A process is described for the production of formaldehyde, comprising (a) subjecting methanol to oxidation with air in a formaldehyde production unit thereby producing a formaldehyde-containing stream; (b) separating said formaldehyde-containing stream into a formaldehyde product stream and a formaldehyde vent gas stream; wherein the vent gas stream, optionally after treatment in a vent gas treatment unit, is passed to one or more stages of: (i) synthesis gas generation, (ii) carbon dioxide removal, (iii) methanol synthesis or (iv) urea synthesis.

The present disclosure relates to an integrated process for the production of formaldehyde-stabilized urea, starting with producing synthesis gas and including the preparation of methanol, ammonia, urea, and formaldehyde in amounts appropriate for the final product.

The present disclosure relates to an integrated process for the production of formaldehyde-stabilized urea, starting with producing synthesis gas and including the preparation of methanol, ammonia, urea, and formaldehyde in amounts appropriate for the final product.

Method for producing solid urea by granulation, wherein the granulation is fed with liquid urea having a purity greater than 98% by weight and not containing formaldehyde.

A process for the production of formaldehyde-stabilised urea is described comprising the steps of: (a) generating a synthesis gas comprising hydrogen, nitrogen, carbon monoxide, carbon dioxide and steam in a synthesis gas generation unit; (b) recovering carbon dioxide from the synthesis gas to form a carbon dioxide-depleted synthesis gas; (c) synthesising methanol from the carbon dioxide-depleted synthesis gas in a methanol synthesis unit and recovering the methanol and a methanol synthesis off-gas comprising nitrogen, hydrogen and residual carbon monoxide; (d) subjecting at least a portion of the recovered methanol to oxidation with air in a formaldehyde production unit; (e) subjecting the methanol synthesis off-gas to methanation in a methanation reactor containing a methanation catalyst to form an ammonia synthesis gas; (f) synthesising ammonia from the ammonia synthesis gas in an ammonia production unit and recovering the ammonia; (g) reacting a portion of the ammonia and at least a portion of the recovered carbon dioxide stream in a urea production unit to form a urea stream; and (h) stabilising the urea by mixing the urea stream and a stabiliser prepared using formaldehyde recovered from the formaldehyde production unit, wherein a source of air is compressed and divided into first and second portions, the first portion is provided to the formaldehyde production unit for the oxidation of methanol and the second portion is further compressed and provided to the synthesis gas generation unit.

A process for the production of formaldehyde-stabilised urea is described comprising the steps of: (a) generating a synthesis gas comprising hydrogen, nitrogen, carbon monoxide, carbon dioxide and steam in a synthesis gas generation unit; (b) recovering carbon dioxide from the synthesis gas to form a carbon dioxide-depleted synthesis gas; (c) synthesising methanol from the carbon dioxide-depleted synthesis gas in a methanol synthesis unit and recovering the methanol and a methanol synthesis off-gas comprising nitrogen, hydrogen and residual carbon monoxide; (d) subjecting at least a portion of the recovered methanol to oxidation with air in a formaldehyde production unit; (e) subjecting the methanol synthesis off-gas to methanation in a methanation reactor containing a methanation catalyst to form an ammonia synthesis gas; (f) synthesising ammonia from the ammonia synthesis gas in an ammonia production unit and recovering the ammonia; (g) reacting a portion of the ammonia and at least a portion of the recovered carbon dioxide stream in a urea production unit to form a urea stream; and (h) stabilising the urea by mixing the urea stream and a stabiliser prepared using formaldehyde recovered from the formaldehyde production unit, wherein a source of air is compressed and divided into first and second portions, the first portion is provided to the formaldehyde production unit for the oxidation of methanol and the second portion is further compressed and provided to the synthesis gas generation unit.

A process is described for the production of formaldehyde, comprising (a) subjecting methanol to oxidation with air in a formaldehyde production unit thereby producing a formaldehyde-containing stream; (b) separating said formaldehyde-containing stream into a formaldehyde product stream and a formaldehyde vent gas stream; wherein the vent gas stream, optionally after treatment in a vent gas treatment unit, is passed to one or more stages of: (i) synthesis gas generation, (ii) carbon dioxide removal, (iii) methanol synthesis or (iv) urea synthesis.

A process is described for the production of formaldehyde, comprising (a) subjecting methanol to oxidation with air in a formaldehyde production unit thereby producing a formaldehyde-containing stream; (b) separating said formaldehyde-containing stream into a formaldehyde product stream and a formaldehyde vent gas stream; wherein the vent gas stream, optionally after treatment in a vent gas treatment unit, is passed to one or more stages of: (i) synthesis gas generation, (ii) carbon dioxide removal, (iii) methanol synthesis or (iv) urea synthesis.

Disclosed is a method for urea finishing. A urea solution is subjected to crystallization and, other than in conventional processes, the urea crystals are shaped by exerting mechanical force onto them. Thus, the conventional prilling or granulation finishing steps can be avoided, and so are the corresponding emissions of ammonia and/or dust. The crystallization comprises a flash crystallization. The invention also pertains to the urea particles obtainable by the process, to a urea plant, and to a method of modifying an existing urea plant.

Disclosed is a method for urea finishing. A urea solution is subjected to crystallization and, other than in conventional processes, the urea crystals are shaped by exerting mechanical force onto them. Thus, the conventional prilling or granulation finishing steps can be avoided, and so are the corresponding emissions of ammonia and/or dust. The crystallization comprises a flash crystallization. The invention also pertains to the urea particles obtainable by the process, to a urea plant, and to a method of modifying an existing urea plant.