Ministry of Higher Education

And Scientific Research

Al-Muthanna University
College of Engineering
Department of Chemical Engineering

PRODUCTION FORMALDEHYDE
Control two equipment Reactor and Heat
Exchanger

Preparation:
Abd Al-Khaliq Mustafa
Class: Fourth
Subject: Process control
Under The Expert Guidance Of:
Dr. forat Yasir Aljaberi
Introduction:
Formaldehyde is widely abundant in nature and the anthropogenic environments
owing to several natural and non-natural decomposition pathways of both biological
and non-natural organic matter. Formaldehyde, also called Methanal (formulated
HCHO), an organic compound, the modest of the aldehydes, used in huge amounts
in a diversity of chemical manufacturing processes. It is formed principally by the
vapor-phase oxidation of methanol and is normally sold as formalin. The chemical
compound formaldehyde (also known as methanal) is a gas with a pungent smell.
It is the modest aldehyde. Its chemical formula is H2CO. Formaldehyde was first
produced by the Russian chemist Aleksandr Butlerov in 1859 but was finally
identified by August Wilhelm von Hofmann in 1868.
Formaldehyde readily results from the incomplete burning of carbon-containing
materials. It may be found in the smoke from forestry fires, in vehicle exhaust, and
in tobacco smoke. In the atmosphere, formaldehyde is formed by the action of
sunlight and oxygen on atmospheric methane and further hydrocarbons. Small
amounts of formaldehyde are made as a metabolic byproduct in maximum
organisms, including humans.[1]

Figure 1: Formaldehyde Formula

Formaldehyde can be listed on a product tag by other names, such as: Formalin,
Formic aldehyde, Methanediol, Methanal, Methyl aldehyde, Methylene glycol,
Methylene oxide.
History:
Formaldehyde is a naturally arising organic compound composed of carbon,
hydrogen and oxygen. It has a modest chemical structure of CH2O. Formaldehyde
was first defined in 1859 by Alexander Mikhailovich Butlerov when he tried to make
methylene glycol. However, formaldehyde wasn’t finally identified until 1868, when
August Wilhelm von Hofmann, a professor of chemistry and director of the
laboratory of the University of Berlin, set out to clearly create both the structure and
identity of formaldehyde. The method that Hoffman used to identify formaldehyde
placed the foundation for the modern formaldehyde manufacturing process.

Properties:
Although formaldehyde is a gas at room temperature, it is voluntarily soluble in
water. It is most normally sold as a 37 % aqueous solution with trade names such as
formalin or formol. In water, formaldehyde changes to the hydrate CH2(OH)2.
Thus formalin contains very little H2CO. These solutions typically contain a few
percent methanol to limit the range of polymerization. Formaldehyde shows most of
the chemical properties of the aldehydes, but that it is more reactive. Formaldehyde
is a good electrophile. It can contribute in electrophilic aromatic substitution
reactions with aromatic compounds and can go through electrophilic addition
reactions with alkenes. In the existence of basic catalysts, formaldehyde go through
a Cannizaro reaction to produce formic acid and methanol. Formalin reversibly
polymerizes to produce its cyclic trimer, 1, 3, 5-trioxane or the linear polymer
polyoxymethylene. Because of the creation of these derivatives, formaldehyde gas
diverges strongly from the ideal gas law, especially at high pressure or low
temperature. Formaldehyde is voluntarily oxidized by atmospheric oxygen to form
formic acid. Formaldehyde solutions should be protected from air [10].

Manufacturing Of Glues and Resin:

Due to the higher binding properties of formaldehyde, it is used widely in the
production of glues and resins used in cabinetry, shelving, stair systems, and in other
items of home furnishing. Not only are these glues widely effective, they are also
reasonable due to the fact that formaldehyde is easily accessible. The greatest
common products produced from formaldehyde include urea formaldehyde resin,
melamine resin, and phenol formaldehyde resin. These are manufacturing by the
reaction of formaldehyde with urea, melamine, and phenol, respectively. These are
strong glues, and are used in carpentering. These resins are also mold to make
different products, and old for making insulate layers. Melamine formaldehyde
resins are solid and are consumed as paper-impregnating resins, in cover flooring,
and in clear coats for automobiles. Phenol formaldehyde resins are used as binders
in structural wood panels. Formaldehyde resins give wet strength of products that is
facial wipes, paper napkins, etc.

