMPONENTS
Xb
METHANOL
WATER
FORMALDEHYDE
0.00989
0.733742
0.256368
TEMP.
150 deg
C
Ki
Ki*Xi
3.004
2.46
1.22
TOTAL
99.9
Ki*Xi
Ki
0.02971
1.805005
0.312769
2.595
1.198
0.73
2.147484
BUBBLE POINT
0.025665
0.879023
0.187149
97.6
Ki*Xi
Ki
2.589
1.105
0.693
1.091836
0.025605
0.810785
0.177663
1.014053
97.6 deg C
DEW POINT CALCULATIONS

COMPONENTS
Xd
METHANOL
WATER
FORMALDEHYDE
0.956096
0.042231
0.001673
67.1 deg C
Ki
Xd/Ki
1.094
0.491
0.266
TOTAL
72.1
Ki
0.873945
0.086009
0.00629
1.435
0.394
0.336
0.966245
DEW POINT TEMP.
Xd/Ki
0.666269
0.107184
0.004979
66.5 deg C
Ki
Xd/Ki
1.05
0.52
0.26
0.778433
0.910568
0.081213
0.006435
0.998216
66.5 deg C
RELATIVE VOLATILITY=Ki/K FOR HEABY KEY
EQUILIBRIUM DATA
TOP
TEMP.
COMPONENTS
Ki
METHANOL
WATER
FORMALDEHYDE
Ai
1.05
0.52
0.26
EQUIL. DATA: y=Ai(LK)*x/(1+ (Ai(LK) - 1)*x)

X
0
0.1
0.2
0.3
BOTTOM
97.6
Ki
66.5
Y
0
0.195071
0.352867
0.48314
2.019231
1
0.5
2.589
1.105
0.693
AVERAGE
Ai
2.342986
1
0.627149
Ai
2.181109
1
0.563575
OPERATING LINES
TOP
X
0.958
0.209
Y
0.957699
0.32168
BOTTOM
X
Y
0
0.0133
0.2 0.328138
NO. OF STAGES DATA

Page 41
Formaldehyde 2014
0.4
0.5
0.6
0.7
0.8
0.9
1
0.592514
0.685644
0.765899
0.835776
0.897166
0.951527
1
Line: Y=X
X
Y
0
0
1
1
Sample Point calculations

EQUIL. POINT
X
Y
0.949137 0.97602
BOTTOM OPERATING LINE POINT
X
Y
0.202175 0.316474
X
0.013
0.013
0.023
0.023
0.035
0.035
0.051
0.051
0.07
0.07
0.093
0.093
0.119
0.119
Y
0.0133
0.02856
0.02856
0.048442
0.048442
0.073698
0.073698
0.104778
0.104778
0.141559
0.141559
0.18313
0.18313
0.22774
X
0.249776
0.249776
0.325915
0.325915
0.434847
0.434847
0.568191
0.568191
0.703466
0.703466
0.81692
0.81692
0.897845
0.897845
Y
0.4
0.4
0.4
0.5
0.5
0.6
0.6
0.7
0.7
0.8
0.8
0.9
0.9
1
0.147
0.147
0.175
0.175
0.202
0.202
0.25
0.22774
0.273025
0.273025
0.316474
0.316474
0.355965
0.355965
0.949137
0.949137
1
1
MOLE/S
14.25074
Ai
0.6
TOP OPERATING LINE POINT

X
Y
0.949137 0.950421
TOP
MOLE/S
8.151891
BOTTOM
Ai
2.181109
TOTAL
Li
6.901898
Vi
15.05379
6.901898
15.05379
(CHOOSING REFLUX RATIO OF 1.5 TIMES MIN. REFLUX RATIO)

EQUIL. L 57.84328
EQUIL
V.
58.21762
SLOPE OF OPERATING LINE (TOP)
EQUIL L/EQUIL V
xb
xd
xf
0.85
EQUIL. L
110
EQUIL. V
68
Vi
4.965182
Li
19.2159
4.965182
19.2159
SLOPE OF OPERATING LINE (BOTT

EQUIL
L/EQUIL V
1.605161
0.0133
0.957699
0.177376
Page 42
Formaldehyde 2014
MIN. REFLUX RATIO

MIN. NUMBER OF STAGES
NUM.
DEN.
NO.
3.22521
7
0.33867
7
9.52297
8
MIN. REFLUX RATIO

TRY
Xf
Ai
Ai*Xf
Theta
1.4
0.13741
8
2.18110
9
0.29972
4
0.38371
6
0.63730
7
0.63730
7
-1.59327
0.22527
5
0.56357
5
0.12695
9
Xf
Ai
Ai*Xf
0.13741
8
0.63730
7
2.18110
9
1
0.29972
4
0.63730
7
0.22527
5
0.56357
5
0.12695
9
Theta
Xd
0.95609
6
0.04223
1
0.00167
3
Ai
2.18110
9
1
0.56357
5
1.6
1.7
0.51577
9
0.62298
5
-1.06218
-0.91044
-0.15179
0.44
1.27
5
0.13
6
-0.1225
-0.11172
-1.36134
-0.97
-0.6689
-0.39917
1.85
1.83
1.84
1.65493
8
0.90
5
0.85364
9
0.87867
5
-0.63731
-0.75
0.09
9
0.05
7
-0.76784
-0.7587
-0.10025
-0.09946
0.02051
1
-0.08839
0.92924
6
THETA VALUE
1.5
-0.01444
1.
8
0.
8
0.
8
0.
1
0.
1
1.9
1.06622
-0.70812
-0.095
0.26310
2
1.84
Xd*Ai
THET
A
2.08535
0.04223
1
0.00094
3
TOTAL
1.84
6.11344
9
-0.05027
-0.00074
6.06243
5
Page 43
Formaldehyde 2014
5.06243
5
MIN. REFLUX RATIO
Calculations For Entering the feed

Xb(LK)
Xd(HK)
Xf(LK)
Xf(HK)
Method Employed is Kirkbride equation
Total Bottom
product
Total Distillate product
log (Nr/Ns)
Nr/Ns
Total Number of stages
Total Number of stages excluding Reboiler and Condenser
Ns
so the feed should enter at the plate
From the graph it comes out to be
Approximately equal
0.00989
0.04223
1
0.13741
8
0.63730
7
55.5870
2
8.52622
4
0.04524
8
1.1098
18
17
8.05763
6
8
9
Page 44
Formaldehyde 2014
FIGURE 9: Equilibrium data and number of Stages

1
0.9
mole fraction of Formaldehyde in Methanol
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
0.2
0.4
0.6
0.8
mole fraction of Formaldehyde in Water
Page 45
Formaldehyde 2014
Dia And Height Calculation

Number Of Stages:
Slope of Top Operating Line
Slope of Bottom Operating Line
Top Composition (Essentially Methanol)
Bottom Composition (Essentially Formalin)
Reflux Ratio
18
0.85
1.605161
96
26
7.593
% Formaldehyde
Flow Rate in gm/sec

Flow Rate in moles/sec
Flow Rate in Kg/hr
1453.596
64.43255
5232.947
Top Product
Vapor Rate at Top
Bottom Product
965.7327
8298.541
4267.214
Material Balance Gives:

Vm at bottom
Liq. Flow Rate at Bottom
7051.367
4392.934
Column Efficiency in %
60
28.33333
Real Stages
Assuming 100 mm water Pressure Drop per Plate
Column pressure Drop
Top Pressure Drop
Bottom pressure
Base Densities:
Liquid Density
Vapor Density
Surface Tension
(All in Pa)
28449
101325
129774
1111
0.695
0.018
Top Densities:
Liquid Density
Vapor Density
Surface Tension
Tray Spacing taken to be 0.5 m
Column Diameter:
F(LV) at Bottom
F(LV) at Top
0.040147
0.032117
Correction For Surface Tension

At Bottom
0.078332
or 29
792
1.13073
0.0469
K1
Page 46
0.08
0.08
Formaldehyde 2014
At Top
Base Velocity:
Top Velocity:
0.094868
3.130886
2.508947
in m/sec
in m/sec
Designing Done for 85 % flooding

Base Velocity:
in m/sec
Top Velocity:
in m/sec
2.66125
3
2.13260
5
Maximum Flow Rate

Base
m^ 3/sec
Top
m^ 3/sec
2.81829
2
2.03863
9
Net Area Reqd.

Base
m^ 2
Top
m^ 2
1.05900
9
0.95593
9
Downcomer Area Taken as 12 % of total Area

Base
m^ 2
Top
m^ 2
1.20342
1.08629
4
Column Diameter:
Base
Top
Height Claculation:
Totla Number of Trays
Crude Hright for Column
(number of stages * tray spacing)
1.23775
7
1.17598
2
Choosing 30 % more space for free space at top and bottom

Additional Hright
m
Total height
m
Or after rounding off, Total height
29
14.5
4.35
18.85
19
Page 47
Formaldehyde 2014
Number of stages after taking efficiency into consideration
Top Temperature in C
Bottom Temperature in C
Average Temperature in C
Vicosities:
Methanol
Water
Formaldehyde
Molar Average Viscosity in Feed
Average viscosity for Light Key
so Efficiency from graph
so Number of stages is still
Number of Stages (Real, 60% column efficiency)
66.5
97.6
82.05
0.29
0.35
1.87
0.684
2.18110
9
almost 100%
18
29
Page 48
Formaldehyde 2014
CONDENSER
Shell and tube exchangers can be effectively used as condensers which are
employed more preferably than direct contact condensers. There are 4 types of
condenser configurations available. They are :
1. Horizontal, with condensation in shell and cooling medium in tubes.
2. Horizontal, with condensation in tubes and cooling medium in shell.
3. Vertical, with condensation in shell and cooling medium in tubes.
4. Vertical, with condensation in tubes and cooling medium in shell.
Of which horizontal shell side and vertical tube side are the most commonly used
ones. A horizontal exchanger with condensation in tubes is rarely used as a process
condensers but is the usual arrangement for heaters and vaporizers using
condensing steam as the heating medium.
In the formaldehyde process, the condenser used is total condenser. The outlet
stream is condensed methanol which is recycled back to the fresh feed. Thus the
overall economy of the process increases. The reflux ratio of 1.5 times the
minimum is utilized in the distillation column which gives the amount of methanol
recycled and produced.
Condenser Mainly has Methanol Condensing in it With Small Amount of

Water Present in it
COMPONENT
TOP
METHANOL
WATER
FORMALDEHYDE
TOTAL
Xd
8.151891
0.360068
0.014265
Feed
63.32255
0.956096
0.042231
0.001673
8.526224
Average Molecular Weight of Vapors

(For Simplicity Taken As 96 % Methanol And 4% Water)
Condensing Temp. of Methanol

(Taken fom J. H. Perry)
31.5
64 deg. C
Page 49
Formaldehyde 2014
Actual Condensing Temp. of Methanol
(Design Temp. of Condnsation)
Inlet Temp. of Methanol Vapors
Cooling Medium
Water Inlet Temp.
Water Inlet Temp.
deg. C
50
deg. C
66.5
Cold Water
(max.)
Enthalpy of Sat. Vap.

