Phenol-Formaldehyde Resin

Amount per Year 50000.00

PF Resin % 80.00% Water Resin 20%
Amount Required (Tonnes/Year) 40000.00 10000

Balanced Equation
nC6H5OH + 2nCH2O → [C8H8O2 ] n + n H2O Let n= 2

No. of Operating Days 330.00

Daily Amount Required(Tonnes/Day) 121.21 30.30303
Daily Amount Required(kg/hr) 5050.51 1262.626

Molar Flow-rate of Resin (kmol/hr) 18.57

Theoretical Molar Flow-rate of Phenol (kmol/hr) 37.14
Required Molar Flow-rate of Phenol 41.26
Mass Flow-rate of Phenol(kg/hr) 3878.66

Molar Flow-Rate of Methanal(kmol/hr) 82.52

Mass Flow-rate of Methanal (kg/hr) 2475.74
Mass Flow-Rate of Formalin (kg/hr) 6691.18

Scale Factor 8.97

Amount of Methanal Produced Stoichiometrically 9.20
Feed Conditions
Molecular Weight:
Phenol Feed
Conversion in Reactor 90%
Aqueous Solution 90%

Phenol:Methanal feed Ratio (1:n) 2

Methanal
wt% in Formalin 37%

Air Composition
Nitrogen % 79.05%
Oxygen % 20.95%
Nitrogen Scale Factor 3.77
PF Resin 272
Phenol 94
Methanal 30
Oxygen 32
Methanol 32
Water 18
Carbon Monoxide 28
Carbon Dioxide 44
Nitrogen 28
NaOH 40
 Formalin Production Process
Formox Process

Conversion Data 99%

Yield Data 92%
Stoichiometric Feed Methanol 10

Component Molecular Mass

Methanol (CH3OH) 32
Oxygen (O2) 32
Methanal (CH2O) 30
Water (H2O) 18
Carbon Monoxide (CO) 28
Nitrogen (N2) 28

Reactor
Inlet
Component Stoichiometric (kmol/hr) Scaled (kmol/hr)
Methanol (CH3OH) 10.000 89.701
Oxygen (O2) 9.490 85.126
Methanal (CH2O) 0.000 0.000
Water (H2O) 7.663 68.736
Carbon Monoxide (CO) 0.000 0.000
Nitrogen (N2) 51.618 463.020

Total

Absorber
Inlet
Component Molar Flow-Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.897 28.704
Oxygen (O2) 37.585 1202.706
Methanal (CH2O) 82.525 2475.738
Water (H2O) 163.819 2948.739
Carbon Monoxide (CO) 6.279 175.813
Nitrogen (N2) 463.020 12964.553
Scrubbing Water 68.084 1225.508

Total 21021.761

Separator
Inlet-Absorber
Component Molar Flow-Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.897 28.704
Oxygen (O2) 0.000 0.000
Methanal (CH2O) 82.525 2475.738
Water (H2O) 219.933 3958.794
Carbon Monoxide (CO) 0.000 0.000
Nitrogen (N2) 0.000 0.000

Total 6463.236

Blending Tank
Inlet
Component Molar Flow-Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.897 28.704
Methanal (CH2O) 82.525 2475.738
Water (H2O) 219.933 3958.794
6463.236
 Inlet
Mass Flow Rate (kg/hr) wt% Stoichiometric (kmol/hr)
2870.421 14.50% 0.100
2724.029 13.76% 4.190
0.000 0.00% 9.200
1237.250 6.25% 18.263
0.000 0.00% 0.700
12964.553 65.49% 51.618

19796.253 100.00%

Outlet Gas Phase

wt% Molar Flow-Rate (kmol/hr) Mass Flow Rate (kg/hr)
0.14% 0.000 0.000
5.72% 37.585 1202.706
11.78% 0.000 0.000
14.03% 11.970 215.452
0.84% 6.279 175.813
61.67% 463.020 12964.553
5.83% 0.000 0.000

