Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: B
ICC - Volume: 174
ICC - Report ID: 174-B
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Formaldehyde from Methanol (Silver Catalyst and Full Conversion)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 174-A,174-C,174-D
ICC - Related Reports List: 286-A,027-D,001-B,001-A
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/174-B.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Formalin</b>. Formaldehyde is a colorless, strong-smelling gas remarkably versatile as a chemical intermediate - it is widely used for the production of resins and coatings employed in the manufacture of building materials and household products. Since the pure gas slowly polymerizes at temperatures lower than 80°C, formaldehyde is usually available as a liquid solution in water with small amounts of methanol. This solution is called formalin. Most of world's formalin is commercially manufactured from methanol and air in the presence of a silver (or a metal oxide) catalyst.</p> <h6>Raw Materials</h6> <p><b>Methanol</b>. Methanol is one of the most important chemical raw materials, used as a solvent, starting material in the production of chemicals and in the fuel sector. Currently, more than 95% of commercial methanol is synthetically produced from synthesis gas, or syngas, which is a mixture of hydrogen and carbon monoxide. </p> <b>Chemicals</b>. </p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/174-B.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Reaction; and (2) Absorption.</p><p>Reaction. First, a methanol-water mixture in a 3:2 ratio is fed to the evaporator. The mixture is evaporated, superheated and the resulting gases are directed to the reactor. In the reactor, the mixture gets into contact with the silver catalyst, which promotes the reaction.</p><p>Absorption. The gases from the previous section enter though the bottom end of a packed absorption column, responsible to cool and condense the incoming gases. In this column, the gases containing Formaldehyde are eluted countercurrent with water, which is fed by the top of the column, and with circulating Formaldehyde solutions, in the intermediate stages. The off-gas that leaves the top of the absorption column is sent to a steam generator, located outside battery limits. The desired Formaldehyde solution leaves from the bottom of the column and it is sent to the storage facilities.</p>
ICC - Short Description: This report presents a techno-economic study of Formalin (37wt% aqueous solution of Formaldehyde) production from methanol in the United States. The oxidation-dehydrogenation uses a silver-catalyzed reaction at conditions that prioritize full methanol conversion. In this case, methanol recovery is unnecessary.
ICC - Main Product: Formalin
ICC - Plant Capacity: 60.00
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Formaldehyde from Methanol (Silver Catalyst and Full Conversion)

Formalin Production Costs Report | Issue B | Q2 2024

Production Cost Report

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60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 60 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

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Production Process Information

Process Consumptions

Labor Requirements

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Operating Cost Summary

Production Costs Datasheet

Plant Capital Cost Details

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

Plant Capital Cost Details

Operating Cost Details

Plant Cost Breakdowns

Plant Capacity Assessment

Process Flow Diagrams

Costs in Different Countries Add-on

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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Formalin production plant examined

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements

Plant Cost Breakdowns

Breakdown of Formalin process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Formalin production plant studied

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Formalin plant capacities

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

Other Formalin Production Cost Reports

Formaldehyde from Methanol (Silver Catalyst and Methanol Recycle)

This report presents a techno-economic study of Formalin (37wt% aqueous solution of Formaldehyde) production from methanol in the United States by oxidation-dehydrogenation using a silver-catalyzed reaction at conditions that prioritize selectivity over conversion. In this case, unconverted methanol is recycled.

Details: 60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 60 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Formaldehyde from Methanol (Metal Oxide Catalyst)

This study presents the economic analysis of Formaldehyde production from methanol in the United States. In the process analyzed in this report, methanol is directly oxidized to formaldehyde in vapor phase over a metal oxide catalyst.

Details: 60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 60 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Formaldehyde Production from Natural Gas

This study provides the economics of Formaldehyde production from natural gas in the United States. In this report, Formaldehyde is obtained via catalytic partial oxidation of methane using a still non-commercial process based on patents issued to Snamprogetti.

Details: 60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $799 USD

The cost analyses presented in this report target a 60 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Other Related Production Cost Reports

Methanol Production from Natural Gas (Steam Reforming)

This study presents the economics of large-scale Methanol production from natural gas in the United States. In the process examined, natural gas is first converted into synthesis gas (syngas) by means of conventional steam reforming and then the syngas is converted into Methanol.

Details: 1,000 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 1,000 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Methanol Production from Natural Gas (Combined Reforming)

This study presents the economics of large-scale Methanol production from natural gas in the United States. In this process, natural gas is first converted into synthesis gas (syngas) by means of conventional steam reforming and secondary autothermal reforming. Then, the syngas is converted into Methanol.

Details: 1,700 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 1,700 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Butanediol Production from Acetylene

This report presents the economics of an 1,4-Butanediol (BDO) production process from acetylene and formaldehyde in the United States. In this process, acetylene initially reacts with formaldehyde by addition, forming 1,4-butynediol. The butynediol is then hydrogenated to produce BDO. It is a typical acetylene-based Reppe process.

Details: 120 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $799 USD

The cost analyses presented in this report target a 120 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Polyoxymethylene from Formaldehyde and Acetic Anhydride

In this report, it is assessed the production of Polyoxymethylene (POM), also called Polyacetal Resin. The economic analysis concerns Polyoxymethylene production from acetic anhydride and formaldehyde in the United States, assuming a process similar to the one owned by Dupont. Formaldehyde is initially concentrated and then polymerized in an inert cyclohexane medium. To enhance thermal stability, hydroxyl end groups are reacted with acetic anhydride.

Details: 110 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $1,999 USD

The cost analyses presented in this report target a 110 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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