Detailed Project Report (DPR) on urea formaldehydes & melamine formaldehyde powder

The reaction between urea and formaldehyde has proved to be extremely complicated.   It took about 40 years to reach the present stale knowledge of this reaction, and there are still many problems. Urea has a four replaceable hydrogen atoms and thus a functionality of four, so there are various possibilities for reaction with formaldehyde.  It therefore have the capacity of building up a three dimensional space lattice. The molecular proportion  of  urea to formaldehyde is very  important,  as  the relative  amount of the reactants determine, to a  large  extent, the  properties of  the product.  The  reaction  temperature  is another  decisive  factor, ambient, medium  or  high  temperature produces  resins  with  different  properties. The same urea-formaldehyde condensation   product   may    have    different applications,  which  demand higher or lower  viscosity. It is therefore essential to define the resins as to their extent of condensation.   These possibilities of variations largely amount for the remarkable versality of urea-formaldehyde resins. The reaction of urea and formaldehyde was studied many years ago, by goldschmidt in 1896. The investigators used various amounts of urea and formaldehyde in acid solutions of various strengths.  He obtained insoluble, white granular deposits which were analysed and found to correspond to the emperical  formula C3H10N7O3. He had no use for this compound then. However,  this  is called  "Goldschmidth  Compound"  was  later  made  with  varying amounts  of formaldehyde and was therefore some  what  different from its original compositions.  Its formula was given as: (CH2 = NOCHNCH2NHCONH CH2OH)x. It was believed that the - N=CH2 group was polymerized to form a high molecular weight substance. Einhorn  and  Hamburger  in 1908 made it a  point  in  their experiment  to  use  only mild  reaction  conditions  only. The condensed urea and formaldehyde in alkaline solutions, by neutralization and drying. They isolated various white, crystalline easily soluble products.  These products were given formula: NH2CONHCO2OH, CO(NH CH2OH)2 and  named  as  methyllolurea  and  N,N1  -  dimethylolurea   are converted  into  insoluble substances,  similar  to  Goldschmidts compound. After  the  successful commercialization of  the  phenolic resins in 1920's the next thermosetting class of resins were  the ureas  which  are  now considerably developed.   Ureas  are  much different from the phenolics in properties and therefore are  not competitive. They mould much the same as the phenolics and  can use  the same kinds of moulds and presses, their  characteristics suggests several uses where phenolics are not suitable. The majority of the ureas plastics are alphacellulose flock filled and thereby can be prepared in highly attractive light pastel shades and colours. These plastics urea a  hard  glossy finish which is fairly mar-resistant. They resist most chemicals and solvents solutions and tasteless and non-toxic. This quickly suggests their use in plastic dishware and utensils. They are readily coloured in both brilliant and pastel shades. The properties of urea plastics possess some of the outstanding characteristics of the urea resins which  are heat resistant at high temeperature, excellent relectrical  resistant, high   moisture   resistant,  good  adhesive   strength,   better mechanical strength and attractive colour and finishes to moulded articles for increased beauty and usefulness.

UREA FORMALDEHYDE AND MELAMINE FORMALDEHYDE MOULDING POWDER (EIRI-1030)

Cost Estimation

Plant Capacity                                        10 Tons/Day
Land & Building (Area 10000 Sq.Mt.)  Rs. 11.41 Cr.
Plant & Machinery                                   Rs. 95 Lacs        
W.C. for 3 Months                                   Rs. 3.04 Cr.          
Total Capital Investment                         Rs. 15.67 Cr.             
Rate of Return                                         50%  
Break Even Point                                   33%

•    EIRI can modify the Capacity of the Project and Total Capital Investment as per your requirement.
•    Note: The project investment cost and capacity are subject to change without any notice. Future projects may have different values of project cost and capacity.

MARKET  SURVEY CUM  DETAILED  TECHNO 
ECONOMIC FEASIBILITY  REPORT covers

• Introduction
• Uses and  Applications
• Properties
• Market   Survey  with   future   aspects 
• Present Manufacturers 
• Detailed  Process of  Manufacture 
• Formulations
• B.I.S. Specifications
• Process Flow Sheet Diagram, Plant  Layout,
• Cost  Economics  with Profitability Analysis 
• Capacity 
• Land  & Building  Requirements with Rates
• List & Details  of  Plant  and Machinery with their Costs
• Raw Materials Details/List and Costs
• Power & Water Requirements
• Labour/Staff Requirements
• Utilities and  Overheads
• Total  Capital  Investment
• Turnover
• Cost  of Production
• Break  Even Point
• Profitability
• Land  Man  Ratio
• Suppliers  of  Plant & Machineries and Raw Materials
• Cash  Flow Statement
• Repayment  Schedule
• Interest  Chart
• Depreciation Chart
• Projected Balance Sheet for 5 Years etc.