CHAPTER I

PRODUCT ANALYSIS

1.1 INTRODUCTION

Formic acid is a simplest carboxylic acid with formula of HCOOH. Its systematic IUPAC
name is methanoic acid. It is an important intermediate in chemical synthesis and it is
occurs naturally. Formic acid was first isolated from certain ants and its name come from
a Latin word formica with the meaning of ant. It is a colourless liquid with highly
pungent smell and penetrating odour. It is miscible with water and is a most polar organic
solvent which can soluble in hydrocarbon. The figure and table shows the molecular
structure and physical properties of formic acid respectively.

Figure 1.1 Molecular structure of formic acid

 2

Table 1.1 Physical Properties of Formic Acid.

Characteristic Properties

Physical State Colourless liquid with pungent, penetrating

Odour
Molar Mass 46.03 g/mol
Boiling Point 101.0oC (374.2 K)
Melting point 8.3oC (281.5 K)
Flash Point 69.0oC (342.2 K)
Density 1.220 g/cm3 at 25oC
Vapour Density 1.59 (Air=1)
Viscosity 1.607 mPa.s at 25oC
Solubility Miscible in water, ether, acetone, glycerol,
methanol and ethanol
Solubility in water 1000000 mg/L at 25oC

Source: National Center for Biotechnology Information. PubChem Compound Database;

(accessed Oct. 5, 2015).

The usage of formic acid is as a preservative and antibacterial agent in livestock

feed. Almost 45% of the total formic acid demand was for the silage preservation, animal
feed, and other agriculture applications in 2012, with the leather & textile and rubber
industry also being the fastest growing end-use segments, primarily due to high
penetration of leather and textiles in all the regions. Sometimes, it is added to feed to kill
E. coli bacteria in the poultry industry. It also widely used in the production of leather and
as a coagulant in the production of rubber, and used in place of mineral acids for cleaning
products.
 3

1.2 SOURCES OF RAW MATERIALS

1.2.1 Sugar Cane Bagasse

Sugar Cane is the species of tall perennial true grasses of the genus Saccharum, tribe
Andropogoneae, native to the warm temperate to tropical regions of South Asia,
Melanesia, and it is used for sugar production. It has stout jointed fibrous stalks that are
rich in the sugar sucrose, which accumulates in the stalk internodes. The bagasse is the
fiber waste after the sugar cane are crushed to extract the juices. Bagasse might contains
of 45-55% of cellulose, 20-25% of hemicellulose, 18-24% of lignin, 1-4% of ash and less
than 1% of waxes.

Figure 1.2: The sugar cane bagasse.

1.2.2 Oxygen gas

Oxygen gas is gaseous chemical component with symbol O, atomic number of 8 and
atomic weight 15.9994. It is the essential element in the respiratory processes of most of
the living cells and in combustion processes. Its the most abundant element in The
Earths crust. Nearly one fifth (in volume) of the air is oxygen. In normal conditions
oxygen is a colourless, odourless and insipid gas; it condensates in a light blue liquid.
Oxygen is reactive and will form oxides with all other elements except helium, neon,
 4

argon and krypton. It is moderately soluble in water (30 cm3 per 1 liter of water dissolve)
at 20 Celsius.

Table 1.2 Physical properties of oxygen.

Characteristics Properties

Molar Mass 15.9999 g/mol

Boiling Point 182.962C
Melting point 218.79C

Density 0.001308 g/cm3

Phase Gas
Colour Colourless
Odour Odourless
Source: www.lenntech.com

1.2.3 Water

Water has the formula of H2O. Water is a transparent fluid which forms the world's
streams, lakes, oceans and rain, and is the major constituent of the fluids of organisms.
Many substances dissolve in water and it is commonly referred to as the universal solvent.
Water is the only common substance found naturally in all three common states of matter
and it is essential for all life on Earth. The supplier will be the main water supplier service
of the state. The tariff of the water price is set by National Water Service Commission.
 5

Table 1.3 Physical properties of water.

Characteristics Properties

Molar Mass 18.015 g/mol

Boiling Point 100oC
Melting point 0oC

Density 999.97kg/m3

Phase Liquid
Colour Colourless
Odour Odourless
Source : Pubchem, water, 2011.

1.3 CATALYST

1.3.1 Potassium Hydroxide

Potassium Hydroxide with chemical formula of KOH which is an inorganic acid. The
appearance of potassium hydroxide is a colourless solid which is a strong base, it form a
strong alkaline solution when dissolves in water.

