Background In 1999 the European Chemical Industry Council (CEFIC) published a document entitled: "Formaldehyde, Introduction to Health, Safety and Environmental protection". This document states: "High concentrations of formaldehyde are highly toxic to living organisms". In 2002, Solutia’s research team explored this reaction further and invented a continuous process that could reliably destroy the formaldehyde to trace levels (less than 1 ppm). In 2002 Solutia commissioned a laboratory to perform a toxicity evaluation of individual process streams. The study report "Direct toxicity assessment (DTA) of effluent samples for Solutia UK Ltd." dated October 2002 identified formaldehyde and phenol to be the main two substances contributing to the toxicity of final effluent from the firm’s plant in Newport, South Wales. Formaldehyde was found to contribute some 70% of the total effluent toxicity despite comprising only around 17% of the chemical oxygen demand (COD). Objectives The overall objective of the project was to contribute to a 99% reduction of formaldehyde (HCHO) in industrial wastewater streams using a process reliant upon the formose reaction. This chemical reaction, by which formaldehyde is converted to sugars, was first reported by Butlerow in 1861. Monsanto (which, till 1997, owned the facilities that now make up Solutia) used this chemistry to develop a formose process for a different waste stream application, but the technology used did not offer complete formaldehyde destruction. In 2002, Solutia’s research team explored this reaction further and invented a continuous process that could reliably destroy the formaldehyde to trace levels (less than 1 ppm). For the LIFE Environment project at its site in Newport, Solutia intended to build a full-scale plant to demonstrate that the introduction of a new technology – the continuous formose process – would lead to a less than 10 mg/L level of formaldehyde in the Dequest Amino effluent discharge, with investment costs substantially lower than for a bio-treatment plant, the Best Available Technique (BAT) for wastewater treatment. Solutia also aimed to inform the most relevant stakeholders in the chemical industry and other relevant industries in the EU about this technology and its positive environmental benefits. Results Solutia, with the support of LIFE, has built a full-scale plant using the continuous formose process that is routinely achieving a formaldehyde reduction of greater than 99%. The acidic Dequest effluent containing very dilute waste formalin (formaldehyde solution) is first collected in the formose buffer tank, equipped with a vent scrubber to eliminate any local emissions. The effluent from this tank is pumped to an inline mixer where it is neutralised with Calcium Hydroxide solution (‘slaked lime’) before entering the waste heat exchanger (WHE). The neutralised effluent stream leaves the WHE at close to the optimum reaction temperature of 80oC and after temperature adjustment passes to the Continuously Stirred Tank Reactor (CSTR). The effluent in the CSTR then reacts with the previous contents to partly convert to formose sugars. Further conversion takes place in the Plug Flow Tank Reactor (PFTR) before the effluent leaves via the WHE. It is then cooled to ~30 to 50 °C and mixed with the remaining site effluent in the existing neutralisation system. The final effluent after pH adjustment is stored and discharged into the Severn Estuary. Solutia found that the weekly average formaldehyde concentration in its effluent was only 1.6 mg/L in 2007, compared with a weekly average of 100 mg/L in 2005. This has led to a significant reduction in the toxicity of the effluent with the toxicity to the more sensitive species reduced by a factor of three. The process can be used for either batch or continuous effluent streams and can be replicated for any industry where formaldehyde is an issue whatever the quantity. The technology can be easily retrofitted, and can also be used in conjunction with a traditional bio-treatment plant to significantly reduce bio-treatment costs. As well as being disseminated through a website (www.formose.eu), the Formose project has received a number of prizes, including being Highly Commended in the Chemical Industry Innovator of the Year Award at the UK Chemical Industry Association’s 2006 awards ceremony. In 2008, the project received a Business Commitment to the Environment (BCE) award. Disclaimer : This « results » section should be considered as a draft until the Commission has completed its evaluation .