Health Articles

Melamine manufacturing profiles

National Energy Corporation of Trinidad and Tobago Limited
BUSINESS OPPORTUNITIES FROM MELAMINE BASED INDUSTRIES
UPDATE ON DOWNSTREAM PROJECTS IN DEVELOPMENT
Vernon Paltoo
Manager, Energy Industry Development
ECTT Energy Luncheon
November 2011

Outline of Presentation
• Overview • Melamine in Manufacturing • Major Markets for Melamine Derived Products • Concepts for Developing Melamine Manufacturing Industries in Trinidad and Tobago • Profile 1 – Melamine Moulding Compounds • Profile 2 - Dinnerware • Profile 3 – Adhesives • Profile 4 – Coatings • Profile 5 – Laminates • Profile 6 - Plasticizers • The Way Forward for Melamine Based Industries • Status on Downstream Projects • Conclusion

Overview
• In May 2010, Methanol Holdings Trinidad Limited (MHTL) began producing melamine from its 60,000 tpy production facility, which forms part of its AUM I Complex. • The production of this commodity, downstream of ammonia, provides an opportunity to leverage the strengths of the energy sector in order to develop linkages with the manufacturing sector. • MEEA/NEC/MHTL hosted a Melamine Symposium on November 17th 2010. Subsequently, development of melamine manufacturing profiles were initiated. • These profiles could be used as a tool by manufacturers and potential investors in assessing/developing potential business • Energy based manufacturing industries would create additional value for the country's natural gas resource.

