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Unique Experienced
Perstorp is involved in every aspect of Perstorp has been deeply involved in the
formaldehyde, from product research to formaldehyde business since 1907, when we
formaldehyde production and sales; from started production based first on copper, then
process development to plant design and silver catalysts. In the 1950s, we helped
equipment sales; from advanced catalyst pioneer the modern direct oxidation process
research to state-of-the-art catalyst and started building the world's first full-
production. Such integration is unique in the scale plant in 1958. We began licensing the
industry. pro-cess in 1966, and added a full design and
equipment supply service in 1992.
We design and construct formaldehyde
plants for clients all over the world. Our Today our process is by far the most
catalysts are also a global business - we sell successful in the world. The facts tell the
catalyst formulations for all types of oxide story:
processes. And we are active in the •
development of catalysts for emission Some 80 plants of various sizes all over the
control systems to enhance environmental world use the Perstorp Formox process.
protection. At a combined annual output of more than
4 million tons (9 billion Ibs), expressed as
Our customers are found in some 25 countries 37%, these represent more than 20% of the
on six continents. Household names in the total global formaldehyde consumption.
chemical and resin industry, other established •
producers, entrepreneurs or small, family- The direct oxidation process accounts for
owned businesses - they all turn to us to over 90% of all capacity installed in recent
update their technology and for the know- years. Of this, Perstorp Formox processes
how to set up production in their region of and catalysts account for far over half. No
the world. competitor even comes close.
Perstorp not only designs and supplies Perstorp's development work is never finish-
plants, it also operates them. The Perstorp ed. All our new techniques, plant designs and
Group, for whom formaldehyde is the most catalysts are tested and perfected in pilot-
obvious core business, is in fact one of the scale units and the test results are confirm-
world's leading producers. This is one of the ed in Perstorp's own formaldehyde plants. In
reasons why we understand your needs. Ours other words, we don't sell you something we
are the same! wouldn't use ourselves.
Table of
contents
Dedicated
At Perstorp Formox, a sale is the start of
our commitment, not the end. Catalyst and
process customers alike may take advantage
of our technical support throughout the PERSTORP FORMALDEHYDE
catalyst lifetime and for reloading. Our CATALYSTS
process customers are additionally offered a
partnership of close cooperation and support
that lasts throughout the operating lifetime of
the plant: from design, construction and start-
up to decades of technical support after your
plant is on stream.
• 1 ECHNICAL RVICE
page 26
•
PERSTORP FORMOX
PROCESS
MORE FORMALDEHYDE
FROM LESS METHANOL
2.
TYPICAL PERFORMANCE FIGURES In the reactor, the gas mixture passes through tubes
(based on 37 wt-% concentration) containing a molybdenum-based catalyst where it is
per metric ton per 1000 Ibs heated further and converted to formaldehyde. The
* exothermic reaction takes place at moderate temperatures
Methanol 42 I -426 kg
(about 350°C/662°F), and the methanol is converted into
Electricity (for blower) 60-70 kWh 27-32 kWh formaldehyde.
Process water 400kg 48 US gal After reaching the peak reaction temperature, the
Cooling water 40-50 m 3
4800-6000 US gal exothermic heat of reaction is immediately removed by a
Catalyst 0.04-0.05 kg** #* heat transfer medium to prevent the formation of by-
Steam produced *** 450-700 kg 450-700 Ibs
products.
The vaporizing heat transfer fluid used in the Perstorp
Molar yield of 92.6-93.7% (15.55-15.75 Ibs/US gal @ 60°F) Formox process ensures isothermal conditions; it allows
** 20,000-25,000 kg (Ibs) of formaldehyde per kg (Ib) catalyst high methanol inlets (improving productivity) and makes
*** Depending on options selected for an evenly spread reaction (safeguarding yield).
6
THE BEST FOR LESS
Since 1992 Perstorp Formox has offered a complete design and supply service
for a wide range of the more popular plant sizes. Though we still retain the
flexibility to tailor a plant to match particular requirements, the standard design
approach has more than proved its worth - tried and tested designs and
components, delivered faster and at lower cost.
Export Cleaned
steam stack gases
EMISSION
CONTROL
SYSTEM
Boiler
feed water
Methanol
Process
water
Cooling
water in
Formaldehyde
solution
5.
