TECHNOLOGY

MyP S.r.l
Of

FORMALDEHYDE Technologies
«Safe chemistry, presentation
respectful for the environment Dr. P. Bellotti
and CEO MyP s.r.l
accessible for everyone»
 INTRODUCTION – MyP MFOR Advanced Technologies

MyP FORMALDEHYDE PRODUCTION PLANTS “MFOR”– Global overview

The Formaldehyde technology of MyP is based on the following KEY PRINCIPLES:

Ø HIGH PLANT PERFORMANCE

Ø LOWEST POSSIBLE TOTAL ENERGY CONSUME

Ø LOWEST POSSIBLE EMISSIONS

Ø FULL AUTOMATIC PRODUCTION PLANTS

Ø HIGH HEALTH AND SAFETY STANDARD

The Formaldehyde plant is designed on the based technology of IRON-MOLYBDENUM catalyst and
MOLTEN SALT
 MFOR - PROCESS Advanced Technologies

MyP “MFOR” INDUSTRIAL PROCESS

The industrial process set up in Formaldehyde plants of the MYP know-out is called modified Perstorp-Reichold
(Formox). Formaldehyde production, from Methanol, takes place through "oxidation in the presence of MoO3
catalysts containing Fe" in accordance with the following formal equation:

CH3OH + 0,5 O2 = HCHO + H2O (delta H = - 159 kJ/mole).

Methanol in the superheated steam stage (about 120°C), obtained from heat exchange with steam circulating
in the evaporator, is mixed with a gaseous current containing mainly oxygen and nitrogen and is conducted on
the catalyst, loaded in the M-FR(n) tubular reactor(s), at a temperature of 140 ÷160 °C and at a relative
pressure of between 200 and 300 mm Hg.
The concentration of CH3OH in the reaction mix is equal to 7÷10% in volume, whilst O2 is 10 ÷11% and
therefore in excess of the reaction’s stoichiometry. Methanol conversion is 98%, whilst Formaldehyde
selectivity reaches 92÷94%, based on the age of the catalyst. Secondary products, other than water, are CO,
CO2, Formic Acid and Dimethyl ether.
The reaction heat is partly reduced by a cooling liquid, composed of molten salts (a mixture of Sodium Nitrite,
Sodium Nitrate and Potassium Nitrate), surrounding the reaction pipes, which is kept in circulation by the
pump(s). The salts also release the enthalpic content into the water circulating in the coils located inside the
MF-R reactor(s), producing medium pressure steam.
 MFOR - PROCESS Advanced Technologies

MyP “MFOR” INDUSTRIAL PROCESS

The gases, composed of Formaldehyde and reaction by-products, leave the reactor(s) at a temperature of
about 280°C, are cooled to 210°C by water circulating in the shell side of the shell and tube heat exchanger,
producing medium pressure steam. The gases are then cooled in an exchanger to a temperature of 120÷140°C,
preheating the air needed for the reaction.

Gases are washed in a counter-current of water (or water and urea) in the multi-stage sprinkler absorption
column MF-C(n).

Gases leaving the column head are cooled in a series of condensators and from there one part is recycled and
one part is conveyed to the catalytic combustion plant (MF–R01 post-combustor) before being discharged to
the atmosphere.

However, the gaseous recycle is combined with a flow of fresh air ensuring that the concentration of O2 at the
reactor inlet remains at the required level (about 10÷11% in volume) and is used in the process.
MFOR - CAPACITY Advanced Technologies

MyP “MFOR” Standard Capacity

MyP TECHNOLOGY offers: Other plants of different capacities, according to customer's request,
through study and customization dedicated.
MFOR - PROCESS Advanced Technologies

