ECHOara: Indústria de formaldeído

Abstract

This study proposes the conceptual development of ECHOara, an industrial plant focused on the production of formaldehyde based on principles of sustainability and technological innovation. Formaldehyde, widely used in the manufacture of resins, adhesives, laminates, and other industrial applications, holds significant economic importance. However, its traditional production is associated with notable environmental impacts, such as reliance on fossil energy sources and the emission of atmospheric pollutants. The company will be located in the city of Coruripe (AL), a strategic location offering tax incentives, logistical access to the port, and high renewable energy potential. In this context, the proposed industrial plant is justified by the need to enable a cleaner alternative aligned with sustainable development goals. The main innovation consists of replacing conventional production routes with a process based on the use of green hydrogen—generated by water electrolysis powered by renewable energy—and the incorporation of technologies that allow for the reuse of carbon dioxide (CO2). As a byproduct of electrolysis, oxygen will also be commercially utilized under a Business-to-Business (B2B) model, with an estimated annual output of 129 thousand tons of oxygen. The methodology included the study of the technological route for formaldehyde production through methanol oxidation, along with the development of mass and energy balances. The processes were simulated using COCO software and Excel. The results indicated the technical feasibility of a continuous, efficient, and environmentally responsible process, with an estimated production capacity of 208.11 thousand tons of 37% formalin per year, representing approximately 0.80% of current global consumption and 1.39% of projected demand by 2035. The plant is expected to operate continuously, 24 hours a day, in three shifts, seven days a week, aligned with the sugarcane harvest season in the Northeast, from August to April. The economic analysis demonstrated the financial feasibility of the project, with an estimated annual revenue of R$1.21 billion, a break-even point of 25.7%, an internal rate of return (IRR) higher than the minimum attractive rate (MARR), and an estimated payback period of 7 years. The final proposal represents an innovative alternative aligned with green chemistry practices, demonstrating strong potential to contribute to the modernization of the Brazilian chemical industry through a sustainable, circular, and technically sound approach.