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Monsanto Process, Formaldehyde Plant, 90,000 Ton per Year, 37% and 50% Concentration

Description

  1. Overview
    1. 90,000 ton/year (200 million lbs/yr @ 37% concentration)
    2. Shut down: spring 2010
    3. Plant produces a 37% and a 50% formaldehyde solution by partial oxidation and dehydrogenation of methanol
    4. Raw materials: methanol, silver catalyst
    5. Original plant equipped with Monsanto process, (2) converters and associated equipment, absorber and distillation column
    6. Modifications: added 3rd converter for capacity improvements, methanol vents scrubber added, waste heat boiler added, installed a DCS on the reactor section (2006)
  2. Product Specifications
    1. Clear aqueous solutions of: 50U: 50.0 - 50.45% FA, <1.05% MeOH, <0.055% formic acid
    2. 37U: 37.0 - 37.3% FA, <1.05% MeOH, <0.035% formic acid
    3. 37M: 37.0 - 37.5% FA, 9 - 13% MeOH
    4. Other concentrations as required up to 50% both inhibited and uninhibited
    5. Complete documentation available
  3. Thermal Oxidizer System
    1. 2.9 - 20 mm btu/hr John Zink thermal oxidizer system
    2. Designed to incinerate two solvent laden gas streams using a small amount of natural gas
    3. One small solvent gas stream with a flow of 120 - 320 scfm, the other larger off gas stream of 8,200 - 17,500 lbs/hr
    4. Gas burner is rated for 2.9 - 20 mm btu/hr (installed new in 2006)
    5. The waste heat boiler portion generates steam at 25,000 lbs/hr with a pressure of 75 psig (normal) up to 125 psig (design)
    6. The unit uses staged burner technology to reduce or eliminate nox
  4. Distillation Column System
    1. 13,000 lbs/hr light aldehydes and light alcohol distillation
    2. Complete system includes: 72" dia. x 75' 316LSS Buehler-Morris distillation tray column
    3. (2) SS shell and tube heat exchangers: 2,889 sq. ft. 304SS, 1,090 sq. ft. 316SS
    4. (2) 316SS plate and frame heat exchangers: 478.35 sq. ft., 73.2 sq. ft.
    5. (3) pumps: 241 lbs/hr to 13,000 lbs/hr
  5. Bepex Briquetter System
    1. Model 300 MS28
    2. Skid mounted
    3. 2.5" dia.
    4. 3,000 psi max. operating pressure
    5. 22 rpm roll speed
    6. Includes 300 hp Siemens AC motor, Foote Jones gearbox and feed hopper
  6. Evaporation System
    1. 316SS 3-effect Buffovak-Blaw Knox evaporation system
    2. 36,900 lbs/hr (16,000 kg/hr)
    3. First effect: 1,480 sq. ft.
    4. Second and third effect: 2,950 sq. ft.
    5. Includes (3) vapor bodies with 1,900 gallon capacity, (3) steam chests and (2) overhead condensers (1,728 sq. ft and 1,605 sq. ft.)
  7. Crystallizer System
    1. 304SS Struthers Wells "Krystal" crystallizer system
    2. 7' dia. x 60" with 9' cone bottom
    3. This unit will evaporate approximately 4,400 lbs/hr of H2O (5 lbs per sq. ft. surface area of heater)
    4. Includes complete accessory package: vaporizer and suspension container, steam chest heater, 4,000 gallon 347SS tank, Lightnin right angle mixer, elbow pump, overheads condenser and hypulse filter
  8. Fluidized Bed Dryer
    1. 25,400 cfm 321SS Fuller fluidized bed dryer
    2. 12' dia. chamber
    3. 1,555 cu. ft. drying chamber capacity
    4. Designed to dry 8,560 lbs/hr of pellets (@ 15% moisture) with a density of 40 lbs/cu. ft.
    5. 114,240 lbs/hr air flow
    6. 1,325,000 btu/hr heat transfer
    7. Includes (3) heating coils (40 psi steam) for under bed heating