Production of Formaldehyde

from Methanol using

different Catalysts.
Supervisor:
Dr. Naseer Ahmed Khan
Committee Members:
Dr. Saeed Gul
Dr. Irshad Ali
Engr. Unsia Habib
Group 23
Name Registration
Muhammad 16PWCHE1111
Zakaria
Kawish Iqbal 16PWCHE1151
Muhammad Umar 16PWCHE1166
Farooq

Supervisor’s Signature

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Table of Contents:

Topic Page

03
Introduction

03
Objectives

04
Literature Review

 Metal Oxide Catalyst Process 04

 Production of Formaldehyde from Methane 06

06
Methodology

07
Uses of Formaldehyde

08
Gantt Chart

10
References

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Introduction:
Formaldehyde (systematic name methanal) is a naturally occurring
organic compound with the formula CH2O (H−CHO). It is the simplest of
the aldehydes (R−CHO). The common name of this substance comes from
its similarity and relation to formic acid.
Formaldehyde is soluble in water and some other chemical solutions.
Rapid absorption of formaldehyde in the respiratory and gastrointestinal
systems is because of its high solubility in water. Formaldehyde is
generally known as formalin. Formalin is 37% formaldehyde solution in
water. For preventing polymerization of formaldehyde, it is mixed with
ten percent of methanol as a stabilizer. In the table 1 the characteristics of
formaldehyde are shown.
Formaldehyde is an important precursor to many other materials and
chemical compounds. In 1996, the installed capacity for the production of
formaldehyde was estimated at 8.7 million tons per year.[12] It is mainly
used in the production of industrial resins, e.g., for particle board and
coatings.
Formaldehyde is more complicated than many simple carbon
compounds in that it adopts several different forms. As a gas,
formaldehyde is colourless and has a characteristic pungent, irritating
odor. Upon condensation, the gas converts to various other forms of
formaldehyde (with different chemical formulas) that are of more practical
value. One important derivative is the cyclic trimer metaformaldehyde
(1,3,5-trioxane) with the formula (CH2O)3. There is also a linear polymer
called paraformaldehyde. These compounds have similar chemical
properties and are often used interchangeably.

Objectives:
To Produce Formaldehyde from Methanol by Dehydrogenation of
Methanol.
To Select a suitable catalyst for dehydrogenation process.

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Literature Review:
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 growthrate 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 world’s 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 center 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, photographing washing, woodworking, cabinet-
making industries, glues, adhesives, paints, explosives, disinfecting
agents, tissue preservation and drug testing. As to be applied in this
project, formaldehyde is most commonly produced in industry
through the vapor- phase oxidation reaction between methanol and
air (Oxygen). However, there are several methods of synthesizing
formaldehyde that are notable and efficient. Here we present several
of these alternative processes:

 Metal Oxide Catalyst Process:

The Formax process developed by Reichhold chemicals to

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produce formaldehyde through direct catalytic oxidation of methanol
and some other 7 by-products such as carbon monoxide and dimethyl
ether forms. In 1921, the oxidation of methanol to formaldehyde with
vanadium pentoxide catalyst was introduced to and patented. Then in
1933, the iron molybdenum oxide catalyst was also patented and used
till the early 1990’s. Improvements to the metal oxide catalyst were
done through the metal composition, inert carriers and preparation
methods. The first commercial plant for the production of
formaldehyde using the iron molybdenum oxide catalyst was put into
action in 1952. Unlike the silver based catalyst in this project, the
iron-molybdenum oxide catalyst makes formaldehyde from the
exothermic reaction (1) entirely. Under atmospheric pressure and 300
– 400 oC, methanol conversion inside the reactor could reach 99%
and a yield of 88% - 92%.
The process begins by mixing of vaporized methanol and air
prior to entering the reactors. Inside the heat exchanger reactor, the
feed is passed through the metal oxide catalyst filled tubes where heat
is removed from the exothermic reaction to the outside of the tubes.
Short tubes (1 – 1.5 m) and a shell diameter 2.5 m is the expected
design of typical reactors. The bottom product leaving the reactors is
cooled and passed to the absorber. The composition of formaldehyde
the absorber outlet is controlled by the amount of water addition. An
almost methanol-free product can be achieved on this process design.
The advantage of this process over the silver based catalyst is the
absence of the distillation column to separate unreacted methanol and
formaldehyde product. It also has a life span of 12 to 18 months,
larger than the sliver catalyst. However, the disadvantage of this
process design is the need for significantly large equipment to
accommodate the increased flow of gases (3 times larger) compared
to the original silver catalyst process design. This increase in
equipment sizing clashes with economic prospect behind the design
costs.