100.00% 14558.525

er
wt%
0.44%
0.00%
38.30%
 61.25%
0.00%
0.00%

100.00%

Desired Amount
wt% wt% kg/hr
0.44% 3% 200.735
38.30% 37% 2475.738
61.25% 60% 4014.710
6691.183
 Outlet
Scaled (kmol/hr) Mass Flow Rate (kg/hr)
0.897 28.704
37.585 1202.706
82.525 2475.738
163.819 2948.739
6.279 175.813
463.020 12964.553

19796.253

Gas Phase Outlet Liquid Phase

wt% Molar Flow-Rate (kmol/hr)
0.0000% 0.897
8.2612% 0.000
0.0000% 82.525
1.4799% 151.849
1.2076% 0.000
89.0513% 0.000
0.0000% 68.084

100.0000%

Outlet
Molar Flow-Rate (kmol/hr)
0.897
0.000
82.525
 219.933
0.000
0.000

Additional Amounts
kg/hr
172.031
0.000
55.916
 Reaction 1 10 CH3OH +

Reaction 2 0.7 CH2O +

wt% Assumptions
0.14% Methanol:Water Ratio
6.08% Additional Water
12.51% Methanol:Air (1:n)
14.90% Excess Oxygen
0.89% Excess Nitrogen
65.49%

100.00%

Outlet Liquid Phase

Mass Flow Rate (kg/hr) wt% Assumptions
28.704 0.44% Methanal in Gas Phase 0%
0.000 0.00% Methanal in Liquid Phase 100%
2475.738 38.30% Methanol in Gas Phase 0.00%
2733.286 42.29% Methanol in Liquid Phase 100.00%
0.000 0.00% VLE Data Value 0.0230693069
0.000 0.00% Water in Gas Phase 11.970
1225.508 18.96%
Scrubbing Water 1225.508
6463.236 100.00%
21021.761

Outlet
Mass Flow Rate (kg/hr) wt%
28.704 0.44%
0.000 0.00%
2475.738 38.30%
3958.794 61.25%
0.000 0.00%
0.000 0.00%

100.00%
6463.236
 5 O2 > 9.9 CH2O + 9.9 H2O +

0.35 O2 > 0.7 CO + 0.7 H2O

ater Ratio 1.305

Water 7.6628
2
4.19
15.81

VLE
Pressure (bar) 1.01
Saturated vapour 0.0233
H2O in liquid phase 1
molar fraction of H2O in gas phase 0.02306930693069
H20 in vapour phase 11.9695774945
0.05 O2 + 0.1 CH3OH
 Formalin Production Process
Formox Process

Conversion Data 99%

Yield Data 92%
Stoichiometric Methanol Feed 10

Component Molecular Mass

Methanol (CH3OH) 32
Oxygen (O2) 32
Methanal (CH2O) 30
Water (H2O) 18
Carbon Dioxide (CO2) 44
Nitrogen (N2) 28

Reactor
Inlet
Component Stoichiometric (kmol/hr) Scaled (kmol/hr)
Methanol (CH3OH) 10.000 89.701
Oxygen (O2) 5.650 50.681
Methanal (CH2O) 0.000 0.000
Water (H2O) 7.663 68.736
Carbon Dioxide (CO2) 0.000 0.000
Nitrogen (N2) 21.319 191.233

Total

Condenser
Inlet
Component Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.897 28.704
Oxygen (O2) 0.000 0.000
Methanal (CH2O) 82.525 2475.738
Water (H2O) 163.819 2948.739
Carbon Dioxide (CO2) 6.279 276.278
Nitrogen (N2) 191.233 5354.512

Total 11083.970

Absorber
Inlet
Component Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.000 0.000
Oxygen (O2) 0.000 0.000
Methanal (CH2O) 0.000 0.000
Water (H2O) 46.240 832.313
Carbon Dioxide (CO2) 6.279 276.278
Nitrogen (N2) 191.233 5354.512
Scrubbing Water 68.084 1225.508