Enthalpy of Sat.
Liq.
deg. C
deg. C
25
35
KJ/Kg
1492.1
KJ/Kg
391.7
Flow Rate of Methanol

Heat transferred from Vapor
KW
(Flow rate of methanol * (Enthalpy of Sat. Vap.- Enthalpy of Sat. Liquid)
965.7326988
295.1922949
Cooling Water Flow

Kg/sec
(Heat reqd. for condensatio/(temp. diff.* sp. Heat))
7.062016626
Assumed Overall Coefficient
LMTD Calculations:
Temp. correction factor
LMTD Temp.
Correction Factor
Corrected LMTD
W/m^2 deg. C
R
S
deg. C
Ft
Ft*LMTD
500
1.65
0.240964
28.12493
0.96
26.99993
Choosing 20 mm O.D. 16.8 mm I.D. 4.88 m (16 ft) long brass tubes
Tube ID
mm
16.8
Tube OD
mm
20
Tube Length
m
4.88
Trial Area
( Heat Required/(Assumed U* LMTD))
m^2
21.86615
Page 50
Formaldehyde 2014
Number of Tubes
(Area of heat trensfer reqd./ area of one tube)
Employing One Shell Two Tube Pass

Triangular Pitch since fouling is very less
Tube Bundle Dia., Db

Number of Tubes in Center
71.30441
72
mm
25
mm
260.7226
10.4289
Shell side Heat Tranfer Coeff. Calculation

Assumed Shell-side Coefficient
W/m^2 deg. C
From the Chart given in Coulson Richardson, Vol. 6
Mean Temp.
Shell-side
Tube-side
(H51-Tw)
Tw
deg. C
deg. C
deg. C
3500
58.25
30
4.035714
54.21429
Mean Condensate Temp.

Viscosity
Liq. Density
Vap. Density
K (thermal conductivity)
Load
where
Nt
L
wc
Nr = 2*Number of tubes in center/3

average number of tubes in the bundle
or
deg. C
mN
s/m^2
Kg/m^3
Kg/m^3
W/m deg. C
Kg/sm
56.23214
0.38
792
1.13073
0.192
0.000763
total number of tubes in the bundle

tube length
total condensate
flow
6.952603
Page 51
Formaldehyde 2014
Heat Transfer Coeff.
W/m^2 deg. C
3652.902
So, Heat Transfer Coeff. Came quite close
Tube side Heat Transfer coeff.

Tube-Side Coefficient.
Tube Cross Sectional Area
Density of Water
Tube Velocity
Tube-Side heat trasf.Coeft..
W/m^2 deg. C
m^2
Kg/m^3
m/sec
W/m^2 deg. C
Over-All Heat Transfer Coeff.
W/m^2 deg. C
0.003991
994
1.780349
7389.688
Fouling Factors for Both side

W/m^2 deg. C
2000
Conductive Heat Transf. Coeff.of Tubes
50
1/U
0.001565
1/U= outer dia*inner dia./tube side coeff. + 1/shell side coeff. +1/foulingcoeff.
...+ outer dia./(fouling*inner dia) + outer dia.*LN(outer dia./innerdia)/(2*tube thermal conductivity)
(inverse of
1/U)
638.9926
Since, U comes out close to assumed heat transfer coeff. Of 500

And the deviation is on positive side. We can take the arrangement
of shell and tube condenser as above to be satisfactory
Page 52
Formaldehyde 2014
REBOILERS
Reboilers are used with distillation columns to vaporize a fraction of bottom
product whereas in a vaporizer essentially all feed is vaporized thus in this way
they differ from a vaporized.
TYPES OF REBOILERS
Forced circulation: pump is required for this kind of reboiler. It is used

essentially for reboiling viscous and fouling fluids.
Thermosyphon natural circulation reboiler: it can be horizontal or vertical.

Liquid circulation is maintained by the difference and density between twophase mixture of vapour and liquid. A disengagement vessel will be required
for this reboiler.
Cattle type reboiler: Boiling takes place on tubes immersed in a pool of

liquid. There no circulation of liquid through exchanger and they are not
suitable for fouling materials and have a high residence time.
SELECTION OF REBOILER
In our case, Thermosyphon reboiler is used. In this type, the heat available in
bottom feed is utilized. This type of reboiler requires a minimum head so that it
can take advantage of density difference thus the support of distillation column
and reboiler needs to be elevated and the cost increases. But the higher cost is
offset by the economic usage of available heat which otherwise would have been
lost.
Page 53
Formaldehyde 2014
BOILER DESIGN
COMPONENT
FEED
TOP
BOTTOM
METHANOL
WATER
FORMALDEHYDE
8.70165
40.3559
14.265
8.151891
0.360068
0.014265
0.549759
40.78652
14.25074
TOTAL
63.32255
8.526224
55.58702
COMPONENT
METHANOL
WATER
FORMALDEHYDE
LIGHT KEY
HEAVY KEY
Xd
0.956096
0.042231
0.001673
Xb
0.00989
0.733742
0.256368
Xf
0.137418
0.637307
0.225275
METHANOL
WATER
Vaporisation Rate Reqd.
Kg/hr
Boiling Point of Formalin solution

Steam available at Pressure
Temp.
(Ref: McCabe Smith, Appendix 8)
deg. C
atm.
deg. C
99.7
2.85
132.22
Latent Heat of Vaporisation

(Ref: McCabe Smith, Appendix 3)
KJ/Kmol
30176
Critical
Temperature
(Ref: J. H. Perry)
Mean Overall diff.
T
Reduced Temp.
(Boiling Point in K/Critical Temp.)
Molecular Weight
From Fig. Heat Flux

Heat Load
7051.367
deg. C
586.0482
deg. C
deg. C
32.52
0.635955
21.152
W/m^2 deg C
KW
42000
592.8398
Page 54
Formaldehyde 2014
(Flow Rate*Latent Heat of Vaporisation/(3600*Boiling Point)
Area Required
(Heat Load/ Heat Flux)
m^2
14.11523
Choosing 20 mm O.D. 16.8 mm I.D. 4.88 m (16 ft) long brass tubes
Tube ID
mm
Tube OD
mm
Tube Length
m
Area of one tube
m^2
Number of Tubes reqd.
46.58493
Calculation for Bundle Dia.
207.77
A dixed tube sheet can be used for a thermosyphon reboiler

(from fig. 12.10, diametrical clearence)
Diametrical Clearence
mm
Shell Inside dia.
( Bundle dia. + diametrical clearence )
16.8
20
4.88
0.303
mm
14
221.77
Page 55
Formaldehyde 2014
PHYSICAL DESIGNING OF SOME OTHER EQUIPMENTS
The plant has beside the major equipments like reactor, distillation column and
absorber column several other heat tansfer and mass transfer equipments. For
example; heat exchangers are used extensively in the chemical plants. These heat
exchangers are required for utilising the heat in the effluent gases. Furnaces are
there to provide extra heat needed and which is not available in the process
streams. Likewise, pumps, compressors and blowers are used to transfer solid,
liquid and gases. A sample designing of some them used in the formaldehyde plant
is given here.
PUMPS
Total moles of methanol( feed + recycle) for 1 mol of formaldehyde = 1.74
HCHO production rate = 14.265 mols / sec
Hence methanol reqd. = 1.74 * 14.265 = 24.8215 mol / sec
Viscosity of methanol at 35o C = .48 Cp
(reference J.H.Perry , nomograph for viscosity of liquids )
weight of methanol = 24. 8215 * 32.06 = 7.96 Kg / sec
Density of methanol = 1015 Kg/m3
Flow rate of methanol = 0.808 * 10-3 m3/sec
S ELECTION
OF PUMP
Using graph between flow rate on x axis and pressure required on y axis from
Donald R Woods suitable pump is Centrifugal Pump.
Page 56
Formaldehyde 2014
Head to be developed = 35- 14.7 = 20.3 Psia. = 1.05 m of water.

Single stage Centrifugal pump is sufficient.
Power required ( reference : fig 2-29 , page 2-27 , D R Woods)
Liquid flow rate = 0.808 L/Sec
Head = 1.05 m of water.
Now assuming 60% efficiency of the pump ,
The pump gives 0.1 KW for water so for methanol=0.1 * 1.015=0.1015 KW
Pipe size selection
Choosing from pump-heat exchanger combination pipe size available from [ fig 230 , Page 2-28 ,D.R. Woods]
Pipe size available = 2.5 cm.
Velocity of methanol = v * 3.142 * d2 /4 = 0.808 L/sec
Hence v = 1.64 m/sec
Pressure loss
P / g = 4f( L/ D)* (<v>2 / 2g)
thus P/ 100m = 4 * 0.009 * 1015 * 100 * 1.642 / ( 2.5 * 10-2 ) = 393 KPa / 100 m
Reynolds no. = d v / =2.5 * 10-2 * 1.64 * 1015 / (0.48 * 10-3) = 86697.92
Material
K /D
Page 57
Formaldehyde 2014
Cast Iron
0.00085
Wrought Iron
0.00015
0.0016
0.000292
(reference : Mc Cabe Smith , Page 101 , ed 4
th
0.009
0.0038
NPSH required = (pressures supplied at flange)- ( vapour pressure of liquid at

pumping temperature + friction losses )
Vapour pressure of methanol at 35 o C ( 308 K)
Ln P = 7.209 (1582.30 / ( T 33.45))
Ln P = 7.209 (1582.30 / ( 308 33.45))
= 1.445
thus P = 27.91 KPa
NPSH required = 101.325 27.91 KPa = 83.525 KPa = 0.64 m water head
BLOWER
Air required per mol of HCHO = 4.019 moles.
100 tonnes/ day of HCHO means
(100 * 103 * 103 * 0.37 ) / ( 30.02 * 24 * 3600) = 14.265 moles/ sec
So air required = 57.332 moles
Taking air to be an ideal gas amd air entering at the room temp. and at a pressure
of 14.7 psia.
Volume of air required per sec
= 57.332 * 22.4 * 10-3 = 1.284 m3 / sec = 1284 dm3/ sec
Pressure at which air is reached = 35 psia.
P= 35 14.7 psia = 20.3 psia.=139.925 KPa.
Page 58
Formaldehyde 2014
Here multi stage blower have to be used.