Table 1.4 Physical properties of potassium hydroxide.

Characteristics Properties

Molar Mass 56.11 g/mol

Boiling Point 1600K
Melting point 679K

Density 2.12 g/cm3 at 25oC

2.044g/cm3 at 20oC
Solubility Soluble in alcohol and glycerol
Insoluble in ether and liquid ammonia
 6

Appearance Dry Powder

Colour Colourless
Odour Odourless
Source: MSDS Potassium Hydroxide, 2005.

1.3.2 Sulfonated Si/C Nanocomposite

Sulfonated Si/C Nanocomposites is a type of solid acid, the properties are shown in the
table below.

Table 1.5 Physical Properties of Sulfonated Si/C Nanocomposite.

Parameters Description

Physical State Solid

PH Acidic

Melting Point 3500 C

Chemical Stability Stable

1.4 BY-PRODUCT

1.4.1 Carbon dioxide

The chemical formula of carbon dioxide is CO2. Carbon dioxide is a colourless and
odourless gas. Carbon dioxide exists in the Earth's atmosphere as a trace gas at a
concentration of about 0.04 percent (400 ppm) by volume. Carbon dioxide is an important
greenhouse gas. Burning of carbon-based fuels since the industrial revolution has rapidly
increased its concentration in the atmosphere, leading to global warming. It is also a
major cause of ocean acidification since it dissolves in water to form carbonic acid.
 7

Table 1.6 Physical Properties of carbon dioxide.

Characteristics Properties

Molar Mass 44.01 g/mol

Boiling Point -78.5oC (194.65K)
Melting point -55.6oC (217.55K)

Density 1.98g/L

Solubility Soluble in water

Phase Gas
Colour Colourless
Odour Odourless
Source: MSDS Carbon dioxide, 2005.

1.5 PRICE OF RAW MATERIAL AND PRODUCT

The price of raw material and product is tabulated into the table below.

Table 1.7 Price of raw material and product in Ringgit Malaysia.

Material Phase Price/kg (RM)

Oxygen Gas 0.86

Formic acid Liquid 2.59 - 3.02

Oligosaccharide (D-xylose) Solid 76.48

Fructose Liquid 3.05

Glucose Liquid 3.17

Water Liquid 0.00032

Sources: Chemicool.com, Alibaba.com, Sigma-Aldrich, US Department Of Agriculture

 8

1.6 PRODUCT USAGE

Formic acid is an environmentally acceptable and highly efficient organic acid. It is used
in many areas, from leather processing to feed preservation. In leather processing, the
acid is used in tanning and dye fixing and serves also as a neutralizing agent and pH
adjuster in many steps of textile processing. In the production of epoxidized soy bean oil ,
formic acid is used in combination with hydrogen peroxide as oxidizing agent. It is also
used to adjust pH values in flue gas desulfurization, latex coagulation and other
applications. Formic acid can serve as a hydride donor in various chemical processes. In
animal nutrition the acid preserves feed and silage. In oil field applications it helps to
dissolve calcium carbonate. The pharmaceutical industry uses formic acid in the
production of various active pharmaceutical ingredients. (Acidpedia, formic acid)

1.6.1 Leather Production

One of the most common industrial uses of formic acid is in the production of leather.
Formic acid ensures efficient, homogeneous tanning of hides in leather production.
Tanning process needs acidic conditions. Therefore, the hides are pre-treated with sulfuric
acid and formic acid prior to tanning in a process called pickling. Without this
conditioning, the tanning agents would quickly become fixed at the surface of the hide
while its inner layer would remain raw. Formic acid is able to penetrating collagen fibres
fast and homogeneously.

1.6.2 Rubber Industry

Formic Acid is the preferred choice for coagulating latex: it is cost-efficient, and
guarantees a consistent high-quality natural rubber product making it one of the best
coagulants for natural rubber latex coagulation in dry rubber production. Natural rubber
latex coagulation by using Formic Acid at an appropriate concentration and with
recommended methods can produce high quality dry rubbers with good color, as required
by dealers and manufacturers.
 9

1.6.3 Livestock Feed Preservative

Formic acid has antibacterial effects, which are used to preserve livestock feeds. It is mix
with propionic acid, which inhibits fungal and yeast growth, and to ensure
microbiologically safe feeds. It also add into drinking water for poultry to inhibits the
growth of microorganisms and algae (Engormix, Sarah Mellor, Christian Lckstd, 2011).