MyP “MFOR” PROCESS DIAGRAM

MFOR - PROCESS Advanced Technologies

MyP “MFOR” PROCESS DIAGRAM

MFOR - PROCESS Advanced Technologies

MyP “MFOR-NEW” PROCESS DIAGRAM

MFOR - PROCESS Advanced Technologies

MyP “MFOR” PROCESS LAY OUT

MFOR - PROCESS Advanced Technologies

MyP “MFOR” PROCESS LAY OUT

MFOR - PROCESS Advanced Technologies

MyP “MFOR” PROCESS NEW LAY OUT

 FORMALDEHYDE - PERFORMANCE Advanced Technologies

“MFOR”– HIGH PLANT PERFORMANCE

1) Production of high-concentration products with the same plant
o Formaldehyde concentration till 55%
o Urea-Formaldehyde concentrate till 85%

2) High catalyst life

o Average catalyst life time: up to 12000hs
o Specific production: up to 30ton Fa37%/kg cat.

3) High plant life time

o Low pressure: Plant operative pressure: < 0.5barg SIEVE TRAYS
o Low linear speed
The MYP plant works with linear speed value less than 15m/s. The competitors work about 25-28m/s. It means that
the flow surfaces are higher than 180% in confront to the competitors. Low linear speed gives advance not only into
energy consumption but also into the plant life, because the mechanical and thermal stress go down.
High thickness PERFORMANCE PARAMETER COMMON STANDARDS MYP TECHNOLOGY
The plant is built with high thickness in order to withstand not only in working conditions but also in highly critical
situations (explosions caused by serious operative mistakes or pollutant inputs)
Average catalyst life time: 8000 hr up to 12000 hr

o Good heat exchange Specific production: 17-19ton Fd37%/kg cat up to 29 ton Fd37%/kg
Every heat exchangers offered have high surface in order to work in high efficiency not only in normal conditions
cat.
but also in bed condition given by fouling phenomena. The extra surfaces is about 30% Methanol inlet Relatively low Highest possible
Pressure drop Relatively fast pressure Slower increase
4) High productivity increase
Plant operative pressure: +/-2barg < 0.5barg
o Highest possible methanol inlet: >11%vv Reactor cooling medium: diathermic oil Molten salts
The high methanol inlet was studied and realized by collaborating with the most important suppliers of
formaldehyde catalyst and with the introduction of a special cooling system. Formaldehyde concentration max. 52% Up to 55%
MFOR - PERFORMANCE Advanced Technologies

MyP “MFOR” FORMALDEHYDE PRODUCTION PLANTS - Performance

EXAMPLE:
MFOR - PERFORMANCE Advanced Technologies

MyP “MFOR” FORMALDEHYDE PRODUCTION PLANTS - Performance

STANDARD PRESSURE DROP REACTOR - dPs

Load 1
Load 2
400,0

300,0
dPs - mmHg

200,0

100,0

0,0

working hours
MFOR - PERFORMANCE Advanced Technologies

MyP “MFOR” FORMALDEHYDE PRODUCTION PLANTS - Performance

SPECIFIC PRODUCTION - ton FD37%/kg catalyst

40
Load 1
Load 2
35

30
ton FD37% / kg catalyst

25

20

15

10

working hours
 ENERGY EFFICIENCY Advanced Technologies

MyP MFOR– LOWEST POSSIBLE TOTAL ENERGY CONSUME

Thanks to the large experience into the management of the plants operation, MyP TECHNOLOGY is able to
design plant with the highest energy efficiency. The technology criteria are:

• Recovery of energy generated from synthesis and combustion reactions

The exothermal production process produced steam. The steam can be applied in:

- Auto-consume for the Formaldehyde and Heating of Glue & Resin reactors
- Steam driven process air fans
- ALTERNATIVE: Generation of Electrical Power

• Installation of inverters for the modulation of the flows

• Low Linear Speed of the flow (gas)
• Low working Pressure

- Electric Power at battery limit < 45 kWh/ton Fd37 (with fan driven by steam turbine)
- < 65 kWh/ton Fd37 (with fan driven by electric motor)

- Internal Energy production: from 100 to 150 kWh/ton Fd37% (ALTERNATIVE: Generation of Electrical
Power)
ENERGY EFFICIENCY Advanced Technologies
ENERGY EFFICIENCY Advanced Technologies