MELAMINE IN MANUFACTURING
Melamine End Markets
End Market
Application
Automotive
Coating for vehicle body paints Coating, color retention, wear resistance, scratch Flame-resistant foam Interior panels and dash Low-temperature flexibility High sound absorption capacity Good thermal insulation properties Constant physical properties over a wide temperature range Application temperature up to 240° [465°F] Flame resistance Agriculture
Rubber vulcanizing agents Building & Construction
Adhesive resins for ceiling tiles Strength, moisture-resistance, efficient utilization of wood, flow characteristics Carbonitriding of steel (concrete), thermal isolation, sound absorption Oriented Strand Board (OSB) Concrete plasticizers Concrete shuttering Construction panels Gypsum Medium Density Fiberboard (MDF) Parallel strand Lumber Structural foams Laminated Veneer Lumber (LVL) Melamine End Markets
End Market
Application
Electrical & Electronics
Wind power blades Domestic appliances Printed circuit boards Fibers, Textiles & Coatings
Fluorescent paints Intumescent paints Leather tanning agents Printed textiles Symphase Technology Special glossy papers Wrinkle-free clothing Furniture
Bathroom fitments Bedroom furniture and fitments Kitchen and bathroom counter-tops Nursery and children's furniture Melamine End Markets
End Market
Application
Anti-punking agents in binders for glass fibre insulation Ion-exchange resins Nitrification agent (nitrogen force) Raw material for cyanuric acid (swimming pools disinfectant) Starting material for melamine derivates and salts for a variety of applications Other Input Materials Required for Selected Products
Other Material
Moulding Compounds
Formaldehyde, Alpha-Cellulose (Refined cellulose) Tableware, Dinnerware and Utensils
Moulding Compound Moulding Compound Laminates
Urea Formaldehyde, Wood, Paper Adhesives
Urea Formaldehyde Melamine faced chipboards for office and home furniture
Urea Formaldehyde & Adhesives Melamine phosphates – Flame Retardants
Coatings
Formaldehyde, other Paint Chemicals Concrete Plasticizers
Sulphur Compounds Concrete Shuttering
Urea Formaldehyde Iron-on Veneer Sheets
Urea Formaldehyde Toilet Compartments (Floor to Ceiling Supported)
Wood, Laminates & Adhesives Office Compartments
Wood, Laminates & Adhesives Furniture, Kitchen and Bathroom Countertops
Wood, Laminates & Adhesives Toilet Seats
Moulding Compounds Electrical Switch Plates, Junction Boxes and Raceways
Moulding Compounds Other Issues for Consideration
Established buyers should be secured for a significant portion of the products before starting a business venture. There may be a need to acquire proprietary technology and standardized work processes for some of these business opportunities. It would be useful to obtain ISO 9000 certification as it relates to quality and management systems. Melamine has been used in consumer applications without incidents since it was commercialized. Even direct or indirect oral contact with any of these products is completely safe. No personal injuries are likely in the event of spillage. Melamine has a very low acute toxicity. If it is inhaled or gets in the eyes, it is only mildly irritating, and the irritation quickly subsides when exposure ceases. Melamine is absolutely not intended to be used as an ingredient in food and feed applications and therefore should never be used as such. Melamine in bonded form is widely and regularly used in dinnerware, meeting the most stringent requirements of the US Food and Drug Administration (FDA). Major Market Applications of Melamine
Worldwide
Americas
Melamine Market Outlook
• Consumption of melamine in 2010 was estimated to be 1.264 million tonnes increasing slightly from 2007 when consumption was at 1.225 • Worldwide capacity has increased by 9% from 2007 to 2010 while consumption only increased by 3%. • This has resulted in a decrease in the utilization of melamine facilities from 87% in 2007 to 70% in 2010. • Due to increase in demand for consumer goods, it is projected that the market size for melamine in 2015 would be 1.663 million metric tonnes • South and Central America will see growth of 4.8% with increased demand for melamine use in wood adhesives and laminates. • Over the past twelve to eighteen months, there has been a steady increase in the price of melamine, from US$1,860 per tonne in January 2010 to US$2,200 per tonne in September 2011 on the US bulk domestic Melamine Derivatives Business Opportunities Profiles
• Melamine Moulding Compounds • Dinnerware • Adhesives • Coatings • Laminates • Plasticizers Manufacturing Industries from Melamine
Conceptual Estate Plan for Downstream
Melamine Industries
BUSINESS PROFILES FOR MELAMINE DERIVATIVES
Melamine Moulding Compounds
Melamine Moulding Compounds
Pre-requisite for Melamine Moulding Melamine Moulding Compound (MMC) is manufactured by combining an alpha-cellulose ( 30%) with melamine and formaldehyde (70%), which is available in an unlimited range of colours. It produces mouldings with surface hardness unsurpassed by any other plastics. Moulded parts have excellent resistance to abrasion, boiling water, detergents, weak acids and weak alkalis as well as acidic foods and extracts. Compared to thermoplastics, melamine moulding compounds exhibit: – Superior surface hardness that cannot be duplicated by thermoplastic materials – Superior heat resistance – Environmentally friendly raw material components that do not contain halogens, chemicals or organic solvents – Superior chemical resistance – Excellent scratch resistance that cannot be duplicated by engineered thermoplastic materials – Unparalleled UV stability and colour retention Melamine Moulding Compound is particularly well-suited for moulding food contact products, including quality dinnerware for domestic and commercial food service. Melamine Moulding Compound moulded articles are specifically approved for food contact. Market Data
