A
W O R K B O O K
F E A T U R E
by Walter L. Hardy, Foster D. Snell, Inc.
PhenoJ-Formaldehyde Resin Manufacture $160,000 for equipment
+
-
$100,000 for working capital
6.65 million pounds molding powder
+
1.65 million pounds cast products
THE
phenolic resins, one of the oldest of the synthetics, are still showing a healthy growth. I n spite of the phenomenal development and production of other plastics, the phenol-formaldehyde resins have many physical and chemical properties as yet unduplicated by other materials. The data on phenolic resin sales for the last 4 years are given in Table I, from the U. S. Tariff Commission. By 1960, the sales of phenolics should reach 600 million pounds and approximately double every 10 years thereafter (based on a prognostication of 200 million population by 1975). An analysis of Table I shows that approximately 447, of the 1955 production of phenolics was consumed in molding powder, 447, as an adhesive or bonding agent in laminating, abrasives, insulation, plywood, and others, 67, in protective coatings, and 6% in miscellaneous uses including cast sheets, rods, tubes, etc. The current productive capacity (530 million pounds) in the United States approximates the 1955 sales. To meet the increasing demand, new facilities will have to be installed. Some of these new facilities will be installed by users (captive plants such as in the electronics and insulation industries), others by current or new prime producers. New foreign installations are planned and still others will be considered as the future requirements demand increased capacity. A phenol-formaldehyde resin plant, of a size suitable for captive use or for foreign installation, can be installed for approximately $160,-
Table I.
Phenolic Resin Sales
(Thousands of pounds)
Use Molding materials Adhesives and bonding Laminating resin Abrasives Friction materials Insulation Plywood W others Protective coatings Miscellaneous
1966
1964
1958
1959
200,000
172,000
204,000
158,000
49,000 16,000 22,000 52,000 36,000 27,000 25,000 29,000 456,000
64,000 11,000 15,000 37,000 28,000 13,000 22,000 27,000 389,000
71,000 12,000 16,000 21,000 34,000 18,000 26,000 28,000 430,000
69,000
000, exclusive of buildings and site (Table 111). Such a plant will produce 20,000 pounds of resin per 8hour day. This production is divided to produce 6650 pounds of cast phenolic products and 26,700 pounds of molding powder containing 507, wood flour filler. The history and chemistry of phenol-formaldehyde resins is Me11 WATER
7 REFLUX
... ... ... 40,000 ...
24,000 61,000 352,000
documented in the literature, to which the reader is referred for such background. In production, the batch process has generally been employed. A continuous process has been developed and is in use with certain economic advantages. Batch production is divided into “onestage,” wherein the entire formaldehyde charge is added to the initial
n
1
HAMMER OR BALL MILL
RIBBON BLENDER
HAMMER OR BALL MILL
T
MOLDING COMPOUND
I
-
CAST SHEETS
LEAD MOLDS
RODS, TUBES, ETC
Figure 1 .
Flowsheet
VOL. 48, NO. 9
0
SEPTEMBER 1956
45A
m d
COSTS
A Workbook Feature Maintenance cost (including maintenance labor), 5%/year of total erected cost Depreciation, 10% total erected plant cost Interest, 6% on total plant investment Insurance, taxes, etc. at 4% of total plant investment
$
31.75 63.50 64.80 43.20
$ 203.25
Total estimated production cost per day
$1091.65
Assume a proportioning of the total estimated daily production cost between the cast resin and molding powder. The total cost of producing these products then becomes:
reaction batch, and “t\vo-stage” processing, wherein part of the formaldehyde enters the initial reaction and the balance at a later stage. Figure 1 shows a flowsheet for the production of molding powder and cast resin product. Typical of the catalysts indicated on this flowsheet are those given in Table I1 for the material balance. A full description of the various processing possibilities and the materials of construction for the processing equipment is impracticable due to the great variety possible. The plant detailed herein is based on < tone-stage” operation to produce both cast products and molding powders. The calculations are based
(26,700 lb./day)
Estimated total production cost per day Estimated total production cost per pound of product Raw material cost (Table I) Total cost per pound of product Overhead Costs
$363.88 0.0546 0.2054 $ 0.2600
$727.77 0.0272 0.1184 $ 0.1456
Administration, 5% of manufacturing or total cost Selling cost, 10% of manufacturing or total cost Total cost, less profit
$
on a design envisioning three reaction kettles-two cast iron with steel jackets and one made of nickel with steel jacket. Nickel and glasslined storage and batching tanks and transfer pumps are required for phenol and formaldehyde. Lead is generally employed for casting molds. Other equipment is of usual steel construction with the exception of the rolling mill rolls, which are usually nickel plated when lightcolored products are desired. Table 111 gives a breakdown of equipment cost estimates. The sum of these, plus an estimated working capital requirement of $100,000, results in a total plant investment of approximately $270,000, exclusive of buildings and site. The estimated cost per day for the production of 6650 pounds of cast products and 26,700 pounds of molding powder equals $1091.65 per 8-hour day, exclusive of raw materials, calculated as follows (on the basis as in Table 111). Labor (excluding maintenance labor) Unskilled, $1.60/man-hour Semiskilled, $2.10/man-hour Supervision, %3.OO/man-hour Reserve at 20% Utilities Steam Power, New York industrial rates Water
46 A
Molding Powder
Cast Resin (6660 l b . / d a y )
INDUSTRIAL AND ENGINEERING CHEMISTRY
$
89.60
50.50 24.00 32.80 $ 196.90 $ 620.00
31.50 40.00 $ 691.50
0.0130 0.0260
$
0.2990
$
0.0073 0.0145 0.1674
The current price for cast phenolformaldehyde resin in sheets (opaque, 23 cu. inches per pound) is 74 cents per pound; and for wood flourfilled molding powder, 21 cents per pound. The estimated balance sheet on a yearly basis is presented in Table IV. T h e plant size indicated should prove economic and profitable for installation bi- a captive user or a foreign company. The yearly production is approximately 1,650,000 pounds of cast products and 6,650,000 pounds of molding powder. A similar plant could be estimated along these same lines which would produce any required proportion of molding powder, cast products, or adhesive-grade resin. Laminating and bonding equipment can be estimated as required.
