Formaldehyde → Sodium Hydroxide

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A reactor equipped as in Examples A and B was charged with phenol and formaldehyde in a formaldehyde to phenol molar ratio (F/P) of about 1.5:1. The formaldehyde was charged as a 50% aqueous solution. About 3% by weight based on the total charge of sodium metaborate was added and sufficient 50% aqueous sodium hydroxide to give a mole ratio (NaOH/phenol) of about 0.054:1. The mixture was heated to about 65° C. and held until the free formaldehyde fell to less than about 1.75%. The mixture was cooled to about 55° C. and distilled under vacuum to a non-volatile solids content of about 65%.

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