Efficiency is taken to be 80% for compressors and 60% for fans.
Compressors used here are of 250 KW
At inlet pressure ( 14.7 psia or 100 KPa) so pipe would be 10 cm in dia. [ fig 2-13]
Velocity = 20m/sec
At outlet pressure ( 35 psia) so the fig [ fig 2-13] cannot be used.
1= MP1/RT
2= MP2/RT
Thus we have d2= d1 ( P1 / P2)1/2
hence d2 = 10 (35 / 14.7) cm = 15.43 cm.
PRESSURE DROP
P / g = 4f( L/ D)* (<v>2 / 2g)
thus P/ L = 4* 0.0032 * 20 * 20 * 1.1614 /( 2 * 50 * 10-2)
= 7.06 KPa / 100 m.
Reynolds no. = d1 v 1 /
d1 = 10 * 10-2 m
v = 20 m /sec.
= 0.185 * 10-4 pa
(reference : J.H. Perry , Table 2.229)
Re = 10 * 10-2 * 20 * 1.1614 / ( 0.185 * 10-4) = 1.256 * 105
(reference : Mc Cabe Smith , Page 101 , ed 4th )
Material
K /D
Page 59
Formaldehyde 2014
Cast Iron
0.00085
0.0016
Wrought Iron
0.00015
0.000292
0.0062
0.0038
VALVE DESIGN
Valves are used to control pressure condition of flowing streams. Valves and vents
are needed as the as like in the reactor, the reactions might be occuring at the
high pressure. But the downstream gases, in this case going to absorber needs to
be brought down in the pressure.
Incoming Pressure = 25 psia.
Outgoing Pressure = 16.17 psia
Pressure equation is:
P = k * 0.6 * * v2/(1.22 *10)
where
k = length factor for the valves

= density of fluid
v = velocity of fluid
= density of gases = M * P/(R * T)

where
M = Avg. Mol. Wt.

P = pressure of gases
R = Universal Gas Constant
T = Temp.
= 25.68 * 25 / 14.7
0.0821 * 616
= 0.864 Kg/m3
P = (25 16.17)/14.7 *76
Page 60
Formaldehyde 2014
this gives k = P * 1.22 *10/( 0.6 * * v2 )
k = 6.08
so, we can use globe valve
equivalent L/D = 320
Similarly, other valves can be designed as given.
AIR FILTER
Air-Filter Types Air filters may be broadly divided into two classes:
(1) Panel, or unit, filters;
(2) Automatic, or continuous, filters.
Panel filters are constructed in units of convenient size (commonly 20- by 20-in or
24- by 24-in face area) to facilitate installation, maintenance, and cleaning. Each
unit consists of a cleanable or replaceable cell or filter pad in a substantial frame
that may be bolted to the frames of similar units to form an airtight partition
between the source of the dusty air and the destination of the cleaned air. Panel
filters may use either viscous or dry filter media. Viscous filters are so called
because the filter medium is coated with a tacky liquid of high viscosity (e.g.,
mineral oil and adhesives) to retain the dust. The filter pad consists of an assembly
of coarse fibers (now usually metal, glass, or plastic). Because the fibers are
coarse and the media are highly porous, resistance to air flow is low and high
filtration velocities can be used. Dry filters are usually deeper than viscous filters.
The dry filter media use finer fibers and have much smaller pores than the viscous
media and need not rely on an oil coating to retain collected dust.
Automatic filters are made with either viscous-coated or dry filter media.
However, the cleaning or disposal of the loaded medium is essentially continuous
Page 61
Formaldehyde 2014
and automatic. In most such devices the air passes horizontally through a movable
filter curtain.
HEPA (HIGH-EFFICIENCY PARTICULATE AIR) FILTERS

These were originally developed for nuclear and military applications but are now
widely used and are manufactured by numerous companies. By definition, an HEPA
filter is a throwaway, extended-medium dry-type filter having (1) a minimum
particle-removal efficiency of not less than 99.97 percent for 0.3-mm particles, (2)
a maximum resistance, when clean, of 1.0 in water when operated at rated airflow capacity, and (3) a rigid casing extending the full depth of the medium
(Burchsted et al., op. cit.). The filter medium is a paper made of submicrometer
glass fibers in a matrix of larger-diameter (1- to 4-mm) glass fibers. An organic
binder is added during the papermaking process to hold the fibers and give the
paper added tensile strength. Filter units are made in several
standard sizes. Air filters used in nuclear facilities as prefilters and buildingsupply
air filters are classified as shown in Table 17-10.
TABLE 9.
Other table presents the relative performance of Group I, II, and III filters with
respect to airflow capacity, resistance, and dust holding capacity. The dustholding capacities correspond to the manufacturers recommended maximum
Page 62
Formaldehyde 2014
allowable increases in airflow resistance. The values for dust-holding capacity are
based on tests with a synthetic dust and hence are relative. The actual dustholding capacity in a specific application will depend on the characteristics of the
dust encountered. In some instances it may be appropriate to use two or more
stages of precleaning in air-filter systems to achieve a desired combination of
operating life and efficiency. In very dusty locations, inertial devices such as
multiple small cyclones may be used as first-stage separators.
Table 10 : Air Flow Capacities and Resistance Holding Capacity for different
Filters
Table 11 : Removal Efficiency of different Filters
Page 63
Formaldehyde 2014
MECHANICAL DESIGN
REACTOR MECHANICAL DESIGN

Reactor Data
Diameter = 1.2 m
Height
=6m
Top and Bottom: Toro spherical head

Operating Pressure of Reactor: 1.1 atm.
Operating Temperature of Reactor: 873 K
Thickness of Shell, t= p*d/(2*f*E) + c

Where c= corrosion allowance
E= 13.37 Kg/m2
t = 16.8*1.01325*10 5/(2*13.37*10 6* 0.85)=7.4 mm

c= 3 mm
hence t= 10mm
Torospherical head
figure 11: Torospherical Head
(Ri- ri)2 (Ri-hi)2 = (R-ri)

or Ri-hi = ((Ri - R)- (Ri + R-2ri))1/2
b
S
f
Considering : Ri / D = 0.8
Ri
R
Or Ri = 0.8 * 1200 mm = 960 mm

Also ri / D = 0.1
Or ri = 0.1 * 1200 mm = 120mm
hi = 960 ((960 496 )( 960+496-2*120))1/2 = 223.74 mm
zi = hi / 3 = 223.24 / 3 = 74.58mm
now, the volume of the head is given by
vh = (D2L / 4 + 0.7D3/2)
Page 64
Formaldehyde 2014
where D is 1200 mm
l= 74.58 mm
hence vh = 0.4 m3
Thickness of head
t=p * w /(2fE-0.2* p) + c
where t = thickness of head.
P = pressure inside vessel.
W = stress intensification factor for torospherical dished head.
c= corrosion allowance
w = * ( 3 + ( rc / ri)1/2)
w = * ( 3 + ( 960 /120)1/2) = 1.46
p= 1.68 kg/mm2
hence t = 1.68 * 960 * 1.46 / (2 * 13.37 * 0.85 0.2 * 1.68) = 2.14 mm
but the minimum thickness has to be taken = 3 mm
corossion allowance = 3 mm
hence total thickness = 6 mm
Design of flat head

p= 1.1 * 101.325 / 1000. = 0.1114 kg/mm2
t = D * (p / fall)0.5
=0.05 mm
but the minimum thickness has to be taken = 3 mm
corrosion allowance = 3 mm
Hence total thickness = 6 mm
2 openings are to be provided for water inlet and steam outlet.
And 2 openings are to be provided for inlet gases and outlet reactor effluent stream.
Velocity of gases maintained :
Velocity in tube = tube length / residence time = 6 / 0.02 = 300 m/ sec.
Page 65
Formaldehyde 2014
Area of tubes * vt = area of shell * vs
vs = vt * (Dt / Ds )2
vs = 224 * ( 16 / 992)2 = 0.56 m/sec
But due to some velocity head loss and since the velocity of gases before entering the
reactor was 2 m/sec it is not changed and kept as it is. Also high velocity in the shell
means correspondingly high velocity in tubes so the mean residence time will further
decrease from 0.02 sec to some lower value which is highly desirable because it will
reduce the amount of formic acid formed.
NOZZLE DESIGN
Velocity of gases = 2 m /sec
Volumetric flow rate of the mixture = 2.131 mol/sec per mol of formaldehyde.
= 33.37 litre/ sec mol = 71.11 * 10-3 m3/sec
Calculation of diameter
*D2 * v / 4 = Volumetric flow rate of the mixture.
D = ( 71.11 * 10-3 * 14.265 * 4 / ( 2 * 3.142))0.5 = 80.45 cm.
Optimum diameter for nozzle:
-
dopt = 282 * G0.52 * 0.37

where G = flow rate in kg /sec
=density of gas
on calculations dopt = 267 mm
choosing dia of 270 mm
Area to be compensated = 6 * 270 = 1620 mm2
Taking h2 = 1.5 * dn = 1.5 * 270 = 405 mm
Area of compensation provided by portion of nozzle outside reactor
= 2 * 202.5 (tn -1.75 - 3)
Area of compensation provided by portion of nozzle inside reactor
= 2 * 202.5 (tn 3)
Area of compensation adjacent shell material = 270 * (6-1.75-3)
Page 66
Formaldehyde 2014
Equating above areas of compensation to total area of compensation
2 * 202.5 (tn -1.75 - 3) + 2 * 202.5 (tn 3) + 270 * (6-1.75-3) = 1620
on calculations tn = 4.86 mm ( taken as 5mm)
Similarly the design was done for the liquid water inlet. Whose diameter comes out to be 80
mm.
Support Design
(Reference Process Equipment Design 2nd Edition by M.V. Joshi Page 367).
Diameter of vessel = 1.2 m
Height of vessel = 6 m
thickness of vessel = 10 mm (shell)
For head
thickness = 6 mm
Straight portion of head = 0.5m
effective height of head = .4123m
density of carbon steel = PS = .286 lb/ Cu-1n
= .286 (12)3 lb/ cu ft
= 494 .208 lb/ cu-ft
= 16.018 494 208
= 7916 K S /m3
Di = 1.2m D0 = 1.22 cm, H = 9.6 m
weight of shell =
=
D
4
1.002
4
Di H Ps
2
.992 7.36 7916

2
= 915 .3 kgf
weight of head =
D
4
Di hs p s
2
2
3
3
r0 r1 ps
3
1.002
.992 0.5 7916

2
Page 67
Formaldehyde 2014
2
3
3
.1072 .0992 7916
3
=63 Kgf
weight of liquid (EDC) filled in reactor
height of liquid
weight
D 4 p
4
0.992 2 4
1.000 10 3 4.88 0.4
= 4526 Kgf
Total weight of Reactor
= 915.3 + 63 + 4526
5500 kgf (indudiny wt. of nozzle & other aceessories)
Total Weight = Weight of Vessel + Attachments + Catalyst Weight

Since this weight is much appreciable so lug support will not work here, so we go for
skirt support.
Skirt Support for vertical cylindrical vessel

Diameter of vessel = 0.992 m = 992 mm
Height of vessel = 7.36m = 7360 mm
Weight of vessel + attachments = 5000 kg.
Diameter of skirt (straight) = 992 mm
Height of skirt
= 1.0 m
Wind pressure
= 128.5 kg/m2
Skirt
Stress due to dead weight
f0
(draw diagram on page 367 M.V. Joshi)
w
D0 k t s k
w dead wt. of vessel contents and attachments

