Detailed Project Report on formaldehyde resins (phenol (pf), melamine (mf) & urea (uf) resins)

FORMALDEHYDE RESINS
(PHENOL (PF), MELAMINE (MF) & UREA (UF) RESINS)

[CODE NO. 1775]  

Urea Formaldehyde Resin

Approximately 1 million metric tons of urea-formaldehyde resin 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), medium density fiberboard (27%), hardwood plywood (5%), and a laminating adhesive for bonding (7%), for example, furniture case goods, overlays to panels, and interior flush doors.


COST ESTIMATION

lant Capacity                                         28.00 MT./day
Land & Building (3 Acres)                        Rs.6.82 Cr  
Plant & Machinery                                  Rs 2.03 Cr       
W.C. for 1 Month                                    Rs. 4.37 Cr
Total Capital Investment                          Rs 13.65 Cr           
Rate of Return                                        39%  
Break Even Point                                   42%

INTRODUCTION    
Urea Formaldehyde Resin    
Chemistry Of Urea-Formaldehyde Resin Formation    
Urea-formaldehyde resins are modified by:    
Phenol Formaldehyde Resin    
Chemistry    
A. Acid Catalysis    
B. Alkaline Catalysis    
CHEMISTRY AND TECHNOLOGY OF APPLICATION OF PHENOLIC RESIN                                                             
ADHESIVES FOR WOOD    
A. General Principles of Manufacture    
C. Physical Properties of Phenol-Formaldehyde Resins    
APPLICATIONS    
A. Phenol–Formaldehyde Wood Binders    
Properties of Phenolic Adhesives for Plywood    
Additives    
Formulation of Plywood Glue Mixes    
The guiding principles for the preparation of plywood adhesive glue mixes are:    
Examples of glue mixes incorporating these principles are listed in Table 1.    
Foundry Sand Binders and Mineral Fiber Binders    
Binders from PF Copolymers with Other Resins    
Melamine Formaldehyde Resin    
USES FOR MF RESINS    
CHEMISTRY    
A. Condensation Reactions    
C. Mixed Melamine Resins    
RESIN PREPARATION, GLUE MIXING, AND HARDENING    
Formula 2    
Formula 3    
FORMULATIONS    
A. MF Formulation for Exterior Particleboard    
B. Formulation for Low-Pressure MF Paper-Impregnated Overlays    
C. MUF Formulation for Exterior Particleboard    
PROPERTIES    
Urea Formaldehyde Resin    
Molecular Weight    
Cure Rate    
Melamine Formaldehyde Resin    
B.I.S. SPECIFICATION    
USES & APPLICATIONS    
Melamine Formaldehyde Resin    
Phenol formaldehyde resin    
have various application in :-    
Moulding Materials    
Bonding Resins    
Bonded Abrasives    
Coated Abrasives    
Wood Particle Board    
Insulation    
Plywood    
Foundry    
Coating    
Others    
Urea formaldehyde resin    
Market SURVEY    
World market of formaldehyde    
Table 1. Annual production volume of main producers of formaldehyde, thou t    
Production of Formaldehyde Resins in Organized Sector from 2008 to 2013    
Installed Capacity, Production & Capacity Utilization of Formaldehyde Resin
     from 2008 to 2013    
Apparent Consumption of Formaldehyde Resin from 2008 to 2013    
Estimated Demand from 2014 to 2020    
Demand and Supply Gap:    
Global Average Price of Formaldehyde Resin
RAW MATERIALS    
Phenol (C6H5OH)    
Formaldehyde (HCHO)    
Urea    
Thiourea    
PRESENT MANUFACTURERS    
FORMALDEHYDE RESINS    
Urea Resins    
Phenol Formaldehyde Resin    
Melamine Resins    
MANUFACTURING PROCESS OF PHENOL FORMALDEHYDE RESIN    
Health & Safety Factor    
TECHNICALITIES AND TESTING OF FORMALDEHYDER RESIN    
Formaldehyde resins    
The manufacturing process    
ROLE OF THE LABORATORY    
PROCESS AND METHOD OF MODIFIED OR SPECIALITY GRADE PHENOLIC RESIN
The blockade of phenolic hydroxyl group    
The introduction of other components    
1, polyvinyl acetal modified phenolic resin    
The polyvinyl acetal molecular weight;    
2, polyamide modified phenolic resin    
3, epoxy modified phenolic resin    
4, phenolic resin modified with silicone    
5, boron modified phenolic resin    
6, xylene modified phenolic resin    
7, two diphenyl ether formaldehyde resin    
MANUFACTURE OF UREA FORMALDEHYDE RESIN    
PRODUCTION    
Storage    
Manufacture of Melamine-Formaldehyde Resins    
Process    
Resinification Theory    
Non-Aqueous Melamine Resins
Formulation    
Melamine Formaldehyde Resin    
Urea Formaldehyde Resin    
Phenol Formaldehyde Resin    
MANUFACTURING PROCESS OF MOFIFIED MELAMINE FORMALDEHYDE RESIN    
Claim:    
EFFECT OF FORMALDEHYDE AND ITS EMISSION    
FORMALIN TECHNICAL-    
HEALTH EFFECTS OF FORMALDEHYDE-    
FORMALDEHYDE EMISSION FROM UREA FORMALDEHYDE RESINS-    
PREPARATION METHOD OF RESINOUS CONDENSATION PRODUCTS OF UREA
FORMALDEHYDE TYPE USED IN COATING COMPOSITION (SPECIALITY GRADE)
FLOW SHEET    
DIAGRAM OF TYPICAL PHENOLIC RESINS PRODUCTION UNIT    
PLANT LAYOUT    
Melamine-formaldehyde resin solution and process for producing the same    
This is object is achieved by    
The invention further provides a process in which    
MANUFACTURERS/SUPPLIRS OF PLANT & MACHINERY    
Chemical Reactors    
Condensers    
Vacuum Pumps    
Industrial Mixers, Blenders & Homogenizers    
Disintegrator    
Stainless Steel Storage Tanks    
Steam Boilers    
Generator Set    
SUPPLIERS OF RAW MATERIALS    
Urea    
Formaldehyde    
Ammonia    
Caustic Soda    
Phenols    
Melamine Powder    

APPENDIX – A :

 .      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT