Metal Oxide Process Formaldehyde Plant Manufacturer

Metal Oxide Process Formaldehyde Plant

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Description of Formaldehyde Manufacturing Process

The metal oxide process is a formaldehyde manufacturing process that uses iron molybdate as the catalyst. Helipont offers two reactor heat carrier types: a heat transfer oil and a molten salt.

Flow chart

Main Formaldehyde Manufacturing Equipment

Methanol pre-evaporator
Absorption tower

Advantages

Less formaldehyde consumption
Longer catalyst work period
Formaldehyde concentration can reach 50%, while methanol content is less than 0.5%.

Formaldehyde Production Process

Send compressed air to the methanol pre-evaporator.
Send gaseous methanol and air through the reactor that contains the catalyst for a reaction.
Condense the formaldehyde gas from the reactor into a formaldehyde liquid.

Annotation: For more information on our production processes, please do not hesitate to contact us.

Raw material specification

Type	Index
Formaldehyde，Wt%	37-57
Based on 37%，
Methanol，Wt%	< 0.8
Formic acid，Wt%	< 0.03
Consumption
Methanol	93%
Methanol，kg/MT*	425
Electricity (IBL)，kW/MT*	72
CW - 10 deg C rise，m3/MT*	50
Steam consumed，kg/MT*	0 (Net. prod.)
Steam output，kg/MT	800undefined（1.2～2.0Mpa)

Comparison of two process

Compare the metal oxide process and silver catalyst process on the economic front (assume 100,000 tons).

Equipment: The metal oxide process requires a larger upfront investment in order to produce the same 55% formaldehyde solution.
Steam output: metal oxide process, 800 kg/MT（2.0Mpa), while silver catalyst process 550 kg/MT（0.6Mpa). Assuming the steam unit price is $22/ton, metal oxide processes save $550,000/year.
Methanol consumption: metal oxide processes save 20kg/TPA of methanol. Assuming the unit price of methanol is $430/t, metal oxide processes save $860,000/year.
Service life of the metal oxide processing equipment is more than 50 years, which is almost 3 times longer than equipment used in the silver catalyst process. This means that using the metal oxide process saves up to $15,000/year in operation costs.
Catalyst cost: The metal oxide process costs $260,000/year, while silver regeneration costs $20,000/year. Thus, the silver regeneration process costs $240,000 less per year
Power consumption cost: metal oxide processes are higher than a silver catalyst process by about $440,000/year. (metal oxide process 70kwh/t, silver catalyst process 26kwh/t, electricity unit price $0.1/kwh)
Using the metal oxide process saves about $740,000/year.

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