Melamine Formaldehyde Resins Production
Melamine Resin Production Costs Report | Issue A | Q3 2024
| Report Details |
| 75 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 75 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report assesses the economics of a batch polymerization process for Melamine Formaldehyde Resins production from melamine and formalin, assuming a plant located in the United States. Melamine condenses with formaldehyde in acid solution to form hydroxymethylmelamines. The reaction product undergoes cross-linking polycondensation, yielding the melamine-formaldehyde resins.
The report provides a comprehensive study of Melamine Resin production and related Melamine Resin production cost, covering three key aspects: a complete description of the Melamine Resin production process examined; an in-depth analysis of the related Melamine Resin plant capital cost (Capex); and an evaluation of the respective Melamine Resin plant operating costs (Opex).
The Melamine Resin production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Melamine Resin plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Melamine Resin plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Overview
Product
Melamine Formaldehyde Resin. Melamine Resin (a.k.a. Melamine Formaldehyde Resins, MF) is a polymer made from condensation of the monomers melamine and formaldehyde. The polymer is hard, very durable and has a great heat and fire resistance, due to the release of nitrogen gas when burning. Properties vary depending on the melamine to formaldehyde ratio, the most common one being 1:2 and 1:3.
Raw Materials
Formalin. Formaldehyde is a colorless, strong-smelling gas remarkably versatile as a chemical intermediate - it is widely used for the production of resins and coatings employed in the manufacture of building materials and household products. Since the pure gas slowly polymerizes at temperatures lower than 80°C, formaldehyde is usually available as a liquid solution in water with small amounts of methanol. This solution is called formalin. Most of world's formalin is commercially manufactured from methanol and air in the presence of a silver (or a metal oxide) catalyst.
Melamine. Melamine is an organic compound used in the production of resins, laminates, and coatings. Its high heat resistance and durability make it valuable in manufacturing kitchenware, flooring, and fire retardants. Melamine is produced from urea and is stored as a crystalline solid. It is essential to industries focused on high-performance, durable materials
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Melamine Resin production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Melamine Resin process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Melamine Resin production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Melamine Resin plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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