D0k = Outside diameter of skirt
Page 68
Formaldehyde 2014
tsk = thickness of skirt
f0
5525
17 .73
kg / cm 2
99 .2 t s k
ts k
Stress due to wind load
fwb
4 Mw
D0 k 2 t s k
M Plw
H
Z
(for H 20m)
Plw kp1 h1 D0
up to 20m height
P1 = wind pressure for lower part of vessel

k1= coefficient depending on the shape factor (0.7 for cylindrical surface)
D0 = outside diameter of vessel
m kp1 h1 D0
f wb
f wb
H
2
4.kp1 h1 D0 H / 2
D0 k 2 t s k
4 0.7 128 .5 7.36 0.992
0.992 100 2 t s k
7.36
100
2
31 .27
kg / cm 2
ts k
Stress due to seismic load
fsb
2
CW
3 Rok 2 .t s k
C = seismic coffecient = .08

W = total weight of vessel
Rok = outside radius of skirt
tsk = Skirt thickness
f sb
2 / 3 .08 5525
0.992 100
ts k
2
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Formaldehyde 2014
.03813
kg / cm 2
ts k
Maximum tensile stress at bottom of skirt

f t max max f w b or fs b f a b
31 .27 17 .77 13 .5
kg / cm 2
ts k
ts k
ts k
Permissible tensile stress = 1400 kg /cm2

13.5
ts k
cm .00964 cm
1400
.0964 mm
Maximum compressive stress on skirt from equation
max f wb or fsb f ab
31.27 / tsk 17.77 / t s k 48.09 / t s k
fs permisssib le
ts k
1
yield po int
3
2000
666 kg / cm 2
3
48.09
cm 0.0721 cm
666
Use a minimum thickness of 6 mm.
Skirt bearing plate

Assuming bolt circle diameter = Skirt diameter + 32.5 cm
=99.2 + 10.75 = 109.95 cm
Compressive stress between bearing plate and concrete foundation
fc
w Mw
A
= weight of vessel, contents & attachment
= area of contact between bearing plate & foundation
Mw
= bending moment due to wind
= Section modulus of area
Pe k p1 h1 D0
Page 70
Formaldehyde 2014
Mw plw
fc
H
H
k p1 h1 D0
2
2
5525 4
109 .95 99 .2
2
0.7 128 .5 0.992 11 .5
109 .95
99 .2
32 109 .95
4
= 33.123 + .018 = 33.14 kg/cm2

which is less than the permissible value for concrete.
Maximum bending moment in bearing plate
bl 2
M max f c
l = difference between outer radius of beaving plate and outer radil of skirt
b = circumferential length
3.1837 16 .25 b
420 .35 b
2
2
M max
Stress f
6 M max
b tB
2522 .09
tB
6 420 .35 b
b. t B
kg / cm 2
Permissible stress in bending is 1575 kg/cm2
tB
2
2522 .09
Em 2 0.0166 cm 2
1575
t B .16
cm
1.6 mm
Since the calculated thickness is less than 12 mm a steel rolled angle may be used as a
beaqring plate. Bolting chair need not be used.
FLANGE DESIGN:
Page 71
Formaldehyde 2014
Design Pressure = 1.1 atm = 16.17 psia

Design temperature = 873 K
Flange material = ASTM A 201, Grade B

Bolting Material = ASTM A 193, Grade B 7
Gasket material = asbestos composition
Nozzle outside diameter = 0.280 m
Nozzle inside diameter = 0.270 m
Allowable stress of flange = 15000 psi
Allowable stress of bolting material =20000 psi
Calculation of Gasket width

do/di = ((y-pm)/(y-p(m+1)))0.5
Assuming a gasket thickness of 1/16 = 1.58 mm
y = 1600
m = 2.00
do/di = ((1600 14.7 2)/(1600-14.7 *3)0.5
= 1.0052
Suppose di = 11.02
So
do = 11.08
Minimum Gasket width = (11.08 11.02)/2 = 0.03
Which is too less, so we shall go for an 1/2 width gasket b =0.50

Mean gasket diameter = 11.02 + 0.50 = 11.52
Calculation of bolt loads

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Formaldehyde 2014
bo = n /2 = 0.50 /2 = 0.25 ; Now bo <=0.25

Load of seat Gasket
Hy = bGy
So, Wm2 = Hy = 0.5 * 3.14 * 11.52 * 1600

= 28938 lb
Load to keep joint tight under operation
Hp = 2bGmp
= 2 * 0.5 * 3.14 * 11.52 * 2.00 * 16.17
= 1170 lb
Load from internal pressure

H = G2p/4 = 3.142 * 11.52^2 * 16.17 / 4
= 3600 lb
Total operating load
Wm1= H +Hp = 1170 + 3600

= 4770 lb
Wm2 > Wm1
So controlling load is Wm2 = 28938 lb
Calculation of minimum bolting area
Am1 = Wm2 / fb = 28938 / 20000 = 1.4469 in2
Calculation of optimum bolt size

Bolt size
Root area
Min no. of Bolts
Actual Number
Page 73
Formaldehyde 2014
0.302
4.79
So, Bolt circle diameter = 11.52 + 2* (1.415 * 0.00236 +9/8)

=16.92
So,
B = 11.02 =0.280 m
A = 20.87 = 0.530m
C = 16.92 = 0.430 m
E =13/16 =0.8125 = 0.0206m
go = 0.236 = 0.006 m
R = 9/8 = 0.033 m
G = 3.425 = 0.087 m
t = 0.096 m
h = 0.175 m
Bolt diameter = 1/2

No. of bolts = 4 (for symmetricity)
Flange O.D. = Bolt circle diameter + 2E

= 16.92 + 2 * 13/16
=16.92 + 1.625
=20.87
MECHANICAL DESIGN OF ABSORBER

Calculate Di =2.56 m
Shell thickness
Page 74
Formaldehyde 2014
Working Pressure = 1.3786 105 N/m2
Working Temperature = 300C
Hydrostatic head = H g
here we consider as density of water because we are using water as on absorbing
medium
Hydrostatic head
= Hg
= 10.62x103 x 9.81
=104.82 103 N/m2
weight of packing approximately
= P2H g
4
= 609
3.56 10.62 9.8

2
= 63.44 KN/m2
Design Pressure = 1.05137 .86 .104 .182 .3.44 103 N / m2
= 320.71 KN/mm2
t
PDi
2fJP
Material Selection Stainless Steel

for this material fall 300C = 165 106 N/m2
Assuming Double welded butt joint with spot radiography J = 0.85
3.2071 10 5 3.56
t
2 165 10 6 3.2071 10 5
mm
= 4.1 mm
Ref. (Coulson & Richardson Volume 6 , Page 641)
Minimum practical wall thickness (including corrosion allowance = 3 mm)
So, t = 8mm
Thickness of wall = 5 mm (including corrosion allowance = 2 mm)
Do 3.56 2.008 m
= 3.576 m
Torispherical Head design
Page 75
Formaldehyde 2014
Do = 3.576 m
Let
Ri = inside crown radius = Do = 3.576 m

ri = inside knucelete radius = .06 Di
= .06 * 3.56 = .2136 m

Assuming thickness t = 8mm
ro = outside knuclde radius = ri + t
= .2136 .008 .2144 m
Ro = Outside crown radius = r1 +1 = 3.576 + .008
= 3.584 m
ho
= outside height of domed head
D
Do
Ro Ro
R o o 200
2
2
(From geometry)
= 0.636 m
Do 2 3.576
.901
4 Ro 4 3.584
2
D0r0
3.576 * .2144
.685
2
2
h
o
hE = effective height of head = minimum of D o / 4R o
D o ro
hE = .636 m
C = shape factor determined by graph
hE
.636
.174
Do 3.576
t
.008
.174
Do 3.576
from graph C = 1.40

t
P Do
2f J
fall 300C = 165 106
J = 1.0
Page 76
Formaldehyde 2014
Design Pressure
P 1.05 1.3786 105 N / m2
1.44753 10 5 N / m2
t
1.44753 10 5 .3.56 1.4

2 165 10 6 1.0
= 2.186 mm
Minimum wall thickness including corrosion allowance (3mm)
ts = 5 mm
ro = outside kunckle radius = .2186 m
Ro = outside crown radius = .3581 m
* Since the diameter of the absorber is less, therefore we join head by welding to the
shell, there is no need of flange arrangement we can use double-welded lap joint for
this.
NOZZLE DESIGN
Moler flow rate = 2 mole/sec (approx)
Density of Water = 990 K/m3
So, Voumetric Flow Rate = Flow Rate of formaldehyde * molar flow rate of
water* mol. Wt. *density
= 14.265 * 2 *18 *990/1000
= 508.40 Kg/sec
dopt = 282 * G0.52 * -0.37
= 282 * 508.40.52 * 990-0.37
= 318 mm
Taking nozzle dia. = 320 mm or 32 cm
Similarly Nozzle Dia for gas comes out to be 48 cm
Nozzle Reinforcement Design
Nozzle is provided on the head and it is welded there internal design pressure
= 3.2071 105 N/m2
3.2071 10 5
/ 10 kg / cm2
=
4
10
= 3.2071 kg/cm2
Page 77
Formaldehyde 2014
thickness of nozzle = tn
PDi
3.2071 3560 mm
2 f J P 2 1300 1 3.2071
= 4.39 mm
No corrosion allowance, since the material is stainless stell.
Actual thickness = 5 mm
Area to be compensated = d tRS
trs = thickness cale for shell
d = 5 cm (internal dia) + 8.4 10-3 (thickness) = 5 cm
= d tRS = 320 5
= 1600 mm2
Area available for compensation As = d t s t rs c (of shell)
= 320 5 8.4 10 3 3
= 640 mm2
Area available for compensation (external branch)
Ao 2H1t n t rn C
let height of nozzle = 5 cm
tn = thickness of nozzle = 5 cm
trn = thickness of nozzle calculated
C = corrosion allowance
Ao = 2 320 5 .1068 0 3200 mm 2
Area available for compensation from internal branch = 0
because the nozzle does not project inside the vessel.
Ao As 3200 640 3840 mm 2
Area to be compensated = 1600 mm2 =A

Since Ao + AS > A
This is satisfactory and no external compensation is required.
Reference Book
Support Design : Process Equipment Design (second editor) By M. V. Joshi
Since on absorber is not large, as result we can safely chose bracket or lug support for
vertical cylindrical vessels.
Page 78
Formaldehyde 2014
Data : Diameter of vessel =3.56 m
Height of vessel = 10.62 m
Clearance from vessel both of foundation = 1.5m
Weight of vessel
Weight of vessel = weight of absorber + weight of pacing
Do 2 Di 2 H s
4
weight of absorber =
3.576
4
.3.56 10.62 7500

2
= 7142.5 Kg
from Page 23-35 John H. Perry.
for Stainless steel 201 s .28 lb / Cu in .
.28 12 3
483 .84
lb
Cu ft
lb
Cu ft
16 .018 483 .84 kg / m3
7500 .14 kg / m3
Mass of packing = 2 Di 2 H b
4
3.56 2 7.62 609 kg
= 4532 kg.
Total weight of Tower
with contents
= 7142.5 + 4532 + 500 Kg extra

= 12174.5 Kg
wind pressure = 128.5 kg/m2
Skirt
Stress due to dead weight
Page 79
Formaldehyde 2014
f0
w
D0 k t s k
w dead wt. of vessel contents and attachments

