A Client produces a chemical component through following reaction:
Formol + Alcohol → Main Product + Water
One of the streams of the process is a mixture formol-alcohol-water. Water has to be removed, purified and sent back to environment, alcohol and formol have to be purified and sent back to reactor. The Client asks Processium to design and develop the process to recover each component. The designed process will be integrated to existing process. The stakes deal with environment and reactor debottlenecking.
One of the main constraints of the Project deals with formol instability; Depending on concentration and temperature, formol turns into methylene glycol and oligomers.
Processium studies driving forces to separate the components (differences between physical properties), and formol conversion kinetics. Several solutions are identified to separate the components and they are studied to validate feasibility and performances. Three processes are identified, pre-designed and compared (robustness, CAPEX, OPEX, development duration, reactor debottlenecking, impact on productivity, expected water quality, …). This comparison allowed Client to choose one of them which is sized based on physical properties, and run at lab-scale to validate performances and sizing.
At the end of the Project, Processium issued a process designed to:
- get an effluent with a DCO at 100 ppm and a formol concentration below detection level,
- send back formol and alcohol to reactor,
- debottleneck the reactor of 37% of its initial capacity.