In the absorber,
the formaldehyde is
absorbed in process
water, the flow of
which can be ad-
The vapor of the heat transfer
justed to produce
fluid flows to the condenser,
the desired
where the heat is recovered in
formalin
the form of export steam, after The exit gas that is not recycled
concentration.
which the condensed fluid to the reactor is sent to the
Cooling water is used to
returns to the reactor. The export integrated emission control
remove the heat of
steam (typically 12 bar, but system (ECS, see page 15),
absorption, thereby promot-
up to 30 bar) from the which consists of a heat
condenser and the ECS 4. ing absorption. The absorber
exchanger and a catalytic
may consist of a single large
steam generator may be Process gas flows from converter. In this system,
tower or, as is increasingly
used for heating purposes or the reactor back to the virtually all carbon compounds
common, two shorter towers.
for generating electricity. vaporizer, where its are oxidized to carbon dioxide
excess energy is used and water. A steam generator
for evaporating the may also be added to further
incoming methanol. boost the thermal efficiency of
7a
TYPICAL PRODUCT VALUES
Formaldehyde content: 37 - 57% as desired
Methanol content: 0.4 - 0.8% (in 37%)*
Formic acid content: 0.015 - 0.030% (in 37%)
(all values expressed as weight %)
Options
• Perstorp Formox plants are designed to run with or
without pressure. Existing plants operating without
pressurization may have this option retrofitted to
further boost capacity.
• superior yield
• environmentally friendly
• quality equipment at a
competitive price
;il ^f_~_:|
• M
т *
^m-
m^
PERSTORP
FORMALDEHYDE
CATALYSTS
"HE CATALY
• testing facilities -
We can conduct tests
and analyses of your
catalyst samples.
• repurchase of spent
catalyst - Besides
lowering your cost '
for new catalyst, this service reduces expensive waste
management at your plant.
Exceptional
service
With Perstorp Formox catalysts, outstanding service is
not an extra - it comes as standard with the outstanding
performance. This service includes:
11
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SAFETY &
ENVIRONMENT
13
PROFIT THROUGH RESPONS
14
BILITY
15
PERSTORP FORMOX
PLANTS
г
The photo montage on the previous page shows a few of the more than 80 plants all
over the world operating with the Perstorp Formoxprocess. Here's a look at the scope
of our undertaking, from the first contact until you are on stream.
2. PROJECT ANALYSIS
We work together with you to define the plant that meets your needs (or to modernize
or expand an existing plant). We can also help you with your feasibility study and
provide data for obtaining permits and approval from the authorities.
4. MANUFACTURE OF COMPONENTS
The equipment can be fabricated to meet your national standards. All suppliers are
approved by us on the basis of the quality of their workmanship. We make regular
inspections of the ongoing manufacturing process, which you are also invited to do.
5. ENGINEERING REVIEW
Consider our engineers a part of your project team! We maintain close contact with you
during the project to coordinate details to your satisfaction, including your preparation
of the site.
6. OPERATOR TRAINING
Before the start-up of your plant, we invite your personnel to a comprehensive training
session in Perstorp, Sweden, tailored to their needs and experience. This training is
later followed up once your plant goes on stream.
—
OF THE WAY
7. SHIPMENT TO SITE
Once the components are ready, they are shipped to your site. Prior to this, you will
have prepared the necessary concrete slabs. Storage tanks, utilities etc are usually built
in parallel with the installation work.
8. INSTALLATION SUPERVISION
Our experienced engineers will be on hand throughout the actual construction and
installation of your formaldehyde plant, providing advice and making sure that
everything is done according to specifications.
9. COMMISSIONING
Perstorp Formox engineers will arrive during the final stages of installation to
supervise all aspects of the commissioning and start-up, including electrical work and
instrumentation, and make final adjustments to the complete system.
11. START-UP
Much of the equipment is started during the commissioning phase and remains in
operation, so the actual start-up may be something of an anti-climax. A button is
pushed, a change in the curves on the monitor is soon observed, and your production
of formaldehyde is underway.
12. FOLLOW-UP
The start-up of your plant is not the end of your relationship with Perstorp Formox. In
one sense, it is just the beginning. We offer you a lifetime of technical support services,
which you can read more about on the next few pages.
,L
ii
TECHNICAL
SERVICE
WE'RE HERE TO SERVE YOI
Continuous active
support
When you purchase formaldehyde technology
from Perstorp Formox, you become more than
our client. You enter a partnership that gives you
access to full technical support for as long as you
are in business. Our service program is dedicated
to continuously upgrading and improving your
formaldehyde production, and to increasing the
profitability of your plant.
