Methanol, air and water is the primary feedstock for formaldehyde production. The feedstock is mixed in a vaporizer, and passed over a silver catalyst bed in an adiabatic reactor. Due to the methanol/oxygen ratio, the reaction gas mixture is above the
upper flammability limit (UFL) for methanol/air mixtures and therefore inherently safe. The formaldehyde produced is separated from unreacted methanol and byproducts through absorption in water, using a selective absorber. In the fasil process, formaldehyde is synthesized through the
catalytic oxidation of methanol. The primary reactions are partial oxidation of methanol (1), and methanol dehydrogenation (2). :(1) :(2) This exothermic chemical reaction is facilitated by the silver catalyst at high temperatures, typically around 600-650 °C. The silver catalyst in the reactor is periodically replaced, a process that can be completed within a day. The used silver is regenerated through an electrolytic process and is fully recycled. The process gas cooling relies solely on water and steam, reducing fire risks. Additionally, all oxygen is converted in the reactor. Oxygen is therefore not present in the absorber, improving safety and the quality of the formaldehyde produced. == References ==