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Process Data set: Melamine-urea-formaldehyde resin, at plant, with solid state and molar ratio 1.35, , for indoor/outdoor use (en) en

Process information

Key Data Set Information

Location

Geographical representativeness description

Data for Brazil used for Center-South Region.

Reference year

2012

Name

Melamine-urea-formaldehyde resin, at plant, with solid state and molar ratio 1.35, , for indoor/outdoor use

General comment on data set

This dataset represents melamine-urea-formaldehyde (MUF) resin production (solid state of 65% and molar ratio of 1.35), for indoor/outdoor use at wood-based panels industry. The processes starts from reception of raw materials at the factory gate. Includes the inputs to the production processes and the main process emissions to air, water and soil. Transport activities for inputs and capital goods, such as industrial machinery, as well as personnel activities were not included within the system boundary. The reference flow was the production of 1 kg of resin, and dataset was based on primary and secondary data for amino resins.

Owner of data set

Diogo Aparecido Lopes Silva

Quantitative reference

Reference flow(s)

Melamine-urea-formaldehyde resin
- 1.0 * 1.0 kg (Mass)

Time representativeness

Data set valid until

2013

Time representativeness description

Data from 2012 to 2013, current technology for production of amino resins in Brazil (see 'Technology').

Technological representativeness

Technology description including background system

A Brazilian MUF resin industrial unit with an annual production volume of 17,000,000 tons (2011-2012) and considered a state-of the-art company was selected for this study. This company is a market leader in the amino resins market, with a 30% marketshare in Brazil. The MUF resin production depends on the reaction of urea, melamine and formaldehyde in a three-step process (Dunky, 1998): the first step is methylolation, the second step is condensation and the third step adds the final urea and melamine. The process begins with the conversion of methanol by catalytic oxidation in a reactor vessel for the obtaining of an aqueous form of formaldehyde, which is cooled and sent to the absorber with water for the production of an aqueous solution. Formaldehyde is then sent to a resin batch reactor, where it is mixed with a combination of urea and melamine. It was assumed 10% of melamine with UF resin (neat resin basis). Other inputs, such as small quantities of catalysts and additives, namely sodium hydroxide and formic acid are also used during the process. This reaction is controlled by parameters such as pH, temperature, viscosity, ratio of formaldehyde to urea, and charging rate until the desired degree of polymerization is achieved. Water can also be removed for the control of the percentage of resin solids, but most of the water is usually recycled for re-use in the manufacturing process. Many production facilities, as emission controllers are employed so as to reduce local emissions (e.g., free formaldehyde and particulate matter) in the production of resins. Therefore, it is considered that few emissions are generated in the resin industrial production.

Mathematical model

Variable / parameter	Mean value	Relative StdDev in %	General comment
gd_price_waste	0.5	%	This parameter was added by GreenDelta during the implementation of the ecoinvent database in openLCA. It is used by those exchanges which did not have a price specified by ecoinvent for being wastes (i.e. negative reference product), and that were considered that they should have a cost/revenue specified. The prices used for them, equal to the prices of the same product in other processes of the database, are modified by this parameter with value 0.5 (i.e. half the price of the normal product), considering that the reference product of a waste treatment process might have a lower price in reality than the same flow produced by a production process. However, you can modify this value to 0 if you prefer to consider no price for them like ecoinvent, or also 1 if you do not want to distinguish wastes from other products.
gd_price_product	1.0	%	This parameter was added by GreenDelta during the implementation of the ecoinvent database in openLCA. It is used by those exchanges which did not have a price specified by ecoinvent and that were considered to be products or co-products of waste treatments (i.e. positive reference product), and that they should have a cost/revenue specified. The prices used for them, equal to the prices of the same product in other processes of the database, are modified by this parameter with value 1. However, you can modify this value to 0 if you prefer to consider no price for them like ecoinvent.
ei_price_product	1.0	%	This parameter was added by GreenDelta during the implementation of the ecoinvent database in openLCA. It is used by those exchanges which did not have a price specified by ecoinvent in this specific system model, but yes in at least one of the other two system models. The prices used for them, equal to the prices of the same product and provider in the other system model, are modified by this parameter with value 1. However, you can modify this value to 0 if you prefer to consider no price for them in this system model like ecoinvent.