7688.611

Separator
Inlet-Condenser
Component Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.897 28.704
Oxygen (O2) 0.000 0.000
Methanal (CH2O) 82.525 2475.738
Water (H2O) 117.579 2116.426
Carbon Dioxide (CO2) 0.000 0.000
Nitrogen (N2) 0.000 0.000

Total 4620.868

Blending Tank
Inlet
Component Molar Flow-Rate (kmol/hr) Mass Flow Rate (kg/hr)
Methanol (CH3OH) 0.897 28.704
Methanal (CH2O) 82.525 2475.738
Water (H2O) 227.232 4090.183
6594.625
Inlet O
Mass Flow Rate (kg/hr) wt% Stoichiometric (kmol/hr)
2870.421 25.90% 0.100
1621.788 14.63% 0.000
0.000 0.00% 9.200
1237.250 11.16% 18.263
0.000 0.00% 0.700
5354.512 48.31% 21.319

11083.970 100.00%

Outlet-Gas
wt% Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr)
0.26% 0.000 0.000
0.00% 0.000 0.000
22.34% 0.000 0.000
26.60% 46.240 832.313
2.49% 6.279 276.278
48.31% 191.233 5354.512

100.00% 6463.103

Outlet-Liquid
wt% Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr)
0.00% 0.000 0.000
0.00% 0.000 0.000
 0.00% 0.000 0.000
10.83% 41.569 748.249
3.59% 0.000 0.000
69.64% 0.000 0.000
15.94% 68.084 1225.508

100.00% 1973.757

Inlet-Absorber
wt% Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr)
0.62% 0.0000 0.000
0.00% 0.0000 0.000
53.58% 0.0000 0.000
45.80% 109.6532 1973.757
0.00% 0.0000 0.000
0.00% 0.0000 0.000

100.00% 1973.757
6594.625

Desired Amount
wt% wt% kg/hr
0.44% 3% 200.735
37.54% 37% 2475.738
62.02% 60% 4014.710
6691.183
 Outlet
Scaled (kmol/hr) Mass Flow Rate (kg/hr) wt%
0.897 28.704 0.26%
0.000 0.000 0.00%
82.525 2475.738 22.34%
163.819 2948.739 26.60%
6.279 276.278 2.49%
191.233 5354.512 48.31%

11083.970 100.00%

Outlet-Liquid
wt% Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr) wt%
0.00% 0.897 28.704 0.62%
0.00% 0.000 0.000 0.00%
0.00% 82.525 2475.738 53.58%
12.88% 117.579 2116.426 45.80%
4.27% 0.000 0.000 0.00%
82.85% 0.000 0.000 0.00%

100.00% 4620.868 100.00%

11083.970

Outlet-Gas
wt% Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr) wt%
0.000% 0.000 0.000 0.00%
0.000% 0.000 0.000 0.00%
 0.000% 0.000 0.000 0.00%
37.910% 4.670 84.064 1.47%
0.000% 6.279 276.278 4.83%
0.000% 191.233 5354.512 93.69%
62.090% 0.000 0.000 0.00%

100.000% 5714.853 100.00%

7688.611

Outlet
wt% Molar Flow Rate (kmol/hr) Mass Flow Rate (kg/hr) wt%
0.0000% 0.897 28.704 0.44%
0.0000% 0.000 0.000 0.00%
0.0000% 82.525 2475.738 37.54%
100.0000% 227.232 4090.183 62.02%
0.0000% 0.000 0.000 0.00%
0.0000% 0.000 0.000 0.00%

100.0000% 100.00%
6594.625

Additional Amounts Molar Flow-Rate

kg/hr
172.031 6.2729842142
0.000 82.5245923285
-75.473 223.0394387257
Reaction 1 10 CH3OH + 5 O2 > 9.2 CH2O + 0.4 O2 + 9.2 H2O +

