PRODUCTION OF LIQUID UREA FORMALDEHYDE RESINS (UF)
Plant capacity is 55,000 TPY. The production plant of liquid UF resins consists of the next reactors:
- R8 capacity 12,000L- R9 capacity 12,000L - R17 capacity 28,000L - R26 capacity 6,000L - R27 capacity 20,000L Depending on the market, the product portfolio and the reactor load, in a continuous shift regime the plant would be able to produce ca. 150,000 TPY of liquid UF resin.
All reactors can run independently from each other and have installed a DCS process control system by HOLLYSYS.
UF resins are obtained with a poly condensation reaction of urea and formaldehyde. Reactors are all equipped with an agitator, a cooling coil (tower water) and an heating coil (steam).
Production process for UF resins, follows these steps: - formaldehyde loading, with a weight dosing, - pH correction before adding urea ,- urea addition,- reaction mixture heating,- acidification (pH reduction) to start the poly condensation reaction, - after a certain time, reaction is stopped and begin resin cooling. Cooling is done with a vacuum system and cooling coils,- final product is transferred to storage.
Following an analogue recipe, same reactors are also able to produce Melamine Urea Formaldehyde Resins (MUF) and Melamine Formaldehyde Resins (MF) just by substitution of a part of urea with melamine. The plant is equipped with all necessary loading, unloading and transport systems for solid urea and melamine powder.
PRODUCTION PROCESS UF RESINS AND DERIVATES
UF resins are obtained by a poly condensation reaction of urea and formaldehyde in an acid medium. The reactors are all equipped by an agitator, a cooling coil (tower water) and a heating coil (steam).
The general recipe for a batch of resin can be divided in the next steps:- loading formaldehyde in a well defined quantity following the specific recipe (by weight dosing)- pH correction before adding urea- addition of the necessary quantity of urea- heating of the reaction mixture- acidification (pH reduction) to start the poly condensation reaction- after a determinate reaction time and process analysis, stop reaction and cooling down of the final resin; the cooling of the reaction medium is executed by means of a vacuum system together with the cooling coils- transfer of the final product to storage
Following an analogue recipe, the same reactors are also able to produce Melamine Urea Formaldehyde Resins (MUF) and\or Melamine Formaldehyde Resins (MF) by substituting all or a part of the urea by melamine.
The plant is, besides the reactors, equipped with all necessary loading, unloading and transport systems for solid urea and melamine powder.
EMISSION AND OFF PRODUCT TREATMENT
All liquid discharges or contaminated liquids such as process waters, cleaning waters of equipment or floors can be recovered in the same (some particular) resin production as process water.
All gaseous discharges or aspirations are captured by a vacuum system and sent to the same catalytic incinerator of the formaldehyde plant to ensure the absence of diffused emissions.
To View the UF Resin Equipment List - Click Here
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