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  Production of Formaldehyde from Methane and
Other Hydrocarbon Gases:

Another method of producing formaldehyde is through the

oxidation of hydrocarbon gases. An increase in the amount produced
of formaldehyde is expected in this process. However, the
hydrocarbon formaldehyde is usually obtained as dilute solution
which is not economically concentrated accompanied by other
aldehydes and byproducts. However, improvements have been
effected by the use of special catalysts and better methods of control.
Wheeler demonstrated that methane is not oxidized at an appreciable
rate below 600°C.
The difficulty in this method is in controlling the oxidation of
reaction. Ethylene, ethane and propane oxidations can be controlled
to yield formaldehyde under similar conditions to methane. Higher
hydrocarbon gases can be oxidized at much lower temperatures than
methane and ethane. These methods have been described by Bibb
also reported by Wiezevich and Frolich, who used iron, nickel,
aluminum, and other metals as catalysts and employed pressures up
to 135 atmospheres. The Cities Service Oil Company has developed a
commercial process using this method.

Reagents Required:
Methanol (commercial); Calcium Chloride (anhydrous); Phenyl
Hydrazine; Potassium Ferricyanide; concentrated Hydrochloric Acid.

Methodology:
A schematic assembly shown in Figure below will be required for
formaldehyde synthesis consisting an atomizer, preheating zone, reaction
column and absorption tower.

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Uses Of Formaldehyde:
 As Synthesis baseline for other chemical compounds.

 As Permanent Adhesive in Plywood and Carpeting (Formalin).

 As Disinfectant as it kills most bacteria and fungi.

 As Tissue fixative and embalming agent.

 For Drug testing.

 Photography.

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 Form FYP-02 Final Year Project

Project Plan
This form is to be filled by the students and supervisor and to be submitted to FYP evaluation
committee in 4th week of academic year. Student shall plan the work properly and prepare
work schedule for one year (both Fall and Spring semesters) with the guidance of the
supervisor.

Academic Year: (2019-20) Semester: ( Fall  Spring) Date:(23/10/2019)

Production of Formaldehyde from Methanol using different
Project Title
Catalysts.
Supervisor Dr. Naseer Ahmed Khan
Reg 16PWCHE1111 6PWCHE1111 6PWCHE1111
No.
Students
M. Zakaria Kawish Iqbal M. Umar
Names
Farooq

Schedule/Phasing:

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Supervisor Signature

Students Signatures
(respectively)
Chairman Approval

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References:
1. J Read, Text-Book of Organic Chemistry; G Bell & Sons:
London, 1935.
2. Olbert, G., Johann, T., Weber, M., Lang, N., Harth, K.,
Stroefer, E., Fieni, M., Siegret, M. (BASF Aktiengesellschaft,
Germany) PCT Int. Appl. WO 2005 63,375
3. Soares, A. P. V., Portela, M. F. Catalysis reviews-Science and
Engineering 47(1), 125-174 (2005).
4. Isaguliants, G. V., Belimestnykh, I. P. Russian academy of
sciences, 100(3-4), 441-445 (2005).
5. M Salman*, J Anwar, W Zaman, M Shafique, S.A Hussain.
2008. Synthesis and characterization of formaldehyde by
catalytic oxidation of methanol.
6. R Shawabkeh*, M.A Sanhoob, A Sulami. 2012. Production of
formaldehyde from methanol integrated final report.
7. X Tang, Y Bai,A Duong, M.T. Smith, L Li, L Zhang. 2009.
Formaldehyde in China: Production, consumption, exposure
levels, and health effects.

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