D0k = Outside diameter of skirt
tsk = thickness of skirt
f0
12174 .5
10 .885
kg / cm2
3560 ts k
ts k
Stress due to wind load

fwb
4 Mw
D0 k 2 t s k
M Plw
H
Z
(for H 20m)
Plw kp1 h1 D0
up to 20m height
P1 = wind pressure for lower part of vessel

k1= coefficient depending on the shape factor (0.7 for cylindrical surface)
D0 = outside diameter of vessel
m kp1 h1 D0
f wb
f wb
H
2
4.kp1 h1 D0 H / 2
D0 k 2 t s k
4 0.7 128 .5 10 .62 3.56
356 2 t s k
10 .62
100
2
18 .14
kg / cm 2
ts k
Stress due to seismic load
fsb
2
CW
3 Rok 2 .t s k
C = seismic coefficient = .08

W = total weight of vessel
Rok = outside radius of skirt
Page 80
Formaldehyde 2014
tsk = Skirt thickness
f sb
2 / 3.08 12174 .5
2
356
ts k
2
.03813
kg / cm 2
ts k
Maximum tensile stress at bottom of skirt

f t max max f w b or fs b f a b
18 .14 10 .885 7.255
kg / cm2
ts k
ts k
ts k
Permissible tensile stress = 1400 kg /cm2
ts k
7.255
cm .005282 cm
1400
.
=
05282 mm
Maximum compressive stress on skirt from equation
max f wb or fsb f ab
10.885 / tsk 18.14 / t s k 29.025 / t s k
fs permisssib le
ts k
1
yield po int
3
2000
666 kg / cm 2
3
29.025
cm 0.0721 cm
666
Use a minimum thickness of 6 mm.
Skirt bearing plate

Page 81
Formaldehyde 2014
Assuming bolt circle diameter = Skirt diameter + 10 % of skirt dia in cm
=356 + 35.6 cm = 391.6 cm
= 3.916 m
Compressive stress between bearing plate and concrete foundation
fc
w Mw
A
= weight of vessel, contents & attachment
= area of contact between bearing plate & foundation
Mw
= bending moment due to wind
= Section modulus of area
Pe k p1 h1 D0
Mw plw
fc
H
H
k p1 h1 D0
2
2
12174 .5 4
391 .6 356
2
0.7 128 .5 3.56 10 .62
391 .6
356
32 391 .6
4
= 0.582 + .001 = 0.583 kg/cm2

which is less than the permissible value for concrete.
Maximum bending moment in bearing plate
M max f c
bl 2
2
l = difference between outer radius of bearing plate and outer radii of skirt
b = circumferential length
0.583 17 .86 b
M max
92 .98 b
2
2
Stress :
6 M max
557 .8
tB
b tB
6 92.98 b
b. t B
kg / cm 2
Page 82
Formaldehyde 2014
Permissible stress in bending is 1575 kg/cm2
tB
2
557 .8
Em 2 0.3541 cm2
1575
t B .59cm
= 5.9 mm
Since the calculated thickness is less than 12 mm steel rolled angle may be used as a bearing
plate. Bolting chair need not be used.
Page 83
Formaldehyde 2014
EFFLUENT TREATMENT
WASTE CHARACTERSTICS
The major waste stream from the process is the "formaldehyde in water" and
formaldehyde vapors released into atmosphere. Beside formic acid, Carbon-mono-oxide
etc., which need to be treated before disposal. Carbon-mono-oxide and other gases are
in low concentration, so they are not treated as such but released at high elevation in
atmosphere.
Formalin is a highly toxic gas, and strict precautions are necessary to minimize risk
to workers and possible released during its handling. Major sources of fugitive air
emissions of chlorine and hydrogen are vents, seals, and transfer operations. Acid
and caustic wastewaters are generated in both the process and the materials
recovery stages.
Scrubber systems should be installed to control gas effluent emissions from condensers
and at storage and transfer points for liquid chlorine. Sulfuric acid used for drying
chlorine should be neutralized before discharge.
KEY ISSUES
The following summarizes the key production and control practices that will lead to
compliance with emissions guidelines.
1) Give preference to the effluent gases.
2) Adopt the following pollution prevention measures to minimize emissions.
3) Use scrubbers at the absorber to minimize the off-gases from it.
4) Recycling of water in air washer should be treated.
5) Recycling of dust containing water should be from suitable pumps.
In the effluent treatment plant, the formic acid going along with the water is passed
through an ion exchange bed. A sample design fo a deionizer for the treatment of formic
acid from the formalin stream is given below. A similar treatment can be devised for
outlet water stream.
Page 84
Formaldehyde 2014
Secondly, the settling tank can be designed for the treatment of rundown water from the
air washer.
DEIONIZER
Process design consideration
For ion exchange system sizing, the quantity of liquid to be processed in a period
of time must be determined. The processing rate if often expressed in gallons per
day or pounds per day.
Processing rate = quantity to be processed / time period minus regeneration time
Equipment must be sized such that the service time is sufficient to allow a unit in
regeneration to be completed prior to the exhaustion of the usable capacity of the
unit in service. The service time of a single unit in a multiple unit system is usually
designed for a service time, which exceeds the sum of the regeneration time
required for all of all the units in service. Having the required feed processing rate
per fixed-bed ion exchanger and the required length of the service period, the
exchanger or adsorption load to each unit for a service period can be calculated.
For continuous ion exchange equipment, the load is calculated on the basis of
exchange load per unit time. Generally, the capacities of an ion-exchange material
to remove a given component are determined experimentally. But the data is
available on common materials.
Variables on which the amount of ion-exchange bed required depends are
conc. of the component to be removed, process flow contact rate, regenerant
chemical conc., etc. Ion-exchange capacities are affected by the rate of mass
transfer between the process fluid and ion-exchange resin.
Page 85
Formaldehyde 2014
REQUIREMENT FOR EQUIPMENT DESIGN
TANKS AND VESSELS

Typically, a tank diameter which will allow service operation at flows that will
exceed 2 gpm/ft2 of tank area and not exceed 12 gpm/ft2 are acceptable. Once
the vessel diameter is determined, the ion-exchange media bed depth can be
calculated (media volume divided by area = bed depth). The resin bed depth in a
fixed-bed-ion-exchange unit usually should exceed 30in. and be limited to a
maximum depth of 96 in.. High flows per unit area and deep ion-exchange resin
depths may result in high-pressure drops. Pressure losses across a resin bed are
normally limited to 10-20 lb/in2. Large pressure losses can, in combination with
exchange media volume changes (result from ionic or osmotic changes), causes
physical damage to the exchange media, the exchanger, and the internals of the
exchanger.
The chemicals that are used to regenerate the resins or the nature of the liquid
being processed dictate the use of interior coating or linings in an ion-exchanger
tank.
PIPINGS AND VALVES

These equipments are commonly constructed with PVC, stainless steel, or lined
carbon steel flanged piping. Selection of valves suitable for the intended service is
especially important.
Lined carbon-steel pipes are generally used on large
equipments.
EXCHANGE MEDIA SUPPORT
Several design, like flat false bottom designs, dished tank bottom with graded
gravel media support beds, are available for supporting the ion-exchange resin.
F L O W D I S TRI B U TI O N
For efficient working of ion-exchange resins, plug flow is generally preferred. Welldistributed liquid flow distributors are required for that.
Page 86
Formaldehyde 2014
DESIGN
Formalin flow rate
= 300 tons/day
Conc. of formic acid (max. possible)
= 0.04%
Formic acid (in Kg/day)
= (0.04/100) * 300 *1000

= 120 Kg/day
Reaction occuring is:

R(OH)2 + 2HCOOH
R(COOH)2 + 2H2O
Density of 37 wt.% formaldehyde solution:

d= 1.000 + 0.003*W
d= 1.000 + 0.003*37
d= 1.111
d= 1111 Kg/m3
Volume of solution
= weight/density
Volume of solution
= 300*1000/1111
volume of solution
= 270.03 m3/day
conc. of formaldehyde
= 120Kg/day
270.03 m3/day
= 0.444 gm/lt
= 444 mg/lt
Eq. Wt. Of HCOOH
=46/1(mol.wt./bascity)
=46
meq/lt of HCOOH
= 444 mg/lt / 46
= 9.65
Total meq treated per day
= 9.65 * 270.03 * 103

= 2605.79 eq/day
Resin Requirement:
Assumed 6-day operation cycle for the specific resin
Treating power of resin
= 70 eq/ft3
Page 87
Formaldehyde 2014
Resin reqd.
=2605.79
eq./day*
day/cycle
70 eq./ft3
=
223.35ft3
of
resin/day
Choosing column diameter = 3 ft. = 0.0762 m
Cross-section area
= 3.142*32/4 = 7.07 ft2
Depth
= volume/cross-sectional area
= 223.35/7.07 = 31.6 ft = 9.48 m
50% of free space is kept for bed expansion for backwashing and cleaning.
So, the height of reqd. column is 1.5 * 9.48 =14.22 m
Height is quite high. So, using 2 columns of 7.11 m height each.
Each containing =9.48/2 = 4.74 m
Free space
= 7.11 4.74= 2.37 m
Regenrant Reqd.
Regenrant used is 10% solution of NaOH
Regenrant requirement is 4.7 lb of NaOH/ ft3 of resin
So NaOH reqd.
= 4.7 lb/ft3 *223.35 ft3/cycle

= 1049.745 lb/cycle = 476.58 Kg/cycle
Requirement of 10% solution

= 476.58*100/10
= 4765.8 Kg/cycle
Water requirement
Water requirement
=100 gallon/ft3 of resin
Water requirement
= 100gallon/ft3 of resin* 223.35 ft3/cycle