As a Disinfectant:
Formaldehyde is a extremely effective disinfectant. It fully negates the actions of
bacteria, fungi, yeast and molds. Aqueous solution of formaldehyde can kill bacteria,
and it is used in the treatment of skin infections. It is also used to deactivate toxic
bacterial products for the manufacturing of vaccinations for certain infections.
Methylamine, a derived of formaldehyde, is used to treat urinary tract infections.
Certain current ointments also use derivatives of formaldehyde. However, these
might not be safe for longstanding use. However, formaldehyde has a pungent scent
that causes severe frustration to the nose and eyes, and this is the reason for its
restricted use. However, many companies have just been successful in
manufacturing a processed form of the chemical, which is not as irritable, yet is an
effective disinfectant.

Textile Industry:
Formaldehyde also discovers usage in the textile industry where it is added to dyes
and pigments. This helps the pigments to bound better with the fabric, thus avoiding
the colors from fading. Formaldehyde-based resins are used to increase a fabric's
resistance to folds and wrinkles.

Automobile Industry:
Key constituents of automobiles are produced using formaldehyde-based products.
Since phenol formaldehyde resins are resistant to fire and high temperatures, they
are used to production automobile parts, such as brake linings.

Preserving Cells and Tissues:

Formaldehyde solution is used in laboratories for the safety of human and animal. A
4% solution is used for the same. If you're doubting how formaldehyde conserves
cells and tissues, it is by the cross-linking of primary amino groups in proteins with
neighboring atoms of nitrogen in protein or DNA, over a -CH2 linkage.
As an Embalming Agent:
Embalming is a process which briefly stalls the decay of human remains.
Formaldehyde is one of the embalming agents. It also repairs those tissues that are
accountable for the firmness of the muscles in an embalmed body. A normal use of
formaldehyde is in the production of ink. So, whether it is the ink that we use in our
printers, or the one used for print books, formaldehyde is a key constituent.
Formaldehyde-based resins are used in the natural gas and petroleum industries to
get improved the yield of these fuels. Hexamine, a derived of formaldehyde, is used
as a component in the manufacture of the quick-tempered RDX. Formaldehyde is
mixed with concentrated (H2SO4) sulfuric acid to form Marquis Reagent, which is
used as a spot-test to detect alkaloids and other compounds. Formaldehyde is added
to paints as a stabilizer. It is also used as a chemical adding in cosmetics.
Formaldehyde is used in the manufacturing of polyacetal which are thermoplastics
used in electrical and electronic application.

Handling:
Formaldehyde should be associated only in original container, fully labeled and
deposited properly inside the way of transportation to avoid out of order up, leakage
or breakage. Formaldehyde should never be opened, mixed or transfer to sample
vessels at any time inside a closed vehicle. A Materials Safety information Sheet
(MSDS) should be in the control of the customer and complete reachable to those
prepared by this chemical. At all period, formaldehyde should only be handled,
mixed or added as example containers with the topmost care, in ventilated regions
such as open air table if in the field and below an right fume hood if in the laboratory.
Formaldehyde should never be opened or mixed while inside a automobile. If there
is the possibility of splashing, a face protect should be damaged while adding or
pouring formaldehyde. At all times, disposable gloves must be worn to avoid dermal
exposure when management and/or mixing this product. Never smoke or don’t have
open flame while working with formaldehyde.

Storage:
Formaldehyde must be kept in a cool, dry, well-ventilated zone and properly labeled.
Formaldehyde should never be kept in automobiles except to carriage to and from
field for the period of diversity operation. Used formaldehyde, either from leak
clean-up or from actions produced from the process of change-out of sample
containers must be kept in a properly label dangerous waste container and made
accessible for recycling under Resources Conservation Recovery Act (RCRA)
protocols. Storing of unwanted formaldehyde should be in a region not frequented
by the general population or responsibility workers and should be in an region not
subject to heat cycles and well ventilated.
Store formaldehyde in label, chemically well-suited containers, away from heat and
flame. Always keep in large-volume containers on a low, safe shelf or in another site
where they will not be accidentally leaked or hit over. Containers bigger than 4L (1
gallon) should be kept in secondary containment. Do not keep formaldehyde bottles
in any area where a leakage would flow to a drain.

Safety:
Because of formaldehyde’s danger, containing human carcinogenicity, Cal/OSHA
has passed specific system (Title 8, California Code of Regulations, Section 5217)
concerning its safe handling. The following basics must be included in a
formaldehyde safety program.
A laboratory-specific Standard Operating Procedure for the use of formalin
formaldehyde must be established. Employees who handle formaldehyde must bring
together familiar preparation on the dangers of formaldehyde and what to do in case
of a contact or leak. Coverage monitor may be required to confirm that employees
are not over-exposed. Formaldehyde should always be used with acceptable
ventilation, rather in a fume hood, to minimize breath of formaldehyde vapor.

