Detailed Project Report on Formaldehyde Resin (Urea, Phenol, Melamine & Their Modified Resins)

FORMALDEHYDE RESIN (UREA, PHENOL, MELAMINE & THEIR MODIFIED RESINS)

[EIRI/EDPR/1491] J.C.: 275 

INTRODUCTION

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.

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 urea formaldehyde 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, urea formaldehyde 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 urea formaldehyde adhesives is a major concern that has come under close scrutiny by state and Federal regulatory agencies.

COST ESTIMATION

Land & Building (3 Acres)                         Rs 7.52 Cr
Plant & Machinery                                       Rs.2.11 Cr         
W.C. for 1 Month                                         Rs.4.63 Cr         
Total Capital Investment                             Rs. 14.73 Cr              
Rate of Return                                             55%   
Break Even Point                                        36%

CONTENTS

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:

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)