Urea Formaldehyde Resin Manufacturing Process

Ingredients:

• Urea: 600 kg
• Formalin: 1400 kg
• Caustic Soda Solution
• Acetic Acid Solution

Process:

1. Preparation:
   • Check all heating and cooling lines before starting.
2. Reaction Process – 1st Stage:
   • Maintain a ratio of Urea to Formalin as 1:2.33.
   • Use 90% Urea in the 1st stage and 10% Urea in the 2nd stage.
   • Mix 1400 kg Formalin with 540 kg Urea in the 1st stage.
   • Add caustic soda solution to maintain pH (8-8.5) and supply steam up to 90 degrees Celsius.
   • Allow the reaction for 1.5 to 2 hours.
   • After 2 hours, add Acetic Acid Solution to maintain pH (4.5-5).
3. Reaction Process – 2nd Stage:
   • In the second stage, perform the reaction in an acetic medium at 90 degrees Celsius for 1-1.5 hours.
   • Regularly check water tolerance and flow time.
   • When water tolerance reaches 1:6 and flow time is 15 seconds, add caustic soda solution to maintain pH (8-8.5).
   • Add the remaining 60 kg of Urea to facilitate the reaction.
   • Start cooling and stop stirring when the temperature is below 40 degrees Celsius.
4. Final Checks:
   • Check final resin properties.
   • Final pH should be between 8-8.5.
   • Water tolerance should be 1:3 or 1:4.
   • Flow time (B-4 cup) should be 18-19 seconds.
   • Check resin solid content, which should be in the range of 45-50%.
5. Unloading:
   • After the final checks, unload the resin.
   • Collect a sample for testing in the laboratory.
6. Laboratory Testing:
   • Send the collected sample to the laboratory for testing.
   • Test resin solid content, ensuring it falls within the specified range.

Quality Check Parameters:

1. Resin Solid Content:
   • Target Range: 45-50%
   • Method: Test using appropriate equipment in the laboratory.
2. pH Level:
   • 1st Stage: 8-8.5
   • After Acetic Acid Addition: 4.5-5
   • 2nd Stage (Final): 8-8.5
   • Method: Use a pH meter for accurate measurement.
3. Water Tolerance:
   • Criteria: 1:3 or 1:4
   • Method: Measure water tolerance in the reaction mixture during the 2nd stage.
4. Flow Time (B-4 Cup):
   • Target Range: 18-19 seconds
   • Method: Use a B-4 cup to measure the flow time.
5. Temperature Control:
   • 1st Stage Reaction: Maintain at 90 degrees Celsius.
   • Cooling: Stirrer off when the temperature is below 40 degrees Celsius.
   • Method: Regularly monitor and control the temperature using appropriate instruments.
6. Unreacted Formalin Check:
   • Criteria: Ensure minimal unreacted formalin by adding the remaining 120 kg of Urea in the 2nd stage.
   • Method: Visual inspection and chemical analysis.
7. General Appearance Check:
   • Criteria: The resin should have a consistent appearance without any abnormalities.
   • Method: Visual inspection of the final product.
8. Sample Collection for Further Testing:
   • Collect a representative sample after unloading for additional laboratory testing.
   • Additional Tests: Conduct tests as per standard laboratory procedures for UF resin, including adhesion, viscosity, and any other relevant tests.
9. Safety Checks:
   • Ensure that safety protocols are followed throughout the process.
   • Verify that all equipment is in proper working condition.
10. Documentation:
    • Record all parameters and observations in a production log for future reference and quality assurance.