Formaldehyde production places high demands on process management, as even small deviations in methanol oxidation can have noticeable effects on efficiency, product quality, and plant condition. Often, there is a lack of continuous transparency about the actual composition of the liquid product stream, so changes can only be detected with a delay. Fluctuating residual contents indicate declining catalyst activity, while an incomplete or unstable reaction, for example, can lead tothe formation of formic acid. Undesirable by-products and incomplete reactions not only negatively affect formaldehyde quality but also increase corrosion risks and maintenance requirements of the plant.

Since classical laboratory analyses are usually only conducted on a random sampling basis, there is little room for quick and targeted process correction. In practice, this often leads to plants being operated with safety margins – at the expense of energy efficiency, raw material consumption, and cost-effectiveness. At the same time, there is increasing pressure to standardize processes, automate them, and make them independent of the pure experiential knowledge of individual employees.

Discover our solution!

LiquiSonic® uses the physical property that the speed of sound in a liquid changes with its chemical composition. Each concentration of, for example, methanol, formaldehyde, or formic acid affects the propagation speed of sound in a characteristic way. By combining the measurement of sound speed and density, a unique measurement value for the respective process liquid is obtained. This method is independent of optical properties such as color or turbidity and is therefore particularlyrobust against process fluctuations. Because, among other things, no chemical additives are required, the measuring device is maintenance-free and the measurement is stable in the long term. The calibration is performed once and is product-specific, allowing for very high measurement accuracy. This ensures reliable concentration monitoring directly in the ongoing process.

With LiquiSonic®, you reduce energy consumption by keeping the reaction process permanently in the optimal range. At the same time, methanol consumption can be reduced, as overdosing is immediately detected and avoided. Fewer by-products mean higher product quality and lower processing costs. In addition, time-consuming and costly laboratory analyses are eliminated, which relieves personnel and further increases process safety.

In an industrial formaldehyde plant, LiquiSonic® is installed directly in the product stream. During ongoing operations, the system continuously monitors the methanol and formaldehyde concentrations. If the residual methanol content exceeds a certain threshold, it is detected early by the plant control system, allowing timely response. In parallel, the measurement signal enables proactive process monitoring, allowing deviations to be compensated early. This prevents an incomplete reaction andthe resulting formation of formic acid is avoided. By specifically adjusting temperature, air supply, or residence time, the reaction is now stabilized. The result: Consistent product quality, fewer unwanted by-products, and significantly extended service life. The customer additionally benefits from higher plant availability and lower operating costs.