Commodity Production Costs Report
Formaldehyde Production from Natural Gas
Formalin Operating Costs & Plant Construction Costs
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.
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): ?
Product
Formalin. 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.
Raw Material
Natural Gas. Natural gas is a naturally occurring mixture of hydrocarbon found in porous subsurface geologic formations. It is composed mainly of methane, but also contains varying amounts of higher hydrocarbons such as ethane, propane, and butane. Additionally, natural gas may also include non-hydrocarbon components considered impurities such as nitrogen, carbon dioxide, and hydrogen sulfide. Natural gas is primarily used as a source of heat energy for residential, commercial, and industrial applications. It may also be used in the production of important chemicals such as ammonia, methanol, and hydrogen.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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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Other Formalin Production Cost Reports
Formaldehyde from Methanol (Silver Catalyst and Full Conversion)
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.
Details: 60 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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 | Q3 2024 | 107 pages | Issue C | From $799 USD
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 | Q3 2024 | 107 pages | Issue A | From $799 USD
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Other Related Production Cost Reports
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 | Q3 2024 | 107 pages | Issue D | From $799 USD
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 | Q3 2024 | 107 pages | Issue A | From $1,999 USD
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