= 22335 gallon/cycle
= 84.55 m3/day
Page 88
Formaldehyde 2014
SAFETY POLICY
E F F E CI TVE
S AF E TY
AN D
LOSS
PRE VE N TI O N
IS
E S S E N TI AL
FOR
CO M P AN Y S
P RO S PE RI TY
Hazards in the chemical industry are much more than in any other
industry.
Besides mechanical and electrical hazards, chances of fire explosion, inhalation

of toxic gases, handling of corrosive and poisonous substances are encouraged in
chemical industry. Thus it is important that the employee should recognize safety
and fire hazards in the manufacture of soda ash.
Objectives of industrial safety program are: a) To lessen human sufferings.
b) To prevent damage to plant and machinery.
c) To reduce the amount of time lost due to accidents.
d) To hold the expense of workman compensation to minimum.
GENERAL SAFETY
1) Alternate means of escape should be provided in the plant area.
2) Gloves and goggles should be used while sampling or welding the
equipment.
3) Going without helmet, gloves and rubber bolts near the leaking
equipment should be avoided.
ELECTRICAL HAZARDS:
Accidents attributed to electrical hazards are:1) Shocks by A.C. and burns by D.C. due to poor indication and protection
from high voltage.
2) Faulty and poor wiring.
3) Static electricity discharges.
Page 89
Formaldehyde 2014
4) Fires from sparking near inflammable material.
PROCESS UTILITIES
Process utilities are a major necessity for any chemical plant. The following are
usually considered utilities although in some companies one or more are treated
under other categories on the cost sheet. The utility cost for the whole plant (from
coat estimation sheet) is Rs.1.97412108
Steam, Cooling water,
Deionized
water,
Electric
power, Refrigeration ,
Compressed air , Instrument air, Effluent treatment. Their effect on the cost of
the production will naturally depend on the process involved Occasionally the
costing of the utilities will be intricate because utilities require other utilities for
their own manufacture.
STEAM
A steam generation unit should be present which is a source of steam where ever
it is required .It is measured in thousands of pounds or for small boilers it may be
measured in boiler horse power(33,749 BTU/hr).A pound of steam generated may
have 1200 to1600BTU/lb.Most plants use several stem pressure levels . In many
plants waste heat boilers are additional source of steam at intermediate pressure
levels .
Steam is available at following rating in our plant
Pressure ----------- 400 Kpa
Temperature-------- 204.44 oC
Latent heat -------------826 Btu/lb or 1920 Kj/kg
WATER
Water requirements
fall
under
three
categories,
cooling,
process,
and
miscellaneous such as washing or drinking. For cooling purpose it is usually

uneconomical and occasionally violation of conservation laws to use to use a
Page 90
Formaldehyde 2014
treated water in once through basis , although untreated river or sea water may
be used in this manner.
Recycled water returns to a cooling tower, where its temperature is lowered
mainly through evaporation. At the tower water is subjected to minor chemical
control for pH adjustment and to suppress the build up of salt.
The temperature difference between the incoming out going water will be a
complex function of ambient and return temperature and humidity .The expense
to operations of cooling or process is usually not significant in the overall
economics of the plant.
COOLING WATER
Cooling water is required to cool hot gases and liquids mainly in the condensers
and heat exchangers. So there should be a source of water nearby, it may be a
pond or a river. Cooling tower is used mainly at the following points in the plant:
1. Reactor Effluent Cooling
2. Absorber Water
Cooling towers should be installed in order to reuse water.
Cooling water is available at 25 oC and the maximum temperature allowed to be
elevated for water is 350 C.
Total quantity of cooling water required =
INERT GASES AND COMPRESSED AIR
These are minor items for most processes. An inert gas may be used to blanket a
chemical reactor or a storage tank,. The gas is usually carbon dioxide or nitrogen.
Compressed air is used for control of valves. In our plant no inert gas is used, only
compressed air is used for control of valves.
ELECTRICAL ENERGY
Electric power is required to run motors, pumps, compressors, blowers etc.
It is very necessary to have a reliable power resource.
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Normally big plants have their own thermal power station, in which there are huge
boilers, in which steam is generated, which is used to run turbines. This generated
steam can be used in reboilers and heat exchangers
In most cases it represents a modest part of total operating cost. Electrical power
in India is mostly purchased from a public utility. All major contracts contain a
demand component, an energy component and a variable fuel-cost component.
The Demand charge is based on the maximum power requirement drawn by the
plant during a measurable period. The demand charges represents fixed charge
switch must be payed by the utility for generation, transmission and distribution
facilities.
The Energy charge is based on kilowatt used. It can be used as a flat unit cost per
kilowatt hour. Because of the demand charge a maximum utilization of the
demand capacity will result in the lower units of electricity.
The Fuel Adjustment charge reflects the increased or decreased cost of fuel to the
power company.
In addition of of the cost of power from the utility company, the power must be
transformed and distributed through the plant properly. For a chemical plant these
distribution charges may be 50% of the purchased price of the power from the
utility.
WASTE DISPOSAL
It may be a major or minor cost. In a large plant, effluents from spills, discarded
fractions, etc are run together into a tank or a pond, neutralized aged, and
perhaps diluted until they are very innocuous to the body of water into which they
are eventually drained. Cost of a plant depends on the maintenance depreciation
and operating labor facility.
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CONTROL OPERATIONS:
Selecting a Controller
Selection criteria
To solve a control task it is required that the controlled system be analyzed
and
a suitable controller be selected and designed.The most important properties of
the widely used P, PD, I, PI and PID control elements are listed in the following
table:
TABLE 12 :Characteristics of different controllers
Which controller to select depends on the following factors:

1)Is the system based on integral or proportional control action (with or without
self-regulation)?
2)How great is the process lag (time constants and/or dead times)?
3)How fast must errors be corrected?
4)Is steady-state error acceptable?
According to the previous chapters (see also above table), controllers and
systems can be assigned to each other as follows:
P controllers are employed in easy-to-control systems where steady-state error
is acceptable. A stable and dynamic control response is reached at minimum
effort.
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what to consider when selecting a controller P controllers It makes sense to
employ PD controllers in systems with great lag where offset is tolerable. The D
component increases the speed of response so that control dynamics improve
compared to P controllers. PI controllers are suitable for use in applications with
low requirements as to the control dynamics and where the system does not
exhibit great lag. It is an advantage that errors are completely eliminated. PI
controllers combine the advantages of both P and I controllers. This type of
controller produces a dynamic control response without exhibiting steady-state
error. Most control tasks can be solved with this type of controller. However, if it
is required that the speed of response be as high as possible regardless of the great
lag, a PID controller will be the proper choice. PID controllers are suitable for
systems with great lag that must be eliminated as quickly as possible. Compared to
the PI controller, the added D component results in better control dynamics.
Compared to the PD controller, the added I component prevent error in steady
state. The selection of an appropriate controller significantly depends on the
corresponding system parameters. Therefore, the above-mentioned applications
should only be considered a general guideline; the suitability of a certain type of
controller must be thoroughly investigated to accommodate the process
it controls.
Ratio control
Ratio control is a special type of follow-up control and is used to maintain a
fixed ratio between two quantities. This requires an arithmetic element (V). Its
input variable is the measured value of the process variable 1(q1) and its output
variable manipulates the process variable 2 (q2) in the secondary control loop.
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FIGURE 12 : Ratio Control

TABLE 13: SHOWING LIST OF CONTROLLERS
S no
Name of Equipment Parameter
to
be Type of Controller
controlled
1
Air Washer
Flow rate of water
Reactor
Temperature,
Ratio
PI
of PI, Ratio controller
reactants
3
4
Absorber
Distillation
Pressure,
flow
rate
of PI
and
Ratio
water.
controller
Pressure & temperature
PI and Split range

controller
Deionizer
Outlet concentration
Filter
Heat Exchangers
Temperature
PI
Mixer
Level
Pressure
P
PI
The operation control includes the necessary steps and method to be

adopted at special situation like at start-up, periodic and emergency
shutdown, and emergency power failure.
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Some general precautions need to be taken before starting-up. These
procedures are handy at the initial start-up of the plant after commissioning
of
plant
or
after
the
shutdown.
Like,
All
Mechanical/Electrical/Instruments/civil jobs are completed, all exchangers

CBD connection are boxed up with blinds in close position and waterflushing hoses are removed.
Similarly, the equipments require an appropriate way to be
operated at the start-up. Like in furnaces, peepholes, explosion doors,
burners should be boxed up. General considerations that should be paid
attention to at the time of start-up are given below:
It should be ensured that:
A. All Mechanical/Electrical/Instruments/civil jobs are completed.
B. All exchangers CBD connection are boxed up with blinds in close position.
C. Water flushing hoses are removed.
D. Blinds installed for hot job Hydro-testing/Positive isolation of equipment
removed. Wedge opening properly boxed up.
E. Unit area is cleaned of foreign material/oil.
F. All exchangers safety valves u/s b/v d/s bleeder of flange opened for
steaming.
G. Pump discharge control valves CBDs B/V downstream flanges wedge opened
for water draining during steaming.
H. Battery limit valves tight shut and blind in open condition.
I. Stabiliser section exchanger CBD B/V D/S and stabiliser bottom drain CBD
B/V D/S wedge opened.
J. All motors are in energised condition and rotor moves in right direction.
K. Chemical solutions prepared for use.
L. Checklist as per pumps list is completed.
M. Utilities like steam/air/cooling water/ service water are commissioned.
N. Control valves opening/closing and failure position is checked and whichever
instruments were handed over to I/M are installed as per list.
O. CBD pump is in working order.
P. Paging system or any other communication system is in order.
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Q. Fire extinguishers and Fire Hoses are made readily available in respective
areas and steam lancers are positioned at critical areas.
R. Tempered water system is commissioned.
S. All the interlocks function is to be checked as per the details given in
manual.
T. Steam Tracers are commissioned.
MAIN STEPS FOR START-UP OF FORMALDEHYDE PLANT
MAIN STEPS FOR SHUT DOWN OF FORMALDEHYDE PLANT
EMERGENCY SHUTDOWN
PROCEDURE IN CASE OF ELECTRIC POWER FAILURE
MAIN STEPS FOR START-UP OF FORMALDEHYDE PLANT

