Sustainability of fasil® process

The catalyst used for the fasil® process consists of pure silver crystals. Unlike other catalyst materials, pure silver does not sublimate. This eliminates the risk of contamination in sensitive downstream applications. Additionally, there is no loss of catalyst material due to migration.

As a result, spent catalyst can be fully recycled. Through electrolysis new silver crystals are regenerated, enabling a closed-loop system. This circular approach to catalyst use is both environmentally sustainable and economically efficient.

Formaldehyde is produced via the catalytic partial oxidation of methanol. Unique for the silver catalyst is that additionally dehydrogenation of methanol to formaldehyde occurs. As a result, the tail gas exiting the process contains 19% to 21% hydrogen by volume.

This hydrogen-rich tail gas is combustible and has a typical heating value of 2.0 MJ/m³. It can be burned to generate steam, without need for additional fuel. When combusted in a thermal oxidizer, the process meets stringent emission standards, achieving lower total volatile organic compound emissions than with catalytic oxidation.

Since hydrogen combustion produces water rather than carbon dioxide, the thermal oxidizer offers a highly sustainable solution — combining effective emission control with energy recovery and minimal CO₂ emissions.

The fasil® process is optimized for high steam export and minimal electricity consumption. Advanced heat integration results in a high steam export and low cooling water consumption.

The absorption column features a sophisticated design that allows for the production of concentrated formaldehyde with low methanol content, eliminating the need for additional distillation. Furthermore, the use of advanced column internals minimizes pressure drop, thereby lowering the electricity demand of the process air blower.