PROJECT DESIGN

REPORT
PROJECT REPORT
ON
Design a Plant to manufacture 10 Tones/day of
FORMALIN

Submitted by
NAME: ADARSH KUMAR SONI
ROLL NUMBER: 17/M17/1
REGISTRATION NUMBER: S/III/22/9

SUBMITTED TO

INDIAN INSTITUTE OF CHEMICAL ENGINEERS,

JADHAVPUR, KOLKATA (WEST BENGAL)
FOR
ASSOCIATE MEMBERSHIP EXAMINATION
PART-III (HOME PAPER) – September, 2022
 Acknowledgement

I am very thankful to the Indian Oil Corporation Limited,

Paradeep, Odisha for their permission to appear in the

examination. I also want to express my sincere thanks to the

seniors, colleagues and friends for their hearty supports in

preparing this report.

Last but not the least; I want to thank my family members for their

moral support.

________________________

Adarsh Kumar Soni

ROLL NUMBER: 17/M17/1

REGN.NUMBER: S/III/22/9
 Self declaration

This is to certify that, the project report entitled: “Design

a Plant to manufacture 10 tones/day of Formalin” has

been prepared by me.

Date

Place

________________________

Signature

Adarsh Kumar Soni

ROLL NUMBER: 17/M17/1

REGN.NUMBER:S/III/22/9
 (A) STATEMENT OF THE PROBLEM

Design a plant to manufacture 10 tones/day of FORMALIN

Process details:

Formaldehyde is manufactured by vapor phase catalytic oxidation of Methanol. Methanol is

diluted with water and is evaporated in the evaporator. The Methanol water vapor mixture is

superheated and mixed with air. Then the mixture is admitted to the Packed bed catalytic

reactor containing silver grains as catalyst. The reaction temperature is maintained at 650C.

Assume a residence time of 10 to 20 seconds. The reaction is first order with respect to

methanol and half order with respect to oxygen. Heat recovery is made from the outgoing

product gases using a waste heat boiler. The product gases are sent to two absorption

columns in series wherein water and dilute Formalin are used for absorption. Finally the

formaldehyde is purified in a distillation column and the methanol is recycled back as a top

product. Assume 90% conversion of methanol. Assume any missing data suitably if

required.

Prepare a design report consisting of the following:

Full Marks

1. Literature Survey 15

2. Detailed flow sheet 15

3. Material and Energy balance of the plant 20

4. Design of Packed Bed Catalytic Reactor including mechanical details 40

5. Design of fractionation column to separate 37% pure formalin 30

6 Instrumentation and process control of the reactor 15

7. Plant layout 10

8 Safety and pollution abatement aspects 10

9. Cost estimation 15

10. Detailed engineering drawing of the reactor and separation column 30

____________

Total 200
 Contents
S.No. Topics Page No.
Chapter 1 Literature survey 1

Chapter 2 Detailed flow sheet 13

Chapter 3 Material and energy balance of the plant 21

Chapter 4 Design of Packed Bed Catalytic Reactor including 42-66

mechanical details

Chapter 5 Design of fractionation column to separate 37% pure 67-93

formalin
Chapter 6 Instrumentation and process control of the reactor 94-105

Chapter 7 Plant layout 106-117

Chapter 8 Safety and pollution abatement aspects 118-145

Chapter 9 Cost estimation 146-164

Detailed engineering drawing of the reactor Drawing Sheet 1

and separation column
Nomenclature 165-169

Bibliography 170-171