Abstract: An apparatus for the production of formaldehyde is disclosed. The apparatus comprises a cooled tubular reactor section (8, 108, 208, 308, 408, 508) having a first inlet, a first outlet and a plurality of tubes each having a first end in fluid communication with the first inlet and a second end in fluid communication with the first outlet. The plurality of tubes contain a first catalyst for the production of formaldehyde by oxidative dehydrogenation. The apparatus is characterised in that the apparatus further comprises a pre-reactor section (7, 107, 207, 307, 407, 507). The pre-reactor section (7, 107, 207, 307, 407, 507) has an inlet. The pre-reactor section (7, 107, 207, 307, 407, 507) has an outlet in fluid communication with the first inlet of the cooled tubular reactor section (8, 108, 208, 308, 408, 508). The pre-reactor section (7, 107, 207, 307, 407, 507) is configured to contain, in use, an adiabatic catalyst bed.

Abstract: An apparatus for the production of formaldehyde is disclosed. The apparatus comprises a cooled tubular reactor section (8, 108, 208, 308, 408, 508) having a first inlet, a first outlet and a plurality of tubes each having a first end in fluid communication with the first inlet and a second end in fluid communication with the first outlet. The plurality of tubes contain a first catalyst for the production of formaldehyde by oxidative dehydrogenation. The apparatus is characterised in that the apparatus further comprises a pre-reactor section (7, 107, 207, 307, 407, 507). The pre-reactor section (7, 107, 207, 307, 407, 507) has an inlet. The pre-reactor section (7, 107, 207, 307, 407, 507) has an outlet in fluid communication with the first inlet of the cooled tubular reactor section (8, 108, 208, 308, 408, 508). The pre-reactor section (7, 107, 207, 307, 407, 507) is configured to contain, in use, an adiabatic catalyst bed.

Abstract: A process for producing formaldehyde-stabilised urea is described comprising generating a synthesis gas, subjecting the synthesis gas to water-gas shift to form a shifted gas; recovering carbon dioxide from the shifted gas; synthesising methanol from the carbon dioxide-depleted synthesis gas; subjecting recovered methanol to oxidation; subjecting the methanol synthesis off-gas to methanation; synthesising ammonia from the ammonia synthesis gas and recovering the ammonia; reacting ammonia and recovered carbon dioxide stream to form a urea stream; and stabilising the urea by mixing the urea stream and a stabiliser prepared using the recovered formaldehyde, wherein a portion of the synthesis gas by-passes either the one or more of the water-gas shift reactors, carbon dioxide removal unit, or water-gas shift reactors and the carbon dioxide removal unit used in the process.

Abstract: An apparatus for the production of formaldehyde is disclosed. The apparatus comprises a cooled tubular reactor section (8, 108, 208, 308, 408, 508) having a first inlet, a first outlet and a plurality of tubes each having a first end in fluid communication with the first inlet and a second end in fluid communication with the first outlet. The plurality of tubes contain a first catalyst for the production of formaldehyde by oxidative dehydrogenation. The apparatus is characterised in that the apparatus further comprises a pre-reactor section (7, 107, 207, 307, 407, 507). The pre-reactor section (7, 107, 207, 307, 407, 507) has an inlet. The pre-reactor section (7, 107, 207, 307, 407, 507) has an outlet in fluid communication with the first inlet of the cooled tubular reactor section (8, 108, 208, 308, 408, 508). The pre-reactor section (7, 107, 207, 307, 407, 507) is configured to contain, in use, an adiabatic catalyst bed.

Abstract: 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) subjecting the synthesis gas to one or more stages of water-gas shift in one or more water-gas shift reactors to form a shifted gas; (c) recovering carbon dioxide from the shifted gas in a carbon dioxide removal unit to form a carbon dioxide-depleted synthesis gas; (d) 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; (e) subjecting at least a portion of the recovered methanol to oxidation with air in a formaldehyde production unit; (f) subjecting the methanol synthesis off-gas to methanation in a methanation reactor containing a methanation catalyst to form an ammonia synthesis gas; (g) synthesising ammo