Commodity Production Costs Report

Formaldehyde from Methanol (Silver Catalyst and Full Conversion)

Formalin Operating Costs & Plant Construction Costs

60 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $799 USD | See Report Editions Prices

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.

The report provides a comprehensive study of Formalin production and related Formalin production cost, covering three key aspects: a complete description of the Formalin production process examined; an in-depth analysis of the related Formalin plant capital cost (Capex); and an evaluation of the respective Formalin plant operating costs (Opex).

The Formalin production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Formalin plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Formalin plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.

Key reference(s): ?

Formalin Production Cost Report Process Schematic

The process under analysis comprises two major sections: (1) Reaction; and (2) Absorption.

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.

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.

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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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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • See All Features

 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • 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
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
  • Print-enabled PDF Format Add-on
  • Updated with Q3 2024 Data
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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

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