China Achieves Major Breakthrough in High-Concentration Formaldehyde Production Technology

On June 23, China made a significant breakthrough in high-concentration formaldehyde production technology-Xinjiang Huachun Energy Co., Ltd. successfully commissioned its 200,000-ton methylal oxidation-to-formaldehyde production facility, achieving full-capacity output of qualified products in a single startup.

This facility, one of the world's largest commercial formaldehyde production plants, adopts the proprietary methylal oxidation process developed by Wuxi Xiyuan Engineering Technology Co., Ltd. The technology boasts high efficiency, producing formaldehyde with a concentration of up to 75%, while featuring low energy consumption and environmentally friendly operations.

Polyoxymethylene (POM), a critical engineering plastic often referred to as "the metal of plastics" due to its exceptional mechanical properties and broad industrial applications, ranks only behind polyamide and polycarbonate in global demand. China's POM industry has maintained stable production capacity, with output showing consistent annual growth.

Wuxi Xiyuan's methylal oxidation process breaks the long-standing monopoly of foreign companies in high-concentration formaldehyde production. By supplying concentrated formaldehyde directly to downstream POM plants, the technology eliminates the need for formaldehyde concentration units, significantly reducing capital costs. Additionally, the process enables the recycling of dilute formaldehyde back into the methylal production system, resolving challenges in wastewater treatment and dilute formaldehyde disposal.

Liu Xiaoli, Chairman of Wuxi Xiyuan, highlighted that the company's innovations in formaldehyde absorption systems-featuring advanced design concepts-have overcome polymerization-induced clogging issues in high-concentration formaldehyde production, enabling large-scale, stable operations. The application of custom catalysts further enhances conversion rates and yield, while their easy replacement and regeneration substantially lower production costs.

Lei Qian, Associate Researcher at the Chengdu Institute of Organic Chemistry, Chinese Academy of Sciences, remarked: "This technology not only improves the efficiency and quality of formaldehyde production but also achieves resource circularity by addressing dilute formaldehyde and wastewater treatment, reducing environmental impact. Its successful application provides a new approach for the sustainable development of China's chemical industry."

Preliminary estimates indicate that adopting the methylal oxidation process for POM production saves 6 tons of steam and 110 kWh of electricity per ton of POM. For a 60,000-ton/year POM plant, this translates to annual savings of 360,000 tons of steam and 6.6 million kWh of electricity, totaling approximately RMB 68.5 million in reduced energy costs.

Located in the Wujiaqu Economic and Technological Development Zone of Xinjiang Production and Construction Corps' Sixth Division, Huachun Energy is a key local chemical enterprise. The company's annual production capacity includes 320,000 tons of formaldehyde, 30,000 tons of urotropine, 60,000 tons of methylal, and 50,000 tons of paraformaldehyde.