1. Start transfer pumps for CH3OH receiver and D.M. water receiver. Also start
the condensate transfer pump.
2. Provide steam to evaporator.
3. Start the blower at 70C and hence vapours start going to dome.
4. Air supply to ignition coil starts to burn methanol vapours so that the
reaction starts.
5. At 400C, stop air supply to ignition coils. Exothermic reaction maintains the
temperature of the silver bed.
6. When steam generator temp. is 100C, stop supply of steam to evaporator.
MAIN STEPS FOR SHUT DOWN OF FORMALDEHYDE PLANT
1. Stop the process water and close cooling water valve.
2. Stop the blower so that reaction stops.
3. Shut off cooling water for condensate cooler.
4. Empty sump to intermediate tank.
5. Stop circulation pump I, process water pump and methanol pump and close
corresponding valves.
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6. Close discharge valve at mixing receiver and feed valve at level regulator
LGV 207.
7. Disconnect instruments by actuating corresponding switches in control and
instrumentation board, and switch main switches for electric current and
compressed air.
8. Close main valves for cooling water, cold water, steam and compressed air.
EMERGENCY SHUTDOWN
1. Disconnect rotary blower after opening vent valve and ventilate reactor and
condenser.
2. Shut off heating of methanol evaporator and close cooling water.
3. Shut off process feed water for absorption and washing column.
4. All other plant equipment is put of operation in same sequence as being
done for normal shutdown.
5. In case of sudden failure of compressed air, steam or cooling water it will be
better to affect an emergency shutdown.
PROCEDURE IN CASE OF ELECTRIC POWER FAILURE
1. Open air vent valve at rotary blower and ventilate contact reactor and
condenser.
2. Shut off process feed water for absorption and washing column.
3. All other plant equipment is put off operation in same sequence as being
done for normal shutdown.
4. In case the power failure lasts only for a minute, it can be started by
turning blower ON and then process water pump, controlling temp in
evaporator. As soon as an increase in temp of contact reactor is noticed, all
pumps and machines are connected again. Cooling water supply must be
available at once.
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COST ESTIMATION
Acceptable plant design must present a process that is capable of operating under
conditions, which will yield profit. Since net profit equals total value minus all
expenses, it is essential that the chemical engineer be aware of the many different
types of cost involved in the manufacturing processes. Capital must allocate for
the direct, plant expenses, such as those for raw material, labor and equipment.
Besides direct expenses many others indirect expenses are incurred, and these
must be included if a complete analysis of the total cost is to be obtained. Some
examples of these indirect expenses are administrative salary, product distribution
cost and cost for interplant communication. A capital investment is required for
every industrial process and determination of necessary investment is an important
part of a plant design process. The total investment for any process consist fixed
capital investment for practical equipment and facilities in the plant plus working
capital, which must be available to pay salaries, keep raw material and products
on hand, and handle other special items requiring the direct cost outline.
When the cost for any type of commercial process is to be determined, sufficient
accuracy has to be provided for reliable decision. There are many factors affecting
investment and production cost. These are;
1. source of equipment
2. price fluctuation
3. company policies
4. operating and rate of production
5. governmental policies
Before an industrial plant can be put into operation, a large sum of money mustbe
supplied to purchase and install the necessary machinery and equipment.
Land and service facilities must be obtained, and the plant must be erected
completely with all piping, controls and services. The capital needed to supply the
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necessary manufacturing and plant facilities is called the fixed-capital investment,
while that necessary for the operation of plant is termed the working capital. The
sum of the fixed capital investment and the working is known as the total capital
investment. Generally, the working capital amounts 10-20% of the total capital
investment. Following is the breakdown of the fixed capital investment for a
chemical process.
DIRECT COST:
1. purchased equipments
2. purchased equipment installation
3. instrumentation and control
4. piping
5. electrical equipment and material
6. building (including services)
7. yard improvement
8. land
INDIRECT COST:
1. engineering supervision
2. construction expenses
3. contractors fee
4. contingency
TYPES OF CAPITAL COST ESTIMATE:
Order of magnitude estimate (ratio estimate) based on similar cost data;
probable accuracy of this estimate over 30%.
Study estimate based on knowledge of major items of equipment,
probable accuracy of this estimate up to 30%.
Preliminary estimate( budget authorization estimate scope method): based
on sufficient data to permit the estimate to the budget, probable accuracy
of this estimate is within 20%.
Detailed estimate based on complete engineering drawing, specifications
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and site survey, probable accuracy of this estimate within 10%.
COST ESTIMATION OF 100 TONS/DAY OF FORMALDEHYDE PLANT:

Formaldehyde plant size = 300 T/day
Fixed capital investment for cost index = $ 5,400,000 for 100 *10 6 lb/year plant
Or Rs 2.7108
(this data is taken from McCata, Vol. And the price is for 1993 hence conversion of
$ to Rs. To be taken as 50)
Therefore present fixed capital investment = 2.7108(2.4)
=Rs 6.48108
Estimation of total investment cost:

1) Direct cost:
a) Purchased equipment cost:(15 40% of FCI )
Assume 40% of FCI=Rs 2.59108
b) Installation cost:(35 45% of PEC)
Assume 45%=Rs 1.17108
c) Instrument and control installed:(6 30% of PEC)
Assume 30% of PEC=Rs 0.78108
d) Piping installation cost:(10 80% of PEC)
Assume 80%=Rs.2.07108
e) Electrical installation cost:(10 40% of PEC)
Assume 40% of PEC=Rs 1.036108
f) Building process and auxilliary:(10-70% of PEC)
Assume 70%=Rs 1.813108
g) Service facilities:(30-80% 0f PEC)
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Assume 80%=Rs 2.07108
h) Yard improvement:(10-15% of PEC)
Assume 15% =Rs 0.388108
i) Land:(4-8% of PEC)
Assume 8%=Rs 0.207108
Therefore direct cost =Sum of all above costs = Rs. 12.124108
Indirect cost:
Expenses, which are not directly involved with material and labour of actual
installation or complete facility
a) Engineering and supervision:(5-30% of DC)
Assume 30%=Rs 3.637.108
b)Construction expenses:(10% of DC)
Assume 10%.=Rs 1.2124108
c)Contractors fee:(2-7% 0f DC)
Assume 7%=Rs 0.848108
d)Contingency:(8-20% of DC)
Assume 18%=Rs 2.182108
Therefore total indirect cost =Rs 7.879108
Fixed capital investment:
Fixed capital investment(FCI) = DC+IC
= Rs 20108
Working capital investment:

10 20% of FCI
Assume 18%=Rs 3.6108
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2) Total capital investment:
= FCI + WC
=Rs 23.6108
Estimation of total product cost(TPC):
Fixed charges:
a) Depreciation:(10% of FCI for machinery)
=Rs 2108
b) Local taxes:(3-4% of FCI)
Assume 4%=Rs 0.8108
c) Insurances:(0.4-1% of FCI)
Assume 0.9%=Rs 0.18108
d)Rent:(8-12% of FCI)
Assume 12%=Rs 2.4x108
Therefore total fixed charges =Rs 5.38108
But, Fixed charges = (10-20% of TPC)
Assume 20%,
Therefore Total product cost =5.38108/0.20
=Rs 26.9108
Direct production:
a) Raw material:(10-50% 0f TPC)
Assume 20%=Rs 5.38108
b)Operating labour(OL):(10-20% of TPC)
Assume 15%=Rs 4.035108
b) Utilities:(10-20% of TPC)
Assume 15%=Rs 4.035108
c) Maintainence:(2-10% of FCI)
Assume 5%=Rs 1.8108
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d) Operating supplies (OS):(10-20% of maintainence)
Assume 20%=Rs .36108
Total Cost = 15.52108
Plant overhead cost:

50-70% of (OL+OS+M = 6.195108)
Assume 30%=Rs 1.85108
General expenses:
a) Administration cost:(40-60% of OL)

Assume 55%=Rs 2.22108
b) Research and development cost:(3% of TPC)
=Rs 0.807108
Therefore general expenses(GE) =Rs 3.027108
Therefore manufaacturing cost(MC)= Product cost+fixed charges+ Plant overhead
=Rs 22.75108
Total production cost:

Total production cost =MC + GE
=Rs 25.777108
Gross earnings and rate of return:
The plant is working for say 335 days a year

Selling price =Rs. 40 /kg for 37 wt% formaldehyde solution
Total income =300335100040
=Rs 40.2.108
Gross income =Total income total product cost
=Rs 14.423108
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Tax =45%
Net profit
=Rs 7.93265x108
Rate of return =net profit/total capital investment

=2.428108/23.6108
= .3361 =33.61%
Pay Back Period:
Pay Back Period, n = Total Initial Investment/ Net Profit

n = 23.6108/ 7.93265108
n= 2.96 years~ 3 years
BREAK-EVEN POINT ANALYSIS
Let the plant operate at no profit, no loss.

There is a fixed production capacity of plant at which such condition occurs.
Let that quantity be x tons/day
Total fixed cost is: Rs 8.6596108
Running cost for 100 tons/day plant is : Rs 10.459108
Running cost for x tons/day plant will be : Rs 10.459108 *x/100
Total Income for x tons/day plant will be : Rs x*335*1000*35
Plotting the graph on excel, we get break-even point at: 670 tons/day]
Rs.
FIXED COST
865960000
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RUNNING COST FACTOR FOR x TONS/DAY
10459000
INCOME FACTOR FOR x TONS/DAY
11725000
CAPACITY
(TONS/DAY)
RUNNING COST
(Rs)
0
100
200
300
400
500
600
700
800
900
1000
INCOME FIXED COST

(Rs)in crores(RS)
0
1045900000
2091800000
3137700000
4183600000
5229500000
6275400000
7321300000
8367200000
9413100000
1.0459E+10
0
11.7
23.5
35.2
46.9
58.6
70.4
82.1
93.8
106
117
865960000
865960000
865960000
865960000
865960000
865960000
865960000
865960000
865960000
865960000
865960000
TOTAL COST
(Rs)
865960000
1.912E+09
2.958E+09
4.004E+09
5.05E+09
6.095E+09
7.141E+09
8.187E+09
9.233E+09
1.028E+10
1.132E+10
TABLE 12 : BREAK EVEN POINT DATA

BREAK-EVEN
1.2E+10
1E+10
COST , Rs.
8E+09
6E+09
4E+09
2E+09
0
0
100
200
300
400
500
600
700
800
900
CAPACITY, tons/day
FIGURE 12: BREAK EVEN POINT

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PLANT LOCATION AND LAYOUT

PLANT LOCATION :
The location of the plant can have a crucial effect on the profitability of a project,
and the scope for future expansion. Many factors must be considered when
selecting a suitable site, and only a brief review of the principal factors will be
given in this section. The principal factors to be considered are:
Location, With Respect To The Marketing Area.
Raw Material Supply.
Transport Facilities.
Availability Of Labour.
Availability Of Utilities: Water, Fuel, Power.
Availability Of Suitable Land.
Environmental Impact, And Effluent Disposal.
Local Community Considerations.
Climate.
Political Strategic Considerations.
Marketing Area
a)
Demand v/s distance
b)
What is the purchasing potential of that area
c)
What is the competitive position in that area
d)
Inventory, storage, warehousing requirements
e)
What amount of competition is expected in the future.
Raw Materials
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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
the major raw material; where this is also close to the marketing area.
Formaldehyde plant should be located near the industries producing methanol in
large quantities, since then it would be easier and cheaper to transport raw
material from supplier to the processing site.
Transport
The transport of materials and products to and from plant will be an overriding
consideration in site selection. If practicable, a site should be selected that is
close at least two major forms of transport: road, rail, waterway or a seaport.
Road transport is being increasingly used, and is suitable for local distribution from
a central warehouse. So, it will be better to have plant location on near highway.
Rail transport will be cheaper for the long-distance transport of bulk chemicals.
So, it should be connected to all major cities by rail.
Availability Of Labour:
Labour will be needed for construction of the plant and its operation. Skilled
construction workers will usually be brought in from outside the site, but there
should be an adequate pool of unskilled labour available locally; and labour
suitable for training to operate the plant. Skilled tradesmen will be needed for
plant maintenance. Local trade union customs and restrictive practices will have
to be considered when assessing the availability and suitability of the labour for
recruitment and training.
Local Community Considerations
The proposed plant must fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not
impose a significant additional risk to the community.
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Land (site considerations)

