PDF Production of Formaldehyde - Compress
PDF Production of Formaldehyde - Compress
Un ver sit
si ty of D i yala
C oll
lleeg eof E ngi
ng i nee
neer i ng
C hemi
hemiccal E ngi
ng i nee
neer i ng De
D epar
par tment
ment
Producti
Produ ction
on of formaldehyde
formaldehyde
A project report Submitted to the Engineering Department
of Chemical of the University of Diyala in a partial fulfillment
for the Degree of B.Sc in Chemical Engineering
By
Sajad
Sajad jaba
jabar sa
sabty
Muh
M uha
anad
nad asaad adham
Mo
M ohammad abdulljalel
ulljalel mudh
udhafar
far
Supe
Super vi so
sorr :
Asssi st. pro
A prof.
f. Dr. ah
ahmed daham wah
waheeb
2015
2015 - 2016
2016
ا كة وع
اب و يك ع زل ( …و
)
2
Dedication
To my beloved family . . . .
My parents .. My Father & My Mother
My Brothers
My Sisters
To my lovely
lo vely friends . . . .
sajad,muhanad,Mohammed
3
Table of Contents
1- Summary ……………………………………………………..... 2
1.3 - So
Sources
urces …………………………………
……………………………………………
…………………….
…………. 3
1.4 - Dem
Demand
and ……………………………………………………
……………… ………………………………………
…3
1.5 - Use of
o f formaldehyde
formaldehyde ……….………………………………...4
……….………………………………...4
1.6.2 - Chem
Chemiical properti
pro perties
es ………………………………………...5
1.7- Pro
Produc
ducti
tion
on method
methodss …………………………………………...6
…………………………………………...6
1.7.1- Fro
Fromm me
methan
thanol
ol by sil
silver
ver catal
catalysts
ysts proces
pro cesss ………………….8
1.7.2- Me
Metal
tal oxide catalyst
catalyst p
proc
rocess
ess ………………………………..10
………………………………..10
1.7.3- Pro
Produc
ducti
tion
on of formal
formaldehyde
dehyde from other
o ther hydro
hydrocarbo
carbon
n gases ..12
1.8- Sele
Selection
ction of proces
pro cesss ………………………………
………………………………………
……….…..13
.…..13
2.1-Mass
2.1-Mass balance ……………………………………………….…..15
2.1.1.1- Materi
Material
al balance on the reactor
reacto r …………………………
……………… ……………15
…15
2.1.1.2- Materi
Material
al balance on the abs
absorb
orber…………………………...18
er…………………………...18
2.1.1.3- Materi
Material
al balance on the distilla
distillation
tion colu
co lumn…………………22
mn…………………22
2.1.2- Seco
Second
nd rrun
un mass bal
b alance
ance ……………………………………..25
……………………………………..25
4
2.1.2.1- Ma
Mass
ss balance
balance on the reactor
reacto r ……………………………….25
……………………………….25
2.2.1- Mi
Mixi
xing
ng po
poin
intt between streams 2 , 3 and 15 …………………29
………………… 29
2.2.4- Mi
Mixi
xing
ng po
poin
intt between streams 6, 7 ………………………….
…………… …………….33
33
2.2.6- Energy balance on the heat exchanger inside the reactor ……34
2.2.10- Mi
Mixi
xing
ng poi
po int of stream 17 , 18 and 19………………………40
19…………………… …40
5
3.2.6- Combination ………………………………………………..49
3.2.7- Press
Pressure
ure drop ………………………………………
… ……………………………………………
……….50
.50
3.3.2 -Packing
-Packing material…………………….………………………56
3.3.3- Sizi
Sizing
ng of pac
packed
ked tower……………………………………
tower……………………………………..56
..56
3.3.3.1- Pac
Packed
ked tower diame
diameter
ter …………….……………………
…………….……………………..57
..57
3.3.3.2
3.3.3. 2 - Packi
Pac king
ng heig
height
ht (Z pac
packi
king
ng)) ……….…………………….60
3.4 - Di
Dist
stil
illa
latt ion colu
co lumn
mn desig
des ign
n …………….………
…………… .…………………...61
…………...61
3.4.2 – Fro
Fromm materi
material
al balance ……………………………………62
………… …………………………62
3.4.3 – Calculati
Calculation
on number of plates ……………………………..63
……………………… ……..63
3.4.5 – Co
Collumn diameter ……………………………
……………… ………………………
…………..
