- Reduced batch failure rate to zero
- Huge savings through reduced waste
- Optimised design - now a global standard
Formaldehyde resins are typically made by reacting formaldehyde with a variety of different compounds, such as urea, melamine, or phenol. A condensation reaction is typically used; whereby formaldehyde acts as the monomer and reacts with urea or melamine to form the polymer.
The process consists of three main steps. The raw material is added, polymerised, and then the reaction is neutralised by the addition of alkali. Determining the reaction endpoint is critical during the process, so the operators exploited the relationship between viscosity and polymerisation to track the reaction progress before quenching.
This graph shows the XL7 perfectly tracking the inverse relationship between viscosity and temperature
Previously, the endpoint was often missed which resulted in a high number of failed batches with significant cost implications.
To tackle this, Hydramotion supplied a custom XL7 viscometer with an optimised design and coating to withstand harsh and abrasive process conditions.
The introduction of the custom instrument allowed operators to exploit the relationship between viscosity and polymerisation to identify the reaction endpoint, whilst also navigating the challenging process conditions.
The installation resulted in huge cost savings and a reduction in the batch failure rate to zero. This custom viscometer design has now become the global standard for formaldehyde resin production, ensuring a more reliable and cost-effective process.