Sufficient suitable land must be available for the proposed plant and future
expansion. The land should be ideally flat, well drained and have load-bearing
characteristics. a full site evaluation should be made to determine the need for
piling or other foundations.
Climate
Adverse climatic conditions at site will increase costs. abnormally low
temperatures will require the provision of additional insulation and special heating
for equipment and piping. Stronger locations will be needed at locations subject to
high wind loads or earthquakes.
Political And Strategic Considerations
Capital Grants, Tax Concessions, and other inducements are often given by
governments to direct new investment to preferred locations; such as areas of high
unemployment. The Availability of such grants can be the overriding consideration
in site selection.
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SITE SELECTION
Location of a plant has crucial impact on profitability and future expansion
LOCATION SELECTION METHODOLOGY
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CITIES AND PARAMETERS
SAN OF DIFFERENT LOCATIONS
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PLANT LAYOUT
The management of equipment and facilities specified from process flow sheet
considerations is a necessary requirement for accurate pre construction cost
estimation or for future design involving piping, structural and electrical facilities.
Careful attention to the development of plots and elevation plans will point out
unusual plant requirements and therefore, give reliable information about building
and site costs required for precise pre construction cost accounting. Rational
design must include arrangements such as processing areas, storage areas and
handling areas in efficient coordination and with regards to such factors are given
below.
1. New site development or addition to a previously developed site.
2. Future expansion
3. Economic distribution of services water, process steams power and gas.
4. Weather condition
5. Safety consideration possible hazards of fire, explosions and fumes
6. Building code requirements
7. Waste disposal problems
8. Sensible use of floor and elevation space.
Some points to be considered in plant layout are,
Effluent plant is located at the end of the premises
Administration buildings, canteens are located near the entrance of the industry
where they will not interfere with production and its is convenient to contact the
people outside the industry.
Laboratory and workshops are placed in the position form where it is easy to
communicate with all other departments.
Location of services like power plant, cooling water, pump house, and switch
house are done such that their usage is not hindered and they are easily accessible
in case of fire.
Pipelines laid are minimal and human safety is taken into account.
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Storage layout: storage facilities for raw materials and products may be located
in isolated areas or in adjoining areas. Hazardous materials become a decided
menace to life and should be isolated when stored. Storage tanks must be
separated to facilitate suitable quantity. Process water may be drawn from river,
wells or purchased from local authority. Electrical power will be needed at all
sites. So plant should be located close to a cheap source of power. A competitively
priced fuel must be available for steam and power generation.
Effluent disposal: Effluent disposal should be according to the Indian standards.
The appropriate authorities must be consulted during the initial site survey to
determine the standards that must be met.
Local community considerations: The local community must be able to provide
adequate facilities for the plant personnel: schools, banks, housing and
recreational cultural facilities etc... Also the plant should be located so that the
local community is not harmed. The proposed plant must fit in with and be
acceptable to the local community.
Availability of suitable land: Sufficient suitable land be available for the
proposed plant and for future expansion. The land should be ideally flat, well
drained and have suitable load bearing capacity. A full site evaluation should be
made to determine the need for pining or other special foundations. It should also
be available at low cost.
Political and strategic consideration: Capital grants, tax concessions and other
incentives provided by governments to direct new investment to preferred
locations, such as areas of high un-employment should be the overriding
considerations in the site selection.
Climate: Adverse climatic conditions at a site will increase costs. Abnormally low
temperatures will require the provision of additional insulation & special heating
for equipment & pipe runs. Stronger structures will be needed at locations subject
to high winds or earthquakes.
Sample plant layout given here is taken from the Korea Plant Industries Association
based in Seoul, Korea.
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The standard plant specifications are:
Production Capacity:
100 tonnes/day (of 37 wt% Formaldehyde solution)
Working Condition:
12 hours/day
Land and Buildings

Land:
3,000 M2
Buildings:
1,000 M2
Construction Schedule
About eighteen (18) months after receipt of the down payment, the plant will be
completed. However, this proposed schedule may be extended or shortened
according to onsite construction circumstances.
Operation Manpower
A sample requirement of manpower for the formaldehyde plant of capacity 400
m3/day is given below. Similarly the manpower requirement for 100 tones/day
plant can be drawn.
Classification
No of Persons
Plant Manager
Engineer
Production Operator
General Worker
Total (based on Korean)
10
TABLE 13 : MANPOWER REQUIREMENT

Designing work can be given to a design and construction company like the one
mentioned above. The design companies divide different works like transportation,
approvals/permits, basic engineering/design, inland and ocean transportation. A
typical case of division of these works between design company and owner is
shown below:
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TABLE 14: WORK DIVISION

Technology Transfer with Training Program
The Company generally provide the Owner with the latest technology and
operational expertise for the effective management of the Plant in addition to the
training of the Owner's engineers and skilled workers at the Plant site and or at
their offices and departments.
FIGURE 13: PLANT LAYOUT
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BIBIOLGRAPHY
(In alphabetical order)
1. Brown, G.G., Unit Operations, 1st edition, C.B.S. publishers (1995)
2. Brownell, L.E. and Young, E.H., Process Equipment Design,1st edition, Wiley,
Prentice Hall (1962)
3. Coulson, J. M. & Richardson, J. F., Chemical Engineering, Volume 2, Reactor
Design, Chapter 2
4. Coulson, J. M. & Richardson, J. F., Chemical Engineering, Volume 6
5. Joshi M. V. , Equipment Design, 2nd Ed., Mc-Millan India Ltd,
6. Kern, D.Q, Process Heat Transfer , J. A., 4th Edition , McGraw
Hill
International Edition
7. .Kirk & Othmer , Chemical Engineering Encyclopedia, Vol. 2 nd (1960) , Inter
Science Publishers , N. Y.
8. McCabe, Warren L., Smith, Julian C., and Harriot, Peter, Unit Operations of
Chemical Engineering, 5th edition, Pergamon Press (1983)
9. McKetta, John J. and Cunninghum, William A., Encyclopedia of Chemical
Processing & Design, Revised edition, Marcel Deker Inc.(1984)
10. Perry, J.H., Chemical Engineers Handbook, 7th edition, McGraw Hill, Inc.
(1985)
11. Peters, Max S. and Timmerhaus, Klaus D., Plant Design & Economics, 4 th
edition, McGraw Hill, Inc. (1980)
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12. Shreve R . N. & Brink J A , Chemical Process Industries , 5th Edition , McGraw
Hill International Edition .
13. Treyball, R. E. , Mass Transfer

14. Wilbrant, Frank C. & Dryden, Charles E., Chemical Engineering Plant Design,
4th edition, McGraw Hill, Inc. (1980)
15. Woods, Donald R., Chemical Plant Design
Data from the Net:

List of Important sites visited:
1. http://www.sciencedirect.com
2. http://www.onesmartclick.com
3. http://www.chemical-engineering-design.com
4. www.udhe.com
5. www.SRIconsultant.com
Page 117
Formaldehyde 2014
NOMENCLATURE
Symbol
Significance
Density
Viscosity
Molecular weight
Height
Diameter
Absolute Temperature
Pressure
Residence Time
Fractional Conversion
Volume
Vo
Volumetric flow rate
Local Heat transfer coefficient
Overall heat transfer coefficient
Heat
Cp
Heat Capacity
Latent heat of vaporization
Time
Length
Thermal Conductivity
NRe
Reynolds Number
NPr
Prandlt Number
Dt
Diameter of tank
Width
Height
Tm
Logrithmic
mean
temperature
difference
O.D.
Outside diameter
I.D.
Inside diameter
Db
Bundle diameter
Ds
Shell diameter
Page 118
Formaldehyde 2014
g
Acceleration due to gravity
To
Average temperature
As
Cross flow area
Mass velocity
De
Equivalent diameter
hs
Shell side heat transfer coefficient
jf
Colburn factor
Viscosity of water
ut
Velocity of fluid in tube
us
Velocity of fluid in shell
kY
Mass transfer coefficient
Vapor phase composition
Gs
Gas flow rate on solute free basis
HTU
Height of transfer unit
NTU
Number of transfer units
YB
Break point composition of bed
Slope
hs
Enthalpy of steam
Enthalpy in vapor phase
Enthalpy in liquid phase
Flow rate of feed
Nt
Number of tubes
Steam flow rate
Li
Mass flow rate of liquid
Vi
Mass flow rate of gas
Ud
Dirt coefficient
BWG
Bingham wire gauge
Tw
Wall temperature
Tf
Film temperature
Universal gas constant
Allowable stress
Joint efficiency
ts
Shell thickness
Page 119
Formaldehyde 2014
Es
Elastic modulus of shell
Et
Elastic modulus of tube
tt
Tube thickness
bo
Gasket width
tf
Flange thickness
Pitch circle diameter
Pw
Wind pressure
Corrosion allowance
Seismic coefficient
tB
Diameter of bearing plate
Cp
Specific heat
Pc
Critical pressure
Tc
Critical Temperature
Tube wall heat transfer coefficient
Sc
Schimdt number
hg
height of gas phase controlling bed area in

absorption column
relative volatility
Page 120

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Formaldehyde 2014

5. Manufacturers and economics

Silver Catalyst process

Reason for choosing silver process

8. The Silver process

Material balance around different equipments

Overall material balance

10. Energy Balance

Energy balance around methanol before evaporation

Reactor effluent gases cooling

B.TECH Project IIT (BHU) Varanasi

Process design of few other equipments

12. Mechanical Design

13. Process utilities

17. Plant location and layout

18. Plant Economics

B.TECH Project IIT (BHU) Varanasi

B.TECH Project IIT (BHU) Varanasi

SUMMARY OF THE PROJECT

CH3OH + 1/2O2 HCHO + H2O

First reaction is desirable which is exothermic with a selectivity of 9, while the

B.TECH Project IIT (BHU) Varanasi

B.TECH Project IIT (BHU) Varanasi

B.TECH Project IIT (BHU) Varanasi

INITIAL BLOCK FLOW DIAGRAM

B.TECH Project IIT (BHU) Varanasi

Antiseptic, Germicide and Fungicide

B.TECH Project IIT (BHU) Varanasi

THE SILVER CATALYST PROCESS

CH3OH + 1/2O2 HCHO + H2O

The other minor reactions that are taking place are:

CO + 2 H2O -162 KCal/g-mol

B.TECH Project IIT (BHU) Varanasi

A small portion of formaldehyde gets oxidized further:

B.TECH Project IIT (BHU) Varanasi

PROCESS DESCRIPTION OF SILVER CATALYST PROCESS

CH3OH + 1/2O2 HCHO + H2O

The other minor reactions that are taking place are:

B.TECH Project IIT (BHU) Varanasi

B.TECH Project IIT (BHU) Varanasi

B.TECH Project IIT (BHU) Varanasi

One (1) evaporator

One (1) air blowers (one with speed variator)

One (1) reactor with boiler tubes

One (1) gas/gas heat exchanger

Seven (7) liquid/liquid heat exchangers

One (1) condensers

One (1) packing absorption column

Two (2) tray absorption columns (bubble caps)

One (1) tray distillation column (bubble caps)

Pumps (Sihi) doubled to secure the process

Pipes, valves, etc.

Protection of electric motors : IP 55 Eexd II BT 4

Composition of the feed entering the evaporator: It is controlled by means

B.TECH Project IIT (BHU) Varanasi

Pressure of the evaporator. Maintained at ~ 900 mm wc & monitored by

Level of the mixture in the evaporator. Maintained at 45% of total capacity

Temperature & pressure inside the reactor. The temperature should be

Composition of the formaldehyde leaving the absorption column. It is

Other gases present should be removed.

Specific gravity of formaldehyde :The specific gravity of formaldehyde is

Conversions and yields vary as a function of temperature. A light-off temperature

B.TECH Project IIT (BHU) Varanasi

EQUIL. DATA: y=Ai(LK)x/(1+ (Ai(LK) - 1)x)