REACTOR DESIGN PROPOSAL OF FORMALDEHYDE

GLOPPITY GLOP INC. May 10, 2013 Authored by: Raymond Feng

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Objective

The objective of Gloppity Glop Inc. is to design a reactor for the production of formaldehyde. While designing the reactor, the company will use the most

efficient method while considering the companys budget and the impact on the
environment.

Background

Formaldehyde or methanal, CH 2 O, is a colorless, carcinogenic, strong odorous, water-soluble, and toxic gas. A highly reactive aldehyde gas is formed by oxidation or incomplete combustion of hydrocarbons.

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In solution, it has a wide range of uses: in the manufacture of resins and textiles, as a disinfectant, and as a laboratory fixative or preservative. Formaldehyde solution (formalin) is considered a hazardous compound, and its vapor toxic. Formaldehyde can be derived from oxidized methyl alcohol and is more desirable to be used than other compounds because although it exhibits the chemical properties found in most aldehydes, it is more reactive. Formaldehyde is found to be a good electrophile and is used various reactions such as

electrophilic aromatic substitution. It is considered a foundation in the synthesis of many compounds that has industrial significance. The main manufactured products formed from glues, resins, and products in home furnishing. Glues that use formaldehyde as a building block are exceptional bonding agents. For example, formaldehyde-based resins are used to manufacture composite products used extensively in cabinetry, countertops, moldings, furniture, shelving, stair systems, flooring and many other household furnishings. These items are extremely economical due to the superior bonding properties and efficient production of formaldehyde-based glues.

Reactor Design Scheme The company decided that the reactor used in the proposed design is a Packed Bed Reactor (PBR)

FEED Methano l Air REACTOR SEPARATOR

PRODUCTS Formaldehyd e Water Carbon Dioxide RECYCLE Methanol

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Synthesis of Formaldehyde

Formaldehyde is produced by the catalytic oxidation of methanol. A mixture of molybdenum and iron or metallic silver, is used as a catalyst in such a reaction. However, there is another process more commonly used, and it is known as the formox process. In this process, methanol and oxygen react at temperatures higher than 250 C, in the presence of iron oxide along with molybdenum or vanadium, to produce formaldehyde. The following chemical equation represents the reaction that takes place.

CH3OH + O2

CH2O + H20

But if you are using a silver-based catalyst, then you have to operate at a temperature of more than 650 C. Although formaldehyde is the intermediate product of oxidation of methane, it is not industrially viable to synthesize formaldehyde from methane, because it is more easily oxidized than methane. The reaction process focuses on the following reactions: 1. 2. 3. 4.

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