..67
67
Controll loo
Contro loopp system
s ystem on aabs
bsorb
orber
er …………………………………74
…………………………………74
Chapter five ……………………………………
……………………………………………
………………..75
………..75
5.1.1- Methanol
Methanol ………………………………………………….76
5.1.1.1- Expos
Exposure
ure ………………………………………………..76
………………………………………………..76
5.1.1.3- Storage…………………………………………………..77
6
5.1.2-Formaldehyde ……………………………………………77
5.1.2-Formaldehyde
5.1.2.2-Expos
5.1.2.2-Exposure
ure ……………………………………………
……………………………………………….78
….78
5.1.2.3-Storage
5.1.2.3-Storage …………………………………………………78
5.2.1- Introduction……...………………………………………78
6.3 - Operati
Operating
ng labor cost
co st ………………………………………
………………………………………82
82
6.4- Equi
Equipment
pment cost
co st …………………………………
…………………………………………
………….83
….83
Conclusion ……………………………………………………...84
Reference………..………………………………………………85
7
CHAPTER ONE
SUMMARY
8
1. Summary
1.1-- Int
1.1 Introdu
roduction
ction
Formaldehyde is released into the air by burning wood, kerosene, or natural gas;
gas ;
from automobiles and diesel exhaust; and from cigarettes and other products. It
is found in the air at home, at work, and outdoors, especially in smog. It is also
found in some foods.
9
1.2-- Health effects
1.2
1.3- Sources
Sources
Formaldehyde is both directly emitted into the atmosphere and formed in the
atmosphere as a result of photochemical oxidation of reactive organic gases in
polluted
polluted atmos
atmosphere
pheress contai
containing ozone and ni nitrogen
trogen oxides.
oxides. Photochemi
Photochemica
call
oxidation is the largest source (could be as high as 88 percent) of formaldehyde
concentrations in California ambient air. A primary source of formaldehyde is
vehicular exhaust Formaldehyde is a product of incomplete combustion. About
9 percent of direct formaldehyde emissions are estimated to come from the
combustion of fossil fuels mobile sources.
1.4-- Demand
1.4
Demand for formaldehyde will grow with the development of the manufacturing
sector mainly the chemical industries such as disinfectants, cosmetics,
pharmaceuti
pharm aceutica
calls, insecticide
insecticide & fungic
fungic ides and the like.
like. The demand for the
output of such establishments is in turn influenced by population growth,
urbanization, income rise and expansion of health services and the like.
Considering the combined effect of the above factors a growth rate of 10% is
taken to forecast the future demand.
Year Projected
Demand
2012 143,000
2013 157,300
2014 173,030
2015 190,333
2016 209,366
10
1.5-- U
1.5 Use
se of formaldehyde
formaldehyde
1.6.1-
1.6 .1- Physical Properties of Fo
Form
rmaldehy
aldehyde
de
Properties
Pro perties Fo
Formi
rmicc aldehyd
aldehyde,
e, methanal,
methanal, methyl al
aldehyd
dehyde,
e,
methylene
methyl ene oxide, Oxo
O xo methane,
methane, ox methyl
methylene
ene
CAS regist
registry
ry number 50-00-0
Molecular
Molecul ar formula HCHO
Molecular weight
weight 30.03
Boiling point –19.5°C
Melting point –92°C
Flash poi
Explos
Explosipoiveintlimi
limits
ts 83°C
7% to(closed
73% cup)
Specifi
Sp ecificc gravity
gravity 1.067 with
with respect
resp ect to ai
airr
Vapo
Va porr pres
pressuresure 3,890 mmHg
mmHg at 25°C
Solu
So lubil
biliity Very s oluble in water; s oluble in al
alco
cohol
hol and ether
Conversion
Conver sion factors 1 ppm = 1.23 mg/m
mg/m ; 1 mg/mmg/m = 0.81 ppm
pp m
Vapor Press
Pres s ure 3284 mm Hg at 20 0C
Vapo
Va porr De
Density
nsity 1.03 for aq. so
solln.; 1.08 for gas
Density/Speciific Gravity
Density/Spec 1.067 (air
(air = 1)
Log Octanol/Water 0.35
Partition Coefficient
Conversion FactorFac tor 1 ppm
pp m = 1.23 mg/m3
mg/m3
11
1.6.2
1.6 .2 - Chemical p
properti
roperties
es
Decomposition
At 150 ºC formaldehyde undergoes heterogeneous decomposition to form
methanol and CO2mai
mainl
nly.
y. Above 350
350 ºC it
it tends to dec
decompo
ompose
se in to CO and H2.