Technical service
meetings
We like to know how your process is performing.
For this reason, we stop by your plant regularly,
and encourage you to visit us as well. Such
technical service meetings are useful for
discussion of any questions you may have about
daily operations, production rationalization or
any other aspects of formaldehyde production.
Operational
feedback
In addition to the technical service meetings, our
specialists are prepared to examine your process
data on a weekly or monthly basis, and provide
you with advice on how to improve your daily
operations.
22
International
seminars
To promote the interests of
formaldehyde producers and
provide a forum for the exchange
of ideas, Perstorp Formox hosts
regular conferences/seminars.
The aim is an annual seminar for
both catalyst and process clients -
with venues alternating between
the Americas and Asia.
In addition, we hold a process
seminar, restricted to process
clients, every third year. This is
held in Europe - normally in
conjunction with a study visit to
our own plants in Perstorp,
Sweden.
Follow-up
training
A properly trained, dedicated crew
will give you the best operating
results. For this reason, we have
your operators attend a two-week
course at our headquarters in
Perstorp, Sweden, prior to start-up.
We also follow up this initial
program during our technical
service meetings.
And what happens when you get
new operators on your staff?
Perstorp Formox can arrange
subsequent training courses for
these new technicians to ensure that
your plant will be run by skilled
personnel at all times. We also run
training courses in conjunction
with some of our international
seminars.
23
FOR YEARS TO COME
Other media
Twice a year, Perstorp Formox publishes informally
speaking, a customer newsletter with information
about the seminars, tips for improvements, news
about applications etc. Customers and suppliers are
invited to contribute to this formaldehyde forum.
Anytime,
anywhere
Perstorp Formox has a worldwide service network
with bases in Europe, North America and Asia to
ensure an immediate contact for service or catalyst
supply.
25
FEW FUNDAMENTAL FACTS
ABOUT FORMALDEHYDE
Formaldehyde: a colorless, water-soluble gas (HCHO), usually derived from methanol by oxidation, and
having a piercing, pungent odor.
Formalin: the aqueous solution of formaldehyde, often expressed as 37 wt-% concentration.
The wood industry is the single largest Fortunately, formaldehyde irritates before it
consumer. Formaldehyde-based resins are endangers. Its extremely sharp odor causes
used as binders for wood composites: discomfort that increases with the
plywood, particle board, OSB, MDF and concentration, and therefore the smell of
compressed hardboard. It is also consumed in formaldehyde gives its own clear warning
surface coatings (high- and low-pressure signal before the concentration level
laminates, films and foils) and in general- becomes hazardous.
purpose glues for furniture and other
woodworking. Using formaldehyde as a building block,
downstream chemical processes bind the free
In the chemical industry it is a building formaldehyde in a variety of molecular
block for a range of synthetic polymers. chains which normally render the
These include traditional plastics (PF, UF formaldehyde harmless. High-grade resin,
and MF) as well as newer, high-growth for example, bonds formaldehyde to such an
products such as acetals, polyurethanes extent that the free formaldehyde content in
(through MDI) and polybutyl terephthalate downstream products is well below the
(through Butane 1-4 Diol). Polyols (alkyd strictest norms. Low-grade resin sometimes
resins etc.) are another big consumer. A wide fails to achieve this.
range of specialty resins (e.g. for textile
treatment) are also produced either directly As a formaldehyde producer and/or user, it is
or from hexamine (resins and detergents) essential to observe all due precautions in
and/or paraformaldehyde. Other uses include terms of safety, health and the environment.
end-effect applications such as tanning and It is also important to be able to provide
sterilizing. Formaldehyde is also a starting clear, reasonable and objective information
point for some important herbicides and to the general public •• your ultimate
Pharmaceuticals. customers - about the proper uses of this key
chemical building block. Perstorp Formox
will be happy to assist you in preparing such
information.
26
[^ Perstorp Formox
e-mail: formox@perstorp.com
www.perstorp.com/formox
Global
SE-284 80 Perstorp
Sweden
North America
600 Matzinger Road
Toledo, Ohio 43612
USA
phone+1 4197295448
fax +14197265925
Asia
9 Temasek Blvd #04-01
Suntec Tower 2
Singapore 038989