Production of Formaldehyde

Hydrocarbons and its derivative are key compounds utilized in chemical industries for
production of a number of products. One of the important compound commercially in
demand is formaldehyde. This is not the end use product but primary raw material utilized in
production of a number of resins. It has been produced since 1900s [5], Potential utilization
of formaldehyde is in production of melamine and urea formaldehyde resins which accounts
for 70% consumption of formaldehyde [2]. Figure 1 represents world consumption of
formaldehyde.

Figure 1 World consumption of Formaldehyde [2]

The derived end user products include wood product industry are demanding now a days
which are driving formaldehyde production and with increase of wood laminates production
further projected demand is being driven fastly. China single handedly is the prime market
place for formaldehyde. It is utilized in production of resins and plasticizers.
On the other hand, there is concern over the carcinogenic effect of formaldehyde as well.
Various studies over low level to mild level exposure to formaldehyde have been performed.
But there is no ultimate concluding remarks regarding human health risks due to
formaldehyde. Mainly formaldehyde is delivered in form of formaline which is basically 37%
by weight formaldehyde. In this study a step wise description of formaline production is
established.
Main Reaction
Formaldehyde can be produced using methanol as raw material through a catalytic reaction
with oxgygen as follow:
CH 3OH  1/ 2O2  HCHO  H 2O
CH 3OH  HCHO  H 2

Air is main source to obtain oxygen for catalytic reaction. For this purpose, air is mixed
together with methanol. Due to flammability concerns, methanol in air is set to be above 36%
 that is upper flammability limit for methanol. As methanol air mixture above upper
flammability limit and below lower flammability limit does not catch fire. This reaction is
catalyzed and exothermic in nature. The heat of reaction is removed using a condenser. After
removing heat in condenser, remaining raw material methanol, formaldehyde and water are
obtained in liquid/condensed form while nitrogen, remaining oxygen and hydrogen produced
during the reaction are flashed using a flash chamber. Formaldehyde is then distilled and
obtained as bottom product while methanol is obtained from top of the distillation column
and recycled back to reactor for optimum conversion of raw material into products. Side
reaction is also useful as it directly produces formaldehyde along with hydrogen. The catalyst
usually silver makes this conversion possible.
Main Process [1]

Air (1)

Flash
Methanol
(2) Chamber
(4)

Methanol
(7) Reactor (3)

Distillation
Column
(5)

Formaldehyde
(6)

(1) Air is taken from atmosphere, it is compressed and heat is added to take it to reactor
inlet temperature.
 (2) Methanol from storage tank is heated to reactor inlet temperature and fed to reactor.
(3) In the reactor, catalyzed exothermic reaction occurs which convert reactant into useful
product.
(4) Exothermic heat is removed and mixture is flashed into a vessel flash chamber to
knock out off gases containing H2, N2.
(5) The bottom liquid product from flash chamber is mixture of formaldehyde and
methanol which is distilled in distillation column.
(6) From bottom distillate of the distillation formaldehyde is obtained which is mixed
with water to form 37% formaline and transported to buyer.
(7) From top of the disttiliation column, volatile component that is Methanol is recovered
and recycle back to reactor for conversion into formaldehyde.
Market and production estimate

Worldwide increase in production to meet global demand is projected to be 20.8 million

metric tons. While single major buyer of formaldehyde may be Chinese market as it takes
largest share in formaldehyde production. 10% of projected demand is targeted to be captured
by production of formaldehyde. So, 200000 metric tons per year production would be
feasible that can be sell easily in the market. The main buyers are:
1. Urea and melamine formaldehyde resin manufactures as these accounts for 70%
consumption of formaldehyde.
2. Polyacetal acid resin, wood product laminates.
For obtaining methanol from Chinese industries will be preferred because transportation of
raw material and or product would not be feasible as product formaline is already 37% by
weight contains water. Sugar industries are now a days producing methanol as by product.
So, sugar industry will be prime target to get reactant (Methanol).
Safety concerns
Methanol is flammable material and proper handling to avoid fire hazards will be adopted.
Methanol has an upper flammability limit of 36% and lower flammability of 6%. So, its
mixture with air will be kept above upper flammability limit in any case during conversion
from raw material to final product. While product formaldehyde is highly carcinogenic. It is
classified as human carcinogenic (group I) by International agency for Research on Cancer
(IARC). It causes leukemia in humans. Exposure to formaldehyde is through inhalation due
to which World Health Organization (WHO) 0.1 mg per cubic meter.
References
[1] Turton, R., R.C. Bailie, W. B. Whiting and J. A. Shaeiwitz, Analysis, Synthesis and
Design of Chemical Processes, Prentice-Hall, Upper Saddle River, NJ,1998.
[2] https://www.marketwatch.com/press-release/global-formaldehyde-market-report-2019---
industry-analysis-by-types-application-and-key-manufactures-2019-07-02
[3] Nielsen, G.D., Larsen, S.T. and Wolkoff, P., 2013. Recent trend in risk assessment of
formaldehyde exposures from indoor air. Archives of toxicology, 87(1), pp.73-98.

[4] https://pubchem.ncbi.nlm.nih.gov/compound/Formaldehyde
[5] Mark, H.F., Kirk, R.E., Othmer, D.F., Grayson, M. and Eckroth, D. eds., 1978. Kirk-
Othmer encyclopedia of chemical technology: Vol. 1. John Wiley & Sons, Incorporated.
[6] https://www.businesswire.com/news/home/20171029005038/en/Phthalic-Anhydride-
Market---Segmentation-Analysis-Forecast