Reaction 2 0.7 CH3OH + 1.05 O2 > 0.7 CO2 + 1.4 H2O

Assumptions
Methanol:Water Ratio 1.305
Additional Water 7.663

Assumptions
Methanal in Gas Phase 0%
Methanal in Liquid Phase 100%
Methanol in Gas Phase 0.00%
Methanol in Liquid Phase 100.00%
VLE Data Value 0.1897
Water in Gas Phase 46.240

Assumptions
Scrubbing Water 1225.508
VLE Data Value 0.023099
0.8 CH3OH
Reactor
INLET
Component kmol/hr Mass flow Rate (kg/h) wt% Mass Flow-Rate (kg/batch)
PF Resin 0 0 0.00% 0
Phenol 41.262296164 3878.6558394402 33.98% 31029.2467155212
Methanal 82.524592329 2475.7377698554 21.69% 19805.9021588433
Methanol 6.2729842142 200.7354948531 1.76% 1605.8839588251
Water 260.73585744 4693.2454339862 41.12% 37545.9634718894
NaOH 4.1262296164 165.049184657 1.45% 1320.3934772562

Total 11413.4237227919 100.00% 91307.3897823353

Distillation
Inlet Outlet (Top Products/Distillate)
Component kmol/hr Mass Flow Rate (kg/hr) wt% kmol/hr
PF Resin 18.568033274 5050.5050505051 44.25% 0
Phenol 4.1262296164 387.865583944 3.40% 4.1262296164
Methanal 8.2524592329 247.5737769855 2.17% 8.2524592329
Methanol 6.2729842142 200.7354948531 1.76% 6.2729842142
Water 297.87192399 5361.6946318471 46.98% 236.8954196599
NaOH 4.1262296164 165.049184657 1.45% 0

11413.4237227919 100.00%
 OUTLET
kmol/hr Mass Flow Rate (kg/hr) wt% Mass Flow-Rate (kg/Batch)
18.5680332739 5050.5050505051 44.25% 40404.0404040404
4.1262296164 387.865583944 3.40% 3102.9246715521
8.2524592329 247.5737769855 2.17% 1980.5902158843
6.2729842142 200.7354948531 1.76% 1605.8839588251
297.8719239915 5361.6946318471 46.98% 42893.5570547771
4.1262296164 165.049184657 1.45% 1320.3934772562

11413.4237227919 100.00% 91307.3897823353

Outlet (Top Products/Distillate) Outlet (Bottom Products)

Mass Flow Rate (kg/hr) wt% kmol/hr Mass Flow Rate (kg/hr) wt%
0 0.00% 18.56803 5050.5050505051 80.00%
387.865583944 7.60% 0 0 0.00%
247.5737769855 4.85% 0 0 0.00%
200.7354948531 3.94% 0 0 0.00%
4264.1175538779 83.61% 60.9765 1097.5770779692 17.39%
0 0.00% 4.12623 165.049184657 2.61%

5100.2924096606 100.00% 6313.1313131313 100%

11413.4237227919
Phenol Conversion 90% Molecular Weight: PF Resin 272
Water in Phenol 10% Phenol 94
Methanal 30
NaOH Catalyst Oxygen 32
Ratio NaOH:Phenol (1:n) 10 Methanol 32
Aqueous Solution % 60% Water 18
% of Water 40% Carbon Monoxide 28
Carbon Dioxide 44
Formalin Nitrogen 28
Methanal % 37% NaOH 40
Water % 60%
Methanol % 3%

PF Resin Product
Resin wt% 80%
Water wt% 20%

Assumptions
All Phenol in distillate
All methanol in distillate
all Formaldehyde in distillate
Wt% of Water in Distillate 80%
Let n= 41.26 41.2623 C6H5OH + 82.52459 CH2O TO 20.63115
(C8H8O2) 41.26229616 + 41.2623 H2O