Polymerization
Gaseous formaldehyde polymerizes slowly at temperatures below 100 ºC,
polymeriza
polym erization
tion accelerated
accelerated by traces
traces of polar impuriti
impurities
es such as acids, alalkali
kaliss
orwater. In water
water sol
so lution formaldehyde hydrates to methyl
methylene
ene gl
glyco
ycoll
H
H2C=O
H2 C=O + H2O
H2O HO C OH
H
Which in turn polymerizes to polymethylene glycols, HO (CH2O)nH O)nH,, al
also
so called
called
polyoxy methy
methyllen
enes.
es.
Reduc tion
Reducti on and Oxidation
Oxidation
Formaldehyde is readily reduced to methanol with hydrogen over many
metaland metal oxide catalysts. It is oxidized to formic acid or CO 2 and H2O.In
the presence of strong alkalis or when heated in the presence of acids
formaldehyde undergoes cannizzaro reaction with formation of methanol and
formic acid. In presence of aluminum or magnesium methylate,
paraforma
paraformalldehy
dehyde
de reacts
reacts to form methy
methyll form
fo rmate
ate (Tishchenk
(Tishchenkoo reaction)
reaction)
2HCHO HCOOCH3
Addition reactions
The formation of sparingly water-soluble formaldehyde bisulphite is an
important addition react
reactiion. Hydroc
Hydrocyani
yanicc aci
ac id reacts with
with formaldehyde to give
glyconitrile.
HCHO + HCN HOCH2 - C - N
Resin formation
Formaldehyde condenses with urea, melamine, urethanes, cyanamide, aromatic
sulfonamides and amines, and phenols to give wide range of resins.
12
Chemical reaction of Formaldehyde
Number
Number Reaction ΔHR,973 K(kJ/mol)
(1) CH3OH +1/2O2 → HCHO+H2O -156
(2) CH3OH →HCHO+H2 +85
1.7-- Produ
1.7 Production
ction methods
Today two main processes are in use for the production of formaldehyde from
methanol, the silver process and the oxide process. The first can be divided in to
two processes, the methanol ballast process and the BASF Badische Anilin&
Soda-Fab
So da-Fabri
rik
k proces
pro cesss as
as sho
shown
wn in Figure
Figure 1.1.
Methanol
ballast
process
Silver
Process
Processes for
BASF
Production of
Process
Oxide
Process
Figure
Figure 1.1. The
T he differen
differentt proces
pro cesss types
types for production
prod uction of formaldehyde
formaldehyde from
methanol.
13
Figure
Figure 2.2.
2. 2. sschemati
chematicc overv
o verviiew of the sil
silver pro
proces
cess.
s. The dashed
das hed square
sq uare shows
sho ws
what only exist in the methanol ballast process
Figure
Figure 2.3. A schem
sc hemati
aticc schem
sc hemee over th
thee oxidation
oxidation proc
p rocess
ess (Table 1.1.)
14
1.7.1-
1.7 .1- From m
methanol
ethanol by silver catalysts pr
proce
ocess
ss
Feed mixture of pure methanol vapor and blown in air is generated in evaporator
the mixture combined with steam and enter the reactor vapor passes through bed
to silver catalyst or silver gauze. The conversion is in completed and the reaction
takes place in 600-720 °C the reaction gases cooled in directly with water, the
DIAGRAM 1
15
FORMALIN (FOLRMALDEHYDE 37 WT. % SOLUTION)
Flash point 64 °C
16
1.7.2-- Metal Oxi
1.7.2 Oxide
de C
Cataly
atalyst
st Proces
Processs
17
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
in 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
li
life
fe span
sp an of 12 to 18 months,
months , larger than the sliver
sliver catal
cat alyst.
yst.
18
1.7.3- Production of formaldehyde from methane and other hydrocarbon
gases
19
1.8- Selection of process
process
The oxide process has to think about how to let out their tail gas, which mostly
consist of nitrogen, oxygen ,CO and other compounds from the absorption tower
such as formaldehyde and methanol exist in the tail gas. Because of these
compounds the tail gas cannot be released into the air as it is, compared to the
silver processes that can let their tail gas go without consideration.
the disadvantage of The oxoxiide process
pro cess design is the need for significantly large
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.
silver
silver catalysts proce
process
ss
20
CHAPTER TWO
MATERAIL AND ENERGY BALANCE
21