Detailed Project Report on Formaldehyde Resin (Urea, Phenol, Melamine)

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)