DEVELOPMENT OF A NEW ADVANCED PROCESS FOR MANUFACTURING POLYACETAL RESINS .1. DEVELOPMENT OF A NEW PROCESS FOR MANUFACTURING HIGHLY CONCENTRATED AQUEOUS FORMALDEHYDE SOLUTION BY METHYLAL OXIDATION

A new technology for the production of highly concentrated aqueous for maldehyde was developed by oxidizing methylal. Whereas the oxidation o f methanol yields 1 mol of water per 1 mol of formaldehyde, methylal o xidation produces only 1 mol of water for every 3 mol of formaldehyde. Thus, the output from methylal oxidation is more than 70% formaldehyd e compared with 55% from methanol oxidation. For this purpose, basic r esearch for methylal synthesis was tried and the world's first commerc ial production of methylal was accomplished. Using this methylal, the world's first technology of methylal oxidation for manufacturing highl y concentrated aqueous formaldehyde was established by development of a new methylal oxidation catalyst composed of iron, molybdenum, and a third component. This highly concentrated aqueous formaldehyde is then fed to the acetal homopolymer and copolymer plant whose combined capa city is 35,000 tons/years. (C) 1993 John Wiley & Sons, Inc.