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Pörner - Model Formaldehyde -Organic Raw Materials
Formaldehyde is one of the most important organic raw materials in the chemical industry. Formaldehyde is an important raw material for the chemical industry and the basis for many industrial products. More than 50 branches of industry using formaldehyde and its derivatives, as adhesives, resins, and in many other applications. The global annual consumption of formaldehyde is about 41 million tons. 51% of them are made in China.
Pörner Grimma is not only a specialist in the formaldehyde method, but also for process applications of formaldehyde derivatives. Technically formaldehyde can be produced by the catalytic oxidation of methanol. These are, two methods, the silver and the metal oxide method.
Although the catalyst has to be changed frequently in the silver method, but the aqueous formaldehyde solution is of higher quality because the formic acid content is lower.
The Silver Catalyst process is the most safe process of formaldehyde production. Formaldehyde concentration and residue methanol produced with the Silver Catalyst Process is as good as from best metal oxide process. Less formic acid and no caustic soda and antifoam agent makes the product more versatile for all formulations and customers.
There is also no hot oil used in this process, just water/steam and this reduces the fire risk. There is no oxygen in the absorber, this not only reduces the fire risk but improves the product quality as well.
The catalyst can be removed without dust and waste in a few hours. Re-catalization can take less than 24 hours so only small holding tanks are necessary to serve customers during re-catalization.
The investment costs for the Silver Catalyst Process are similar compared to the Metal Oxide Process but there are other advantages to this system:
- the catalyst is inexpensive because it is fully regenerated,
- there is less electricity consumption,
- higher steam generation and less cooling demand.
These factors more than compensate for the slightly higher methanol consumption compared to the Metal Oxide Process.
- An evaporated Methanol Water Mixture is fed together with ambient air to the silver catalyst. The generated process gas is than absorbed in water and condensed in a selective absorption step.
- Standard trade solutions up to 49 % w/w formaldehyde with 1-2 % w/w methanol are produced without distillation.
- Alternatively we offer the special tail gas recycling technology to achieve high concentrated formaldehyde solutions up to 55 % w/w formaldehyde with 0,5 -1 % w/w methanol without distillation.
- The H2-rich absorption tail gas is combusted in a thermal oxidizer or special boiler and is generating steam or can even be fed to a gas motor generating electric power.
The Metal Oxide Process yields better quantities of formaldehyde therefore there is slightly less consumption of methanol. It also has similar investment costs to the Silver Catalyst Process.
Our process also allows the free choice of catalyst supplier as Pörner and its licensor are independent companies with the client’s wishes at heart. The final decision on which process to choose depends on the individual client and their needs.
Factors that influence this decision include costs of raw materials, utility costs, catalyst costs and safety and operation aspects etc.
- Methanol is fed together with ambient air to the metal oxide catalyst (iron oxide in combination with molybdenum and/or vanadium).
- The generated process gas is than absorbed in water and condensed in an absorption step.
- About one thrid of the absorption off gas is recycled to the reactor. Formaldehyde solutions up to 55 % w/w formaldehyde with 0,5 -1 % w/w methanol are produced.
- The absorption off gas is oxidized on a palladium catalyst which can be equipped alternatively with waste heat recovery.