{
  "authors": [],
  "basis": {
    "capacity": "20 t/h formalin 50 wt% = 80 000 t/a HCHO (100 %) at 8000 h/a (ASSUMED)",
    "location": "generic (not chosen)",
    "operating_hours_per_year": 8000
  },
  "benchmarks": [],
  "chemistry": {
    "inputs": [
      {
        "chemical": "methanol",
        "grade": null,
        "note": "feed:MEOH: methanol from storage (e.g. methanol-1), 0.574 kg/kg formalin",
        "role": "feedstock"
      },
      {
        "chemical": "air",
        "grade": null,
        "inventory_key": "feed:AIR",
        "note": "Ambient air, 1.0 mol% water ASSUMED; the oxidant",
        "role": "feedstock"
      },
      {
        "chemical": "water",
        "grade": null,
        "inventory_key": "feed:PW",
        "note": "Demineralised process water to the absorber, sets the formalin strength",
        "role": "feedstock"
      }
    ],
    "outputs": [
      {
        "chemical": "formaldehyde",
        "grade": null,
        "inventory_key": "product:FORMALIN",
        "note": "Formalin 50 wt% to storage, counted by mass of the solution",
        "role": "main-product"
      },
      {
        "chemical": "carbon-dioxide",
        "grade": null,
        "inventory_key": "product:STACK",
        "note": "Fossil CO2 from the catalytic oxidation of CO, DME, methanol and formaldehyde in the ECS",
        "role": "emission"
      }
    ],
    "utilities": [
      {
        "chemical": "electricity",
        "grade": null,
        "inventory_key": "feed:POWER",
        "note": "Process gas blower and pumps (ASSUMED electric drives)",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "product:STEAM",
        "note": "MP steam 1500 kPa(a) exported (ASSUMED level)",
        "role": "co-product"
      },
      {
        "chemical": "cooling-water",
        "grade": null,
        "inventory_key": "product:CW",
        "note": "25/35 C (ASSUMED), absorber coolers",
        "role": "utility"
      }
    ]
  },
  "description": "Fresh air and recycled absorber off-gas are drawn through one blower, liquid methanol is\ninjected and vaporised against the hot reaction gas, and the 8.5 mol% methanol feed reacts\nin a multitubular reactor whose boiling hot-oil shell raises MP steam. The reactor is a\nconversion model whose per-pass conversion and selectivities (formaldehyde, CO, dimethyl\nether) reproduce the open plant ranges of the EU BREF on large volume organic chemicals\n(2017): yield 93 % on methanol, conversion above 99 %. It is not kinetics. The absorber, the\nliquid-side heats and all duties come from an independent balance script; core has no\nqualified property method for aqueous formaldehyde, so the energy balance is not checked by\ncheme. Methanol is a boundary feed (processes/methanol-1 makes it in this library).\n",
  "design_basis": {
    "assumptions": [
      "Route: metal oxide (Formox type) partial oxidation of methanol with excess air below the lower explosion limit, off-gas recycle, absorption in water, catalytic oxidation of the vent (ECS) (D-001).",
      "Reactor model: conversion reactor with a per-pass methanol conversion and selectivities chosen to reproduce the plant yield of 93 % on methanol (BREF LVOC 2017 Table 6.10: 91-94 %) and a plant methanol conversion of 99.3 % (BREF s. 6.2.3: > 99 mol%); not kinetics (D-004).",
      "ASSUMED reactor inlet 8.5 mol% methanol (EPA-450/4-91-012: 5-10 vol%) and absorber off-gas 6.0 mol% O2 (BREF Table 6.6: 5-7 %); these two fix the fresh air and the recycle (D-005).",
      "ASSUMED blower 100.5 -> 150 kPa(a), isentropic efficiency 0.75, motor 0.95 (D-007).",
      "ASSUMED reactor outlet 553.15 K, reaction gas to absorber 403.15 K, absorber off-gas 303.15 K and 112 kPa(a) saturated with water, product 333.15 K (D-005, D-006).",
      "ASSUMED heat of solution of gaseous formaldehyde in water 62 kJ/mol, to be sourced (D-006).",
      "ASSUMED ECS conversions CO 99.8 %, HCHO 99.5 %, CH3OH 99.5 %, DME 99.0 %; stack 423.15 K (D-008).",
      "All flows, temperatures and duties are concept estimates; the energy balance rests on ideal-gas enthalpies and assumed liquid-side heats, not on a qualified property method (D-009)."
