Johnson Matthey license the FORMOX™ formaldehyde process, with plant capacities ranging from 70 MTPD to nearly 840 MTPD.
The process enables the production of concentrations above 55%, which means reduced costs of downstream production, storage and transport. No other process gives you as much formaldehyde (or UFC) per ton of methanol and, since methanol is the chief cost of formaldehyde/UFC production, the FORMOX process means superior overall economy.
In the FORMOX formaldehyde process a mixture of air and methanol is vapourised and passed into catalyst-packed reactor tubes containing a molybenum and iron oxide catalyst. The reaction which takes place at 350oC is highly exothermic and generates heat to provide steam for turbines and process heating.
FORMOX plants are also available for direct production of UFC (urea formaldehyde concentrate). This technology is well proven with more than 15 plants operating worldwide. If your downstream formaldehyde production is UFC or MUF resin, you may want to consider this approach.
Urea formaldehyde concentrate manufacture for urea production
Formaldehyde in the form of urea-formaldehyde concentrate (UFC) is used as an additive in the manufacture of solid urea. Johnson Matthey’s skills in catalyst design, along with ammonia, methanol and formaldehyde process technology development have been used to create a new and cost effective integrated method of synthesising small quantities of UFC (up to 85 wt% urea-formaldehyde) which allows a urea producer to make significant savings when compared to the alternative of open market purchases.