Formaldehyde is a versatile, reactive substance, basic to the chemical industry because of its low cost and ease of production. It is manufactured by vapor‐phase oxidation of methanol using two principal processes. One method employs a pure silver catalyst and the other an iron molybdate catalyst. Several other processes are under development, but none have been commercialized. All processes are capital intensive, requiring integrated reaction, heat recovery, and purification systems to achieve optimum economic benefits.
Formaldehyde is sold as concentrated, aqueous solutions, and may contain methanol to inhibit polymerization. It is also sold in alcohol solutions, which contain little water. Its principal uses are in the production of amino and phenolic resins, polyhydric alcohols, acetal resins, paraformaldehyde, and fertilizers. It reacts with numerous organic compounds in condensation‐type reactions, resulting in formation of one or more new carbon‐carbon bonds.
In recent years, formaldehyde has come under increased scrutiny because of its potential negative health effects. It is an irritant to the eyes, nose, and throat, and is a suspected human carcinogen.