    ],
    "source": "process/design-basis.yaml"
  },
  "engineering": {
    "description": "",
    "name": "Formaldehyde (Formox, iron-molybdate)",
    "requires": "cheme-as-code>=0.8",
    "stage": "concept",
    "stages": [
      {
        "id": "concept",
        "title": "Concept and feasibility"
      },
      {
        "id": "basic",
        "title": "Basic engineering"
      },
      {
        "id": "detail",
        "title": "Detail engineering"
      }
    ],
    "tool": "plantcode"
  },
  "facets": {
    "feedstock_basis": [
      "fossil"
    ],
    "product_classes": [
      "chemicals"
    ],
    "region": "generic",
    "unit_operations": [
      "compression",
      "reaction",
      "heat-exchange",
      "absorption"
    ]
  },
  "families": [
    "oxygenates"
  ],
  "gap_count": 5,
  "gates": null,
  "id": "formaldehyde-1",
  "issues": {
    "closed_count": 0,
    "list_url": "https://github.com/ChemE-as-Code/process-library/issues?q=is%3Aissue%20label%3A%22process%3Aformaldehyde-1%22",
    "new": {
      "action": "https://github.com/ChemE-as-Code/process-library/issues/new?template=1-action-item.yml&labels=process%3Aformaldehyde-1&process=formaldehyde-1",
      "change": "https://github.com/ChemE-as-Code/process-library/issues/new?template=4-design-change.yml&labels=process%3Aformaldehyde-1&process=formaldehyde-1",
      "hold": "https://github.com/ChemE-as-Code/process-library/issues/new?template=2-engineering-hold.yml&labels=process%3Aformaldehyde-1&process=formaldehyde-1",
      "process": "https://github.com/ChemE-as-Code/process-library/issues/new?template=6-process-development.yml&labels=process%3Aformaldehyde-1&process=formaldehyde-1",
      "tq": "https://github.com/ChemE-as-Code/process-library/issues/new?template=3-technical-query.yml&labels=process%3Aformaldehyde-1&process=formaldehyde-1",
      "tracker": "https://github.com/ChemE-as-Code/process-library/issues/new?template=7-process-tracker.yml&labels=process%3Aformaldehyde-1&process=formaldehyde-1"
    },
    "open": [],
    "open_by_gate": {},
    "open_count": 0,
    "private": false,
    "repository": "ChemE-as-Code/process-library"
  },
  "keywords": [
    "formaldehyde",
    "formalin",
    "Formox",
    "metal oxide process",
    "iron molybdate",
    "methanol oxidation",
    "absorption",
    "catalytic oxidiser",
    "ECS"
  ],
  "lca": {
    "allocation": null,
    "backend": "factors",
    "boundary": "gate-to-gate",
    "categories": [
      {
        "id": "climate-change",
        "method": "GWP100",
        "title": "Climate change",
        "unit": "kg CO2-eq"
      }
    ],
    "contributions": [
      {
        "basis": "ipcc2021-gwp100 (124-38-9, air, fossil)",
        "category": "climate-change",
        "impact": 0.0511593,
        "key": "emission:CO2",
        "phase": "operation",
        "share": 1.0,
        "status": "PUBLISHED"
      }
    ],
    "data_sources": [],
    "factors_status": "published",
    "functional_unit": {
      "amount": 1,
      "chemical": "formaldehyde",
      "grade": null,
      "label": "1 kg formaldehyde",
      "product": "FORMALIN",
      "product_name": "Formaldehyde",
      "product_title": "Formalin 50 wt% to storage",
      "unit": "kg"
    },
    "goal": "Preliminary gate-to-gate life cycle inventory of formalin 50 wt% from the concept design of a metal oxide (Formox type) plant: every foreground exchange per kg of formalin from the balanced flowsheet, for the library's LCI dataset. No background is linked yet: every input and the exported steam are declared gaps with the background activity they should connect to, so no impact result is claimed.",
    "inventory": [
      {
        "direction": "input",
        "key": "feed:AIR",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.74955,
        "title": "Ambient air (humid)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:MEOH",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.57373,
        "title": "Methanol from storage (boundary feed; made by processes/methanol-1)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:PW",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.18555,
        "title": "Process water (demineralised) to the absorber",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "feed:POWER",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.084495,
        "title": "Electric power",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:FORMALIN",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 1.0,
        "title": "Formalin 50 wt% to storage",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:STACK",
        "kind": "material",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.50884,
