FORMALDEHYDE RESIN (UREA, PHENOL, MELAMINE)
[EIRI/EDPR/1397] J.C : 174
INTRODUCTION
Urea Formaladehyde Resin
Approximately 1 million metric tons of urea-formaldehyderesin are produced annually. More than 70% of this urea-formaldehyde resin is used by the forest products industry for a variety of purposes. The resin is used in the production of an adhesive for bonding particleboard (61% of the urea-formaldehyde used by the industry), mediumdensity fiberboard (27%), hardwood plywood (5%), and a laminating adhesive for bonding (7%), for example, furniture case goods, overlays to panels, and interior flush doors.
Urea-formaldehyde resins are the most prominent examples of the class of thermosetting resins usually referred to as amino resins.2,3 Urea-formaldehyde resins comprise about 80% of the amino resins produced worldwide. Melamine-formaldehyde resins constitute the remainder of this class of resins, except for minor amounts of resins that are produced from other aldehydes or amino compounds (especially aniline), or both.
Amino resins are often used to modify the properties of other materials. These resins are added during the processing of such products as textile fabrics to impart permanent characteristics; automobile tires to improve the bonding of rubber to tire cord; paper to improve the tear strength, especially of wet paper; and alkyds and acrylics to improve their cure. Amino resins are also used for molding products, such as electrical devices, jar caps, buttons, and dinnerware, and in the production of countertops. The use of urea-formaldehyde resins as a major adhesive by the forest products industry is due to a number of advantages, including low cost, ease of use under a wide variety of curing conditions, low cure temperatures, water solubility, resistance to microorganisms and to abrasion, hardness, excellent thermal properties, and lack of color, especially of the cured resin.
The major disadvantage associated with ureaformaldehyde adhesives as compared with other thermosetting wood adhesives, such as phenol-formaldehyde and polymeric diisocyanates, is the lack of resistance to moist conditions, especially in combination with heat. These conditions lead to a reversal of the bond-forming reactions and the release of formaldehyde. For this reason, ureaformaldehyde resins are usually used for the manufacture of products intended for interior use only. However, even when used for interior purposes, the slow release of formaldehyde (a suspected carcinogen) from products bonded with ureaformaldehyde adhesives is a major concern that has come under close scrutiny by state and Federal regulatory agencies.
COST ESTIMATION
Plant Capacity 1250 Kg/Day
Land & Building (1500 sq.mt.) Rs. 1.52 Cr
Plant & Machinery Rs. 27.55Lac
Working Capital for 1 Month Rs. 22.47 Cr
Total Capital Investment Rs. 2.14 Cr
Rate of Return 25%
Break Even Point 59%
CONTENTS
INTRODUCTION
CHEMISTRY AND TECHNOLOGY OF APPLICATION OF PHENOLIC RESIN ADHESIVES FOR WOOD
APPLICATIONS
PROPERTIES
B.I.S. SPECIFICATION
USES & APPLICATIONS
Market Position
RAW MATERIAL
PRESENT MANUFACTURER
PROCESS OF MANUFACTURE
MANUFACTURE OF UREA FORMALDEHYDE RESIN
FLOW SHEET DIAGRAM OF TYPICAL PHENOLIC RESINS PRODUCTION UNIT
PLANT LAYOUT
OTHER RELATED INFORMATIONS
GENERAL-IMPROVING PROPERTIES OF THE RESIN
MANUFACTURERS/SUPPLIRS OF PLANT & MACHINERY
SUPPLIERS OF RAW MATERIALS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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