Synthesis of Formalin.

 Natural gas process

Normally three methods are used for the manufacturing of formaldehyde from natural

gas

1) Oxidation in gaseous phase by passing mixture of gas and air over catalyst.

2) Oxidation of natural gas by ozone.

3) Iodination of subsequent hydrolysis.

Formaldehyde is also synthesized by cracking of methane in electric discharge. Many

types of catalyst e.g. copper, nickel, cobalt, chromium, manganese, gold and silver are

used for production of formaldehyde. Maximum conversion of 60% to 70% of methane

to formaldehyde occurs in this process.

 Silver Catalyst Process

The silver catalyst processes for converting methanol to formaldehyde are generally

carried out at an atmospheric pressure and at 600 – 720°C .The reaction temperature

depends on the excess of methanol in the methanol-air mixture. The composition of

mixture must lie outside the explosive limits. The amount of air used is also determined

by the catalytic quality of the silver surface. The following reactions take place:

CH3OH + ½O2 → HCHO + H2O

CH3OH → HCHO + H2
 Metal Oxide Process

In this process formaldehyde is formed by oxidation process only. The reactions

are:

CH3OH + ½O2 → HCHO + H2O

HCHO+ ½O2 → CO + H2O

The reactions occur over a mixed oxide catalyst containing molybdenum oxide

and iron oxide in a ratio 1.5 to 3.The reaction is carried out at 250 –350°C and

essentially at atmospheric pressure. Methanol conversion is 95 – 98% per pass.

 Production from Methane and other Hydrocarbons gases

Another method of producing formaldehyde is through the oxidation of

hydrocarbon gases. An increase in the amount produced of formaldehyde is

expected in this process. However, the hydrocarbon formaldehyde is usually

obtained as dilute solution which is not economically concentrated

accompanied by other aldehydes and by-products. However, improvements

have been effected by the use of special catalysts and better methods of control.

Wheeler demonstrated that methane is not oxidized at an appreciable rate below

600°C. The difficulty in this method is in controlling the oxidation of reaction.

Ethylene, ethane and propane oxidations can be controlled to yield

formaldehyde under similar conditions to methane. Higher hydrocarbon gases

can be oxidized at much lower temperatures than methane and ethane.