Exposure Limit:
The legal on far above the ground permissible exposure limit (PEL) is 1 p/m in an
8-hourworkday. Short-term exposure (15 minutes) is restricted to 2 p/m while the
attainment level for formaldehyde is 0.5 p/m.

Disposal:
Dissolve or mix the material with a flammable solvent and burn in a chemical
furnace equipped with an afterburner and scrubber. Notice all federal, state, and local
environmental procedures.

Spill Procedure:
Evacuate region. Wear self-contained inhalation apparatus, rubber boots and heavy
rubber gloves. Cover with lime or soda ash and abode in closed containers for
removal. Ventilate region and wash leak site after material pickup is complete.
Combustible Liquid
Fire Hazards: Extinguisher: Water spray, Carbon dioxide, dry chemical powder
or suitable foam. Special Procedure: Wear self-contained breathing apparatus and
protective clothing to avoid contact with skin and eyes, wear rubber gloves. Unusual
Fire hazards: Produces toxic fumes under fire conditions.

Shipping:
Formaldehyde should be conveyed only in original container, fully labeled and kept
properly within the automobile to avoid shifting, leakage or breakage. Formaldehyde
should never be opened, mixed or shifted to sample vessels at any time inside a
closed automobile. A Materials Safety Data Sheet (MSDS) should be in the control
of the user and made accessible to those working with this chemical. Shipped in
drums, barrels and bottles or carboys. Generally sold and transported as a 37%-40%
aqueous solution, and under certain conditions may become a white solid. If carried
in kegs or barrels there is generally a loss in weight and corrosion of the fastenings
if these are of metal. May produce acidity; this causes significant depreciation and
is generally due to the presence of inherent impurities. If packed in a shipping
container, on unpacking, time should be allowed for spreading of any fumes, before
entering container.

Feasibility:
World Formaldehyde Production to Beat 52 Million Tons in 2017. Formaldehyde is
the maximum commercially significant aldehyde. Urea-, phenol-, and melamine-
formaldehyde resins (UF, PF, and MF resins) account for nearly 70% of world
demand for formaldehyde in 2015; other huge applications include polyacetal resins,
pentaerythritol, methylene is(4-phenyl isocyanate) (MDI), 1,4-butanediol (BDO),
and hexamethylenetetramine (HMTA).World consumption demand of 37%
formaldehyde is estimate to raise at an average annual rate of about 4% from 2015
to 2020.Between 2010 and 2015, world capacity for 37% formaldehyde increased at
an average annual rate of about 3%, slightly behind world consumption, which
increased at an average annual rate of 4.4% through the same period.
 Figure 2: World Consumption Data

Formaldehyde resins are used in the wood products industry largely as glues. Growth
of these resins is toughly correlated to construction/restoration activity (which
accounts for over 50% of consumption), and to a lesser degree, the automotive
industry.
China is the single major market for formaldehyde, accounting for 42% of world
consumption demand in 2015; other countries with big markets include the United
States, Germany, the Netherlands, Spain, Italy, Belgium, Poland, Russia, India,
South Korea, Japan, Brazil, and Canada. China is estimate to involvement high
growth rates and important volume increases in demand for 37% formaldehyde
during 2015–2020. Demand for 37% formaldehyde in the United States is estimate
to grow reasonably, mainly driven by UF resins, PF resins, and MDI. Central
Europe.
Flow Sheet of Production of Formaldehyde Using Silver Process:

Figure 2.1: Flow Sheet of Formaldehyde using Silver Catalyst

Process Flow Diagram Of Silver Process:

Figure 2.3: Process Flow Diagram of Formaldehyde Using Silver Catalyst

Instrumentation and Control for the system:
Introduction
Measurement is a fundamental necessary to process control whether that control is
affected automatically, semi automatically, or manually. The quality of control
obtainable also bears a relationship to the precision, reproducibility and
dependability of the measurement method which are employed. So, selection of the
most effective means for measurement is an important first step in the design and
formulation of any process control system.
In manual control an operator may periodically read the process variable and adjust
the input up or down in such a direction as to derive the temperature to its desired
value. Manual control is used in non- critical application, where any process
condition occurs slowly and in small increments and where a minimum of operator
attention is required. While in programmed control, measurement and adjustments
are made automatically on a continuous basis. Today automatic control is used in
industry due to following benefits.
 Improvement in product quality
 Increase in process yield of production rate
 Rise safety for personnel and equipment
 Economics saving in materials, energy of time
 Improvement of working conditions
 Success of operation not possible by manual control

Control Mechanism
The Controllers reorganizes the offer signal and produces an output signal relative
to some function of the error. The output signal of the controller is the initiating force
positioning of the final control element.

