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Abstract
We report the first comprehensive review of the industrial process for the catalytic partial oxidation of methanol to formaldehyde using silver catalyst. Formaldehyde remains a key, large volume industrial chemical which is ubiquitous to household, commercial, aviation, pharmaceutical and automotive products due to its high reactivity and versatility. Critical analysis of the various technological approaches used to manufacture formaldehyde, characteristics of silver catalysts employed, process conditions, and performance values has been presented. The three common plant types are almost complete conversion (BASF type); incomplete conversion followed by distillation (ICI type); and the off-gas recycle process which dominates world production due to its extensive use in China. Polycrystalline silver remains the most popular catalyst, with only minimal use of alternate supported catalysts or gauze materials. Catalyst physical properties such as bulk density, purity, mechanical strength, size fraction and sh...
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