Formaldehyde production technology and catalysts

Johnson Matthey’s FORMOX™ process technology is the world’s leading solution for formaldehyde production, offering unmatched safety, efficiency, and sustainability. With plants ranging from 70 to 1670 MTPD* and high-performance catalysts, we deliver cost-effective, reliable solutions tailored to your production needs.

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Advanced formaldehyde plant technology

Johnson Matthey license the FORMOX™ formaldehyde process, with plant capacities ranging from 70 MTPD to nearly 840 MTPD.

The FORMOX™ formaldehyde process enables production of formaldehyde concentrations up to 55%. With superior methanol-to-formaldehyde conversion, our technology ensures lower operating costs and higher yields than alternative methods.

How the FORMOX process works

In the FORMOX formaldehyde process methanol is vapourised in the process gas and passed into a tubular reactor containing a variety of different possible loading plans based on molybdenum and iron oxide catalysts.

The reaction is exothermic and generates heat to provide steam for process heating or other purposes.

FORMOX plants are also available for direct production of UFC (urea formaldehyde concentrate). This technology is well proven with more than 30 plants operating worldwide. If your downstream formaldehyde production is UFC or UF resin, you may want to consider this approach.

Key benefits of FORMOX plants

Modern high-performance formaldehyde plant technology

Depending on operating regime and selected CAP, 92.2–93.3% molar yield from methanol, ensuring maximum output.

Standard plant portfolio for every need

Scalable solutions from 70 to 1670 MTPD, tailored to your production requirements.

Built for safety, reliability, and best overall economy

Simple and robust operation
High steam production (750–800 kg/ton) reduces external energy demands on site.
Low methanol consumption (423–428 kg/ton) lowers feedstock costs.

Sustainable operation with superior efficiency

Lower power consumption (35–70 kWh/ton).

Best-in-class productivity

High catalyst efficiency:
20,000–35,000 kg formaldehyde per kg catalyst.
Flexible output:
Formaldehyde concentrations up to 55%, or UFC (up to 85%).

High-performance formaldehyde catalysts

Johnson Matthey develops, manufactures and markets a range of high-performance FORMOX catalysts, used in different CAPs (Catalyst Activity Profile) to match the specific needs of all types of oxide formaldehyde processes – not only our own.

FORMOX catalyst advantages

Partial oxidation catalysts with excellent selectivity and conversion

Standard or tailor-made designed CAPs with high flexibility to meet desired productivity and performance requirements

Long-lasting performance: 20,000–35,000 kg formaldehyde per kg catalyst

Emission control: Designed to meet environmental standards

Typical FORMOX plant performance

Typical performance figures
(based on 37 wt-% concentration)

	PER METRIC TON
Methanol	423 - 428 (1)
IBL power (2)	35 - 70 kWh
Cooling water	35 m³
Catalyst (3)	0.03 - 0.05 kg
Steam produced (4)	750 - 800 kg
Steam pressure	12 - 22 bar g (174 - 319 psi)

(1) Molar yield of 92.2-93.3%
(2) Range covering different power saving options and age of catalyst
(3) 20,000-35,000 kg (lbs) of formaldehyde per kg (lb) catalyst, depending on operating conditions
(4) Saturated steam - superheated steam can be produced as an option