        "title": "ECS outlet to stack (atmosphere)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "product:STEAM",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.561275,
        "title": "MP steam export 1500 kPa(a) (hot-oil steam generator and ECS steam generator)",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "product:CW",
        "kind": "energy",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 0.65496,
        "title": "Cooling water return",
        "unit": "kWh"
      },
      {
        "direction": "output",
        "key": "emission:AR",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0224076,
        "title": "AR to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CH3OH",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 6.03991e-06,
        "title": "CH3OH to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CO",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 5.69174e-05,
        "title": "CO to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:CO2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0511593,
        "title": "CO2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:DME",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 2.30247e-05,
        "title": "DME to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:H2O",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0412455,
        "title": "H2O to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:HCHO",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.81117e-06,
        "title": "HCHO to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:N2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 1.31369,
        "title": "N2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:O2",
        "kind": "emission",
        "phase": "operation",
        "provenance": "calculated",
        "quantity": 0.0802443,
        "title": "O2 to the environment",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "emission:NOX",
        "kind": "emission",
        "phase": "operation",
        "provenance": "estimated",
        "quantity": 1.1973e-05,
        "title": "NOX to the environment (estimated)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "consumable:femo-catalyst",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 3e-05,
        "title": "Iron molybdate reactor catalyst (R-101)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "disposal:consumable.femo-catalyst",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 3e-05,
        "title": "Disposal: Iron molybdate reactor catalyst (R-101) (metal recovery of Fe and Mo at a reclaimer (BREF s. 6.3.5); the inert carrier is disposed of by the reclaimer)",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "consumable:ecs-catalyst",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 7.5e-06,
        "title": "Noble-metal ECS catalyst (R-301)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "disposal:consumable.ecs-catalyst",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 7.5e-06,
        "title": "Disposal: Noble-metal ECS catalyst (R-301) (platinum recovery (BREF Table 6.11: recycled))",
        "unit": "kg"
      },
      {
        "direction": "input",
        "key": "consumable:oil-filters",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 3e-05,
        "title": "Oil and filters (heat-transfer oil top-up, lubricants, gas and product filters)",
        "unit": "kg"
      },
      {
        "direction": "output",
        "key": "disposal:consumable.oil-filters",
        "kind": "material",
        "phase": "operation",
        "provenance": "assumed",
        "quantity": 3e-05,
        "title": "Disposal: Oil and filters (heat-transfer oil top-up, lubricants, gas and product filters) (incineration of waste oil and filters (BREF s. 6.3.5: reclaimer or incineration))",
        "unit": "kg"
      }
    ],
    "no_total": {},
    "not_computed": [],
    "pcf": [],
    "publishable": true,
    "result": {
      "classification": "partial",
      "gaps": 9,
      "label": "partial screening carbon footprint",
      "publication": "public"
    },
    "sources": [
      "lca/README.md",
      "lca/dataset.yaml",
      "lca/factors.yaml",
      "lca/gaps.csv",
      "lca/inventory.csv",
      "lca/lca.yaml",
      "lca/mappings.yaml",
      "lca/results.csv",
      "lca/results.md",
      "lca/uncertainty.csv"
    ],
    "totals": {
      "baseline": {
        "climate-change": 0.051159
      }
    },
    "withheld_reason": null
  },
  "lci_gaps": [
    {
      "dataset": "formaldehyde-formox-iron-molybdate-20-t-h-formalin-50-wt",
      "key": "feed:MEOH",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "formaldehyde-formox-iron-molybdate-20-t-h-formalin-50-wt",