Process Control
Control in one form or in another is an important part of any chemical engineering
operation. In all practices, there rises the necessity of keeping flows, pressures,
temperatures, compositions, etc. Within certain limits for reasons of safety or
conditions. It is self-evident that automatic control is highly desirable, as manual
operation would necessitate continuous monitoring of the controlled variable by a
human operator and the efficiency of observation of the operator would unavoidable
fall off with time. Moreover, variabilities in the controlled variable may be too quick
and frequent.
Objectives of Instrumentation and Control System
 Suppressing and killing the external disturbances
 Operate the process in a stable manner
 Optimize the process operation

Components of the Control System

Following are the main components of a control system:
Process:
Any operation or series of operations that produce a desired final result in a process.
Measuring Element:
As all parts of control system, determining element is perhaps the most important. If
measurements are not made properly the Remaining of the system cannot operate
suitably, also the measured variable is chosen to symbolize the desired conditions in
the process.
Controller:
The controller is the device that replies to any error detecting mechanism. The output
of the controller is determined function of the error. Final Control Element: The final
control element receives the signal from the controller and by some prearranged
relationship change energy input to the process.

Types of Control
Many different types of controls are used in industry dependent upon requirements
and particular needs. They range from very simple control to very complex system,
in general they may be divided into two major classes as follows:
 Feedback control.
 Feed forward control
Feedback Control
It is our general behavior that we leant from practice. A feedback control, as the
name suggest, is also founded on same principal. If any input to a system is changed
it will change in the system called as “disturbances”. These disturbances are noted
down and modified action is taken on the input to unwrap the effect that change.
Advantages
 It does not require the ID and measurement of disturbance.
 Effective for all disorders.
 Insensitive to modeling errors
 It can deliver zero steady state offset.

Disadvantages
 It waits until the effect of disturbance has been felt by the system.
 Poor response for slow processes or with significant dead time.
 It may create uncertainty in the closed loop response.

Feed Forward Control

In daily life experience we pride on being able to plan forward. No deriver of
automobile waits for his vehicle to leave the road before operating the steering
wheel.
Relatively, he participate the effect of curbed road by introducing the corrective
action before controlled variable is affected. When this idea is properly applied to
control system the loop that is formed is called feed forward in appreciation of the
fact that the manipulating variable is open to a disturbance rather than to controlled
variable.
Advantages
 It acts before the effect of disturbance has been handled by system.
 It is good for slow systems or systems with significant dead time.
 It does not introduce the uncertainty in control system.
Disadvantages
 It requires the ID of all possible disturbances and their direct measurement.
 Cannot handle with unmeasured disturbances.
 Complex to process parameter deviation.
 It cannot removed steady state offset.
 It needs good knowledge of process model.
In order to design a control system to work not only automatically but resourcefully,
it is frequently essential to obtain both steady state and dynamic behavior in which
this knowledge is gained is dependent essentially upon the process being controlled
and control element to be applied.

Process Variable
The operation of a process is rely upon the control of the process variables. These
are defined as situation in process materials or machine, which are subjected to alter
the temperature, pressure, flow and liquid level are the main variable, and trailed by
perhaps a dozen less often encountered variables such as chemical composition,
viscosity, density, humidity, moisture content and so forth. Measurement is a
important requisite to process control either the control can be achieve automatically,
semi automatically or manual. The quality of control attainable also bears a
relationship to precision, reproducibility and reliability of the measurement
technique, which are selected.
So, selection of the most effective means of measurements is an significant first step
in the design and modeling of any process control system. An automatic control is
used to measure, accurate and modifies changes of the four principle types of process
variations.
 Temperature measurements
 Pressure measurements
 Flow rate measurements

Valve Selection
Valves used in chemical plants can be divided into two categories depending on their
function:
1. Shut off valves – The main purpose of shut off valves is to close off the flow.
2. Control valves – They can be either automatic or manual and their objective is
used to regulate the flow.
Control Valves:
Selection of control valves is an important factor. It is important that good flow
control is achieved
Whilst the pressure drop is kept low as possible. Control valves may fail to open,
this is occurs when power supply failure happens. Diaphragm valves are commonly
used in this case. This type of valve can be seen in the figure below:

Figure 6: Diaphragm valve

Flanged Valves:
Flanged valves can be used for drainage. An example of the type of flanged valve
used in this case is shown in figure below. These are generally closed and are in
operation usually during site or unit maintenance.

