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Process Data set: Urea-formaldehyde resin, at plant, with solid state 65% and molar ratio 1.35, for indoor use (en) en

Process information

Key Data Set Information

Location

Geographical representativeness description

Data for Brazil used for Center-South Region.

Reference year

2011

Name

Urea-formaldehyde resin, at plant, with solid state 65% and molar ratio 1.35, for indoor use

Classification

Class name : Hierarchy level

ILCD: Painel aglomerado

General comment on data set

This dataset represents urea-formaldehyde (UF) resin production (solid state of 65% and molar ratio of 1.35), for indoor 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)

Urea formaldehyde resin in- situ foam
- 1.0 * 1.0 kg (Mass)

Time representativeness

Data set valid until

2012

Time representativeness description

Data from 2011 to 2012, current technology for production of amino resins in Brazil (see 'Technology').

Technological representativeness

Technology description including background system

A Brazilian UF 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 UF resin production depends on the reaction of urea 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. 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. 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 %
gd_price_waste	0.5	%
gd_price_product	1.0	%
ei_price_product	1.0	%

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 UF 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 1.5 years of sampling between 01/2011-12/2012.
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.
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)	2021-01-19T16:28:53.880-02:00
Data set format(s)	ILCD format
Data entry by	Diogo Aparecido Lopes Silva
Publication and ownership
UUID	7c1a20f1-2778-4e84-94e3-faa0d0e1bca9
Date of last revision	2020-05-13T12:18:24.629-03:00
Data set version	00.00.012
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		sodium hydroxide, 50% in H2O, production mix, at plant	3.67E-4 kg	3.67E-4 kg
Product flow	AGRIBALYSE / Others	Electricity, production mix	0.16164 MJ	0.16164 MJ
Elementary flow	AGRIBALYSE / Elementary flows / water / river	Formic acid, thallium(1+) salt	1.46E-4 kg	1.46E-4 kg
Product flow	chemicals / organics	methanol, at regional storage	0.321 kg	0.321 kg
Product flow	Materials production / Water	process water	37.8 kg	37.8 kg
Product flow		urea, as N	0.343 kg	0.343 kg