MyP PRODUCTION PLANTS – Historical key efficiency steps

MFOR- EMISSION Advanced Technologies

MyP MFOR – LOWEST POSSIBLE EMISSION IN ATMOSPHERE

Thanks to MyP’s applied plant off gas incineration technology Formaldehyde and COT emissions in the
atmosphere are reduced to absolute minima:

- Formaldehyde emission in the atmosphere: < 3mg/Nm3

- COT emission in the atmosphere (continuous online monitoring): < 15mg/Nm3

The process state-of-the-art equipment are very critically chosen and/or developed to reduce operative
emissions and the risks for incidental emission to an absolute minimum.
MFOR- EMISSION Advanced Technologies

MyP MFOR – “POST COMBUSTOR” PROCESS DIAGRAM

 MFOR - AUTOMATION Advanced Technologies

MyP “MFOR” FORMALDEHYDE PRODUCTION PLANTS - Automation

- Complete PLC/DCS controlled plant

- Full and semi-automatic control of process

parameters

- Fully integrated safety control and automatic

safety shutdown

- Operator only as supervision from

centralized control room

- High guarantee for Safety and Environment

MFOR - CATALYST Advanced Technologies

MyP “MFOR” FORMALDEHYDE PLANT - CATALYST

Formaldehyde is produced into MFOR by using iron-molybdenum based catalysts

Overview Formaldehyde and Methanol Market – Production technologies

 MFOR - COOLING Advanced Technologies

MyP “MFOR” FORMALDEHYDE PLANT - COOLING

MOLTEN SALTS OR DIATERMIC OIL

The formaldehyde reactor is a multi-tubolar heat exchanger where the thermal energy, developed by the reaction, is removed by a cooling media.
In the industrial practice, different kinds of fluids are used for the above-mentioned duty.
Pointing the attention on safety and economy, below are described the characteristics of some of them:

DOWTHERM A
It’s a mixture of biphenyl and biphenyl ether.
It’s used at the boiling point and, then, the reaction temperature has to be controlled by adjusting the pressure over the liquid.
Boiling point at 760 Torr 258 C
Flash point 124 C
The fluid is flammable and must be avoided the contact with air
It’s toxic DFG MAK 0,2 ppm

DIATHERMIC OIL
It’s a mixture of synthetic and/or mineral high boiling hydrocarbons
It’s used in liquid state with consequent limit in the reaction temperature (the boiling point at 760 Torr is close to 320 C)
Flash point 182 C
Increase of the energy costs because it requires a greater synthesis gas flow: in order to keep the reaction temperature below 300 C, the methanol
percentage in the reacting mixture has to be reduced.
Possibility of hydrocarbons cracking over 310 C, with solid deposits that inhibit the correct heat transfer.
Release of flammable vapours
The contact with air has to be avoided.
 MFOR - COOLING Advanced Technologies

MyP “MFOR” FORMALDEHYDE PLANT - COOLING

MOLTEN SALTS OR DIATERMIC OIL

MOLTEN SALTS
It’s an eutectic mixture of inorganic salts (53% KNO3, 40% NaNO2, 7% NaNO3)
Melting point: about 143 C
Slow thermal degradation over 450 C
No cracking or fouling phenomena
Fire danger only in presence of organic substances or other easily oxidable or combustible stuffs.
The molten salts mixture doesn’t need to be pressurised and it’s operated, at the atmospheric pressure, with simple and economical devices
Molten salts are toxic only if swallowed in a large amount
The thermal conductivity is five times higher than oils.

MYP technology uses the MOLTEN SALTS salts for the following reasons: 200 C
200
high level of safety and health 2,5 Bar 0 Bar C
2,5 Bar 250
low environmental impact C
simple design and effective system for maintenance 0,1 Bar (pieno 280 C
330 C
atmospheric working pressure di sale fuso) tubi

1100
del
280 C
fascio
300
2,5 Bar 0 Bar 2,5 Bar C
280
C
320 C
320 320 C
C