Figure 7: Flanged Valve

Non- Return Valves:
This type of valve is used to prevent the back-flow of the fluid in the process. It is
important that non-return valves have been correctly installed to ensure they are
working adequately, i.e. they should be fitted in the correct orientation. An example
of this type of valve is shown in figure below:
 Figure 8: Non-return valve
Gate Valves:
Gate valves are frequently used for shut –off purposes. It is important that a valve
selected for this purpose gives a positive seal in the closed position and minimum
resistance to the flow when the valves are open. Gate valves exist in a wide range of
sizes and it is possible to operate them manually or automatically by the use of a
motor. When gate valves are fully open they have a low pressure drop. When
operating gate valves attention must be paid to ensure they are not operated partially
open. This is because the valve seal can become deformed, so as a result the valve
will not seal properly. Below figure shows a diagram of a gate valve which has been
frequently used in the piping and instrumentation diagram.

Figure 9.4: Gate valve

An example of a control these two equipment:

1. Reactor
The most important aspect in the reactor operation is the ri.1aintenance of air to
methanol ratio. This is particularly important for safety purposes. It is therefore
recommended that a ratio control1er be employed to regulate both flow rates.
Controlled flows of methanol are mixed in proper proportions with air through the
ratio controller arrangement before the reactants stream enters the reactor tubes.
Ratio control is a special type of feed forward control where two disturbances (loads)
are measured and held in a constant ratio to each other. It is mostly' used to control
the ratio of flow rates of two streams. Both flow rates are measured but only one can
be controlled. The stream whose flow rate is not under control is usually referred to
as wild stream. Figure below shows ratio control configurations for two streams.
Stream A is air and the wild stream. In Figure we measure both flow rates and take
their ratio. This ratio is compared to the desired ratio (set point) and the deviation
(error) between the measured and desired ratios constitutes the actuating signal for
the ratio controller. This ratio is very important to adjust before the feed entering in
the reactor. The air to methanol ratio is adjusted at 35:7.5 which is very feasible for
the production ofFonl1a1dehyde.Therefore by using ratio control we can easily
adjust this ratio for the maximum yield.

Methanol (Controlled Stream)

2. Heat Exchanger
Heat exchangers are inherently stable operating units. Extensive instrumentation is
therefore not usually proposed. However: control on flow parameters is necessary
and proper indication and recording of the inlet and outlet conditions is
recommended.

Temperature measuring elements and heat-exchanger installation should be placed

as close as possible to the active heat exchange surface, consistent with requirements
for adequate mixing of the process stream. A thermal element installed several feet
downstream of the exchanger in the process .

pipeline will cause a time delay in the control system. This time delay or distance-
velocity lag has a particularly noticeable effect on control performance.
Thermocouples in protective thermal well are proposed' as temperature measuring
elements. Particular care must be taken to minimize 98

the effect of air gap between thermocouple and thermal well by proper installation
of conducting, sleeves.

These elements introduce measuring lags, which may have time constants of the
order of magnitude of the main time constant of the system. However, high fluid
velocities past the thermal well tend to minimize the measuring lag. For the switch-
condenser and the heat exchanger connected to reactor a temperature transmitter
using derivative action for lag compensation is suggested. For the temperature
control of heat exchangers the following control schemes can be employed.

The normal method for controlling heat exchangers is to measure exit temperature
of the process fluid and adjust input of the heating or cooling medium to hold the
desired temperature. It is suggested that for the waste heat boiler this control scheme
should be used.
cooling medium to hold the desired temperature. It is suggested that for the waste
heat boiler this control scheme should be used.
 References:

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[5]. Kirk, Raymond E., Donald F. Othmer, Jacqueline I. Kroschwitz, and Mary
Howe-Grant. Encyclopedia of Chemical Technology. New York: Wiley, 1991. Print.

[6]. Rosaler, Robert C. Standard Handbook of Plant Engineering. New York:

McGraw-Hill, 1995. Print.

[7]. ScienceLab: Chemicals & Laboratory Equipment." ScienceLab: Chemicals &

Laboratory Equipment Web <http://www.sciencelab.com/>.

[8]. Smith, J. M., Hendrick C. Van. Ness, and Michael M. Abbott. Introduction to
Chemical Engineering Thermodynamics. New York [etc.: McGraw-Hill, 2001.
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[9]. Holman, J. P. Heat Transfer. New York: McGraw-Hill, 2010. Print.

[10]. Holland, Charles Donald. Fundamentals of Multicomponent Distillation. New

York: McGraw-Hill, 1981. Print.