1.7 DEMAND OF FORMIC ACID

Silage storage or animal feed additives has exceeded leather and tanning as the world
biggest demand for formic acid in 2009 with nearly 49% domination in 2013 (IHS Inc.,
2013). Improved living standards worldwide have led to an increasing demand of meat
which resulting in increasing market of formic acid worldwide. Europe was the largest
consumer for market in silage storage and animal feed additives since the European
Union inhibits antibiotic growth additives in early 2006. The demand in this application is
expected to grow rapidly in most markets during 2012 to 2018.
 10

1% Asia
2.50% 2.50%

Western Europe
6%

7%
Central and South
America

48% North America

Central and Eastern

Europe
33%
Middle East

Other

Figure 1.3 World consumption of formic acid in 2012 based on countries

Source: IHS Chemicals, 2013

1.8 SUPPLY OF FORMIC ACID

The key companies in this market are BASF SE (Germany), Perstorp AB (Sweden),
Feicheng Acid Chemicals Co. Ltd. (China), Gujarat Narmada Valley Fertilizers Co. Ltd.
(India) and others (ReportsnReports, 2014). These companies are consistently focusing on
expanding their production capacity to achieve a competitive advantage.
 11

BASF

Beijing Chemical
4.40% Industry Group
3.80% Feicheng Acid Chemical

Gujarat Narmada Valley

Fertilizer
Jinan Petrochemical
11.40%
32.10%
Linyi Shengchun

Perstorp
13.80%
Polioli

PT Pupuk Kujang-PT
1.30% Saturama Wicaksana
1.40% 13.90% Rashtiya
1.10%
Shanxi Yuanping
1.40%
Chemical
4.90% 2.20% Shandong Liaocheng Luxi
1.30% 3.20%
Chemical
3.80% Taminco

Figure 1.4 World supply of formic acid in 2013 based on leading companies
Source: TranTech Consultants, 2014.

1.9 DEMAND AND SUPPLY OF FORMIC ACID

Global demand growth is forecast at 3.6%/year to 2018 (TranTech Consultants, 2014).

Regionally, consumption will rise by 4.6%/year in Asia-Pacific, 3.5%/year in
Asia/Middle East, 3%/year in the Americas, 2.6%/year in Western Europe and 1.9%/year
in Japan. Worldwide, some 105,000 ton/year of new capacity will come on stream within
the next four years. The supply is expected to grow at CAGR 1%/year with deficient of
255000 ton/year to 2020.
 12

800000 741647
715875
690999
700000 666987
643810
621438
599844
579000
600000
486647
500000 460875
435999
Tons/year

411987
388810
400000 366438
344844
324000 Supply
300000 Demand

200000

100000

0
2012 2014 2016 2018 2020 2022
Year

Figure 1.5 Global demand and supply of formic acid forecast to 2020.

1.10 PLANT CAPACITY

The market analysis is calculated based on deficient in 2017 since the proposed plant is
predicted to start operating on that year. Taking the operating hour of plant as 350
days/year, where in 1 year two weeks will be used for maintenance. Take plant capacity
of 5% global deficient, the product flow rate is 1518 kg/h.
 13

Table 1.8 The demand, supply, deficient, and capacity.

Analysis Value

Demand 666987 tons/year

Supply 411987 tons/year

Deficient 255000 tons/year

Capacity 12750 tons/year

1.11 FUTURE MARKETING POTENTIAL OF FORMIC ACID

Global trend and forecasts to 2019 says market value of the formic acid market in 2012
was estimated for about $451,339.4 thousand and is estimated to reach $618,808.7
thousand by 2019 (ReportsnReports, 2015). The European formic acid market is
projected to reach $226,868.1 thousand by 2018, at a CAGR of 4.0% from 2013 to 2018
(Micro Market Monitor, 2015). The European formic acid market covers countries like
U.K., Germany, France, Italy and the region is expected to dominate this market with its
growing demand for formic acid in different applications, especially in agriculture,
leather & textile, and rubber industry. Meanwhile, lower labour and capital costs and a
rapidly growing market have made China the top choice for additional investment and
capacity. China will strengthen its position as the single-largest producer and exporter of
formic acid and not need additional capacity till 2018 (TranTech Consultants, 2014).