Modelling and validation

LCI method and allocation
Type of data set	Unit process, black box
LCI Method Principle	Other
Deviation from LCI method principle / explanations	Attributional
Modelling constants	The LCI is entirely done with an attributional methodology. No allocation or substitution methods have been considered in the process.
Data sources, treatment and representativeness
Data cut-off and completeness principles	It was assumed 1 % of the total mass of material resources consumed as cutoff criterion for the LCI construction.
Deviation from data cut-off and completeness principles / explanations	None.
Data selection and combination principles	All the input/output data was collected for the Brazilian Center-South region as it accounts for more than 30% of the national production of amino resins in the country. Data for 01 company, located in the States of Minas Gerais was collected.
Deviation from data selection and combination principles / explanations	None.
Data treatment and extrapolations principles	see 'Geography' and 'Technology' in 'General information' section.
Data source(s) used for this data set	ILCD format Silva et al. (2013). Life cycle assessment of medium density particleboard (MDP) produced in Brazil, 2013 Silva et al. (2015). Environmental performance assessment of the melamine-ureaformaldehyde (MUF) resin manufacture: a case study in Brazil. Wilson, J.B. (2009)
Sampling procedure	Average values representing one year of MUF resin production were obtained from on-site measurements and internal companies documents such as records of raw material consumption, emissions and waste management inventories. When process input/output data was not avaiable, secondary data were used from literature - Wilson (2009).
Data collection period	The data was collected during 2 years of sampling between 01/2012-12/2013.
Completeness
Completeness of product model	No statement

Administrative information

Commissioner and goal
Project	SILVA, D.A.L. (2012). Life cycle assessment of MDP wood-based panel production in Brazil. 207p. Dissertação (Mestrado) - Escola de Engenharia de São Carlos, Universidade de São Paulo, São Carlos, 2012 (in Portuguese).
Intended applications	This LCI can be used for any types of LCA studies.
Data generator
Data set generator / modeller	Diogo Aparecido Lopes Silva
Data entry by
Time stamp (last saved)	2021-01-19T16:34:24.735-02:00
Data set format(s)	ILCD format
Data entry by	Diogo Aparecido Lopes Silva
Publication and ownership
UUID	43a37de0-55c6-409e-be5a-7e9c28099f0c
Date of last revision	2020-05-13T13:44:47.614-03:00
Data set version	00.00.009
Unchanged re-publication of	Silva et al. (2015). Environmental performance assessment of the melamine-ureaformaldehyde (MUF) resin manufacture: a case study in Brazil.
Owner of data set	Diogo Aparecido Lopes Silva
Copyright	No
Access and use restrictions	The data set can be used free of charge by anybody to perform LCA studies, to distribute it to third parties, to convert it to other formats, to develop own data sets etc.

Inputs and Outputs

Inputs

Type of flow	Classification	Flow	Mean amount	Resulting amount
Product flow	Energy carriers and technologies / Electricity	Electricity from Brazilian hydroelectric power plants	0.045 MJ	0.045 MJ
Elementary flow	AGRIBALYSE / Elementary flows / water / river	Formic acid, thallium(1+) salt	7.0E-5 kg	7.0E-5 kg
Product flow		Sodium hypochlorite, 15% in H2O, at plant	5.0E-5 kg	5.0E-5 kg
Product flow	Valuable substances / Materials / Plastics	Melamine resin foam	0.1 kg	0.1 kg
Product flow	chemicals / organics	methanol, at regional storage	0.16 kg	0.16 kg
Product flow		urea, as N	0.39 kg	0.39 kg
Product flow	water supply / production	tap water, at user	0.23 kg	0.23 kg