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