• With new demand for melamine based automobile parts, the overall global production of Melamine Moulding Compound appears to be under-supplied at present. • Overall outlook for global market demand is good with increasing demand in South and Central America, as well as the African markets. • Forecast for projected growth for the next 10 years is about 3% per • The future market will be driven by creative internet or e- marketing, innovations in the industry and economics. The current retail price for Melamine Moulding Compound range from US$2.00 to 3.00 per lb for coloured product and US$1.25 to 1.75 per lb for non-coloured. • The historical demand for the product had an average growth rate of about 3% over the last ten years. Market Data
• Specific markets for production from Trinidad and Tobago are Regional, South and Central America, Africa and the US. • There are no major potential barriers to accessing these markets. • Some of the major manufacturers of melamine moulding compound include: – Amity Thermosets PVT Ltd (India) – Kaihua County Hao Teng Melamine Products Factory (China) – Shijiazhuang Golden Colour Chemical Co. Ltd (China) – Henan Premtec Enterprise Corporation (China) – Jiashan Luyuan Chemical Co. Ltd (China) • Major sources for supplying turnkey operations and equipment are from China, Taiwan, US and India. Melamine Moulding Compounds
Estimated Requirement*
US$250,000 – 500,000 US$50,000 – 100,000 3 – 5 tonnes per day Manpower requirement Utility Requirements 500 kW electricity 20 tpd water Potential Markets T&T, SA, CA, Africa, US, Europe Other Input Materials Refined cellulose, formaldehyde * depending on plant size and level of automation Melamine Moulding Compounds
The major pieces of equipment
used for processing melamine
formaldehyde molding compound
(MF powder) include:
•Chemical Reactor Vessel
•Kneading Machines (kneading
mixers)
•Belt Dryers
•Crushers
•Ball Mills,
•Dust Separators
•Dust Collectors
•Powder Sieve
Melamine Moulding Compound Mixing Equipment
1500litres, 2000litres, 2500litres Rotations: 30 - 50 per minute Power: 18.5kW, 26kW Dinnerware
Dinnerware
• The current trend for eating outdoors has resulted to a ready-market for melamine based dinnerware. Presently melamine dinnerware is favoured for casual outdoor dining rather than formal dinner parties. • Adding decorative overlays during the moulding cycle can enhance the appearance of the moulded articles. • This important added value will allow us (T&T) to insert our unique local brand art-form skewed to worldwide end users' cultural and other preferences. • This novel artistic medium with expressions that are beautiful or thought- provoking, as with our Carnival ingenuity, would be suitable for international e-buying by tourists or nationals living abroad. The added advantage is that this will also serve to promote our natural, cultural and industrial assets. Market Data
• Overall global production of uniquely designed high-end Melamine Dinnerware is currently in good demand. • Overall global market demand is favourable with increasing demand from Regional, South and Central America and Africa markets. This global market requirement is currently estimated at about 6 million units per year. • Forecast projected growth for the next 10 years is approximately 3% per • The future market will be driven by creative internet or e-marketing, innovations in the industry and economics. • The current retail price for a melamine dinner plate ranges from US$0.80 • The historical demand for the product had an average growth rate of about 4% over the last ten years. Market Data
• Specific markets are Regional, South and Central America, Africa and the • No major potential barriers to accessing these markets are foreseen. • There are several hundred current manufacturers and suppliers of melamine dinnerware worldwide. Major manufacturers include: – Henan Hylink Imp. & Exp. Co. Ltd (China) – Quanzhou Jieli Trade Company Limited (China) – Livang Xinrong Melamine Products Co. Ltd (China) – Fuzhou Fortune Homeware Co. Ltd (China) – Zhejiang Lesheros Houseware Manufacturing Co. Ltd. (China) • Major sources for supplying turnkey operations and equipment are from China, Taiwan, US and India. Dinnerware
Estimated Requirement *
US$300,000 – 500,000 US$60,000 – 100,000 600 to 1,200 pieces per day Manpower requirement Utility Requirements 60 kW electricity 5 tpd water Potential Markets T&T, SA, CA, Africa, US Other Input Materials Melamine moulding compounds * depending on plant size and level of automation Flow Diagram for
Melamine Tableware Making Plant
Melamine Tableware Making Plant Information
Manpower
（ person）
• Floor space – 600 sq m Production Technician • Capital Outlay: US$300-500,000 Tableware Moulding Machine
Technical parameters: Cylinder diameter Oil reservoir capacity 120 gallons Dense Two Colour Melamine
Tableware Moulding Machine
Adhesives
Adhesives
• Adhesives are high quality glues specifically designed to bond a wide array of decorative laminates, melamine board, wood and wood-based panel products. • Each adhesive has been developed and selected to suit most applications required by cabinet makers, joiners, furniture manufacturers, post-formers and builders. • Melamine Adhesives are among the many adhesive in use. Due to the availability of urea formaldehyde, Trinidad and Tobago is well suited for adhesive manufacturing. Market Data
• There has been an increase in demand for multiple speciality high performance and nano-formula adhesives. This is as a result of requirements of the automobile, aircraft, construction and other industries. As such, overall global production for specialty adhesives at present appears to be highly favourable. • Overall global market demand is excellent with increasing demand from this Region, the US, South and Central America, Africa and EU markets. • Forecast projected growth for the next 10 years is expected to be about 5% • Due to the hundreds of different formulae of adhesives, current retail prices for adhesives could vary from regular store pricing to NASA and other space travel speciality needs. The future is promising because of the many new innovative extreme performance adhesives, creative internet or e-marketing, innovations in industry and the current global economies' desire to cut costs. • The historical demand for adhesives has increased by 5% annually over the • Specific target markets are