Urea-formaldehyde resins based on native UFC

Safe Technology, Inc offers integrated solution for UF resin manufacturing with on-site UFC.

Technology

The raw materials for this two staged process are methanol and urea.

At the first stage of the process mixed in vaporizer with atmosphere air methanol is oxidized in reactor on mixed oxides catalyst bed and transforms into formaldehyde gas. Air saturated with formaldehyde is cooled in a heat exchanger and is directed into absorber column where formaldehyde is absorbed by urea solution, making methanol free UFC containing 60 % formaldehyde and 25 % urea; or by water making methanol free (not more than 0,2%) concentrated formaldehyde solution (formaldehyde content 50%). The air that contains traces of formaldehyde, methanol and reaction by-products, leaving the absorber column is partly recycled, partly directed to the catalytic converter where it is fully purified and released into atmosphere.

Then UFC via storage is pumped into the second process stage which is batch resin synthesis, conducted on standardized equipment in batch reactors with the capacity from 10 to 60 m³. The heat and distillate water from the oxidation reaction can be utilized here. Conducting the synthesis in mild acid-base mode without water removal stage is a distinctive aspect of the present technology.

The process is fully computerized. Load cells  are implemented for weighing all the components, that helps to conform strictly to the formulation; solid materials feed is automated. The process is controlled from the operator’s workstation, all the process data is displayed on the operator’s monitor.

Manufacturing resins in a suggested way is ecologically safe, effective and profitable.

UFC - 85 and UF resin integrated plants

JSC “Safe Technologies” designes and constructs  UFC and UF resin plants, completely furnished with technological, control and other equipment.

The plant consists of:

• Resin manufacturing department with a laboratory for additive agents making, incl.:
• main equipment
• piping, fittings, cables, pumps, thermal insulation etc.
• storage facility, including automated vehicle offloading system and reactor feed
• UFC storage tanks
• finished product storage tanks
• instrumentation and automation system

The reactor is mounted on load cells for the purpose of more precise metering control of the ingredients.

Ingredients needed in small qualities (e.g. caustic, ammonium sulphate) are fed from metering tanks also equipped with load cells. The feed is stopped automatically by reaching preset weight.

Automated urea feed line consists of hoppers and conveyors. It is controlled by reactor tensometric gauges signaling to the conveyor gate valves.

UF resins are stored in steel tanks coated inside with epoxy composition. To keep the finished product in homogenous, state storage tanks are equipped with agitators.

Services provided:

• pre-design stage
• technological design
• coordination with inspecting authorities, incl. sanitary-protection area defining
• equipment manufacturing and shipping
• building and constructing of all kinds of resin manufacturing sub-facilities
• supervised installation
• commissioning
• performance tests
• personnel training.

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