Urea-formaldehyde resins
Our company has developed unique solutions in the field of synthesis of the UF resins used for manufacturing FB, MDF, OSB and LVL, usual and waterproof plywood. Our company provides industrial engineering services in resin manufacturing out of shipped or on-site made UFC .
On-site UFC guarantees cost effective process
At the moment, the own UF resin plant is invariably included in the design of any new wood based industry enterprise in Russia. Neither of enterprises that switched to on-site resin came back to the shipped one.
On-site resin manufacturing becomes common practice everywhere in the wood based industry – both for economical (cost effective) and ecological (conforming to the strict environmental safety regulations) reasons.
Resin on site. Why?
On-site resin manufacturing has many advantages, some are listed below:
- Flexible process that depends on the raw materials, finished product requirements, process features;
- Tailored technology that answers current needs of the wood working factory, allows adjusting the process depending on conditions at the factory. Owing to fast equipment changeover, low grade product output is minimized;
- Seasonal storage and transportation problem solution;
- Product conformity to the formaldehyde emission class E1 guaranteed Е1
- Resin consummation decrease by 20% and more, resulting in production cost decrease;
- Self sufficient process, independence from resin vendors and price collusion.
UFC to 37% formalin advantages in resin manufacturing
At present almost all resin manufacturing enterprises have switched over to the economically effective and environmentally safe 'UFC to resin' technology.
The reason for it one finds in some problematic issues related to 37% formaldehyde solution usage as a raw material:
- 37 % formaldehyde solution offload and storage requires special precautions since this is 'hazard class II' material
- Formalin tends to settle inside tanks in the form of paraform that evaporates during steam heating, or can cause serious problems with cleaning when old
- Safety level of many formalin storage facilities does not conform to modern regulations
- The '37% formalin to resin' synthesis process is time consuming
- '37% formalin to resin' process is characterized by forming gas emissions and waste water in considerable quantities during the synthesis process and process of board manufacturing
- Waste water thermal destruction requires an additional energy
- Synthesized in the process resin has a higher degree of methanol and formaldehyde emission than the resin, manufactured from UFC
What is preferable – to buy UFC or to manufacture it on site?
Some problems often arise when switching over from 37% formalin to shipped UFC.
- UFC vendor-dependent enterprise is bound to store extra UFC or to negotiate with several vendor at once with the purpose to avoid idle time when short of supplies.
- Market grade UFC 85, supplied by wholesale vendors is manufactured on such an equipment and by such a process when it is difficult to ensure constant mol ratio of the finished product.
Different vendors supply a variety of UFC, with slightly different nonvolatile content, buffer capacity, hydrogen potential.
All that results in the necessity to vary the resin making process every time changing synthesis mode, adjusting it every time to new raw materials.
- UFC storage costs increase. During winter constant UFC storage tanks heating is necessary, also, one needs winter shelter. One has to have in mind that UFC heating is done by hot water, not steam; that requires additional equipment even when steam is available.
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The reasonable suggestion is to manufacture UFC-85 on site.
Two processes instead of one, seems complicated.
Seeming complication of the fabrication process in reality turns out to be a rationalization. On site UFC 85 manufacturing helps to avoid UFC transportation, unloading and storage issues, that means avoiding extra costs and ecological hazards as well.
Planning becomes clearer, no dependency on irregular costs and shipments.
Our Company has developed and owns “know how” in the field of manufacturing concentrated methanol free formaldehyde solution, which is used as a raw material for fabrication melamine-formaldehyde and phenol resins. Methanol free formalin and UFC 85 are manufactured on the same equipment, change over from one process to another takes about one hour.
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