      "key": "consumable:femo-catalyst",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "formaldehyde-formox-iron-molybdate-20-t-h-formalin-50-wt",
      "key": "consumable:ecs-catalyst",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "formaldehyde-formox-iron-molybdate-20-t-h-formalin-50-wt",
      "key": "consumable:oil-filters",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "formaldehyde-formox-iron-molybdate-20-t-h-formalin-50-wt",
      "key": "disposal:consumable.oil-filters",
      "link": "technosphere",
      "type": "output"
    }
  ],
  "maintainers": [
    {
      "name": "Artur Schweidtmann"
    }
  ],
  "maturity": "concept",
  "preliminary": true,
  "provenance": {
    "library_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "previews": {
      "sheets": [
        "BFD",
        "PFD"
      ],
      "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
      "tool": "cheme 1.6.0 (pyDEXPI 2.1.0)"
    },
    "previews_stale": false,
    "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0"
  },
  "publication": {
    "license": "CC-BY-4.0",
    "status": "public"
  },
  "references": [
    {
      "title": "European Commission JRC (2017) Best Available Techniques (BAT) Reference Document for the Production of Large Volume Organic Chemicals, EUR 28882 EN, chapter 6 Formaldehyde",
      "url": "https://eippcb.jrc.ec.europa.eu/reference/production-large-volume-organic-chemicals-0"
    },
    {
      "title": "US EPA (1991) Locating and Estimating Air Emissions from Sources of Formaldehyde (Revised), EPA-450/4-91-012",
      "url": "https://www.epa.gov/sites/default/files/2020-11/documents/formaldehyde.pdf"
    },
    {
      "doi": "10.1002/14356007.a11_619",
      "title": "Reuss, G. et al. Formaldehyde. Ullmann's Encyclopedia of Industrial Chemistry (route reference lead; not audited in this run)"
    }
  ],
  "repository": {
    "access": "public",
    "path": "processes/formaldehyde-1",
    "url": "https://github.com/ChemE-as-Code/process-library"
  },
  "representations": [
    {
      "bytes": 27414,
      "id": "BFD",
      "kind": "bfd",
      "preview": "artifacts/formaldehyde-1/BFD.svg",
      "source": "process/BFD.xml",
      "status": "preview",
      "title": "Block flow diagram"
    },
    {
      "bytes": 91656,
      "id": "PFD",
      "kind": "pfd",
      "preview": "artifacts/formaldehyde-1/PFD.svg",
      "source": "process/PFD.xml",
      "status": "preview",
      "title": "Process flow diagram"
    },
    {
      "id": "process-model",
      "kind": "process-model",
      "source": "process/flowsheet.yaml",
      "status": "viewer",
      "title": "Flowsheet and stream table"
    },
    {
      "id": "equipment-list",
      "kind": "equipment-list",
      "source": "equipment/equipment-list.yaml",
      "status": "viewer",
      "title": "Equipment list"
    },
    {
      "id": "lca",
      "kind": "lca",
      "source": "lca/lca.yaml",
      "status": "viewer",
      "title": "Life cycle assessment"
    }
  ],
  "summary": "Methanol is vaporised into a recycle-diluted air stream, oxidised over an iron molybdate catalyst below the explosion limit, and the formaldehyde absorbed in water to 50 wt% formalin; the vent is cleaned in a catalytic oxidiser and both the reactor and the oxidiser raise steam. Concept stage, assumed basis, preliminary gate-to-gate inventory.",
  "title": "Formaldehyde by methanol oxidation over iron molybdate (Formox type, 20 t/h formalin 50 wt%)",
  "validation": {
    "notes": "Concept PFD with closed mass, component and element balances (cheme validate, cheme process streams); the reactor and ECS outlets are calculated by cheme from the stated conversion and selectivities, and cheme's reactor duties reproduce the script's (R101 10.14 MW, R301 1.08 MW). The absorber outlets, the recycle split and every duty come from scripts/formox_balance.py with ideal-gas enthalpies and assumed liquid-side heats (heat of solution of formaldehyde ASSUMED); core cannot evaluate the energy balance (no property package covers the O2/H2O/organics gas or aqueous formaldehyde). Capacity, air humidity, reactor inlet methanol, temperatures and pressures are assumed. Not reviewed. Main products and feeds are listed under chemistry with their chemicals registry entries (issue #251).",
    "status": "unreviewed"
  },
  "viewer": {
    "commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "dirty": false,
    "sheets": [
      "process/BFD.xml",
      "process/PFD.xml"
    ],
    "skipped": [],
    "snapshot": "snapshots/formaldehyde-1/",
    "stale": false,
    "tool": "cheme-as-code 1.6.0",
    "views": [
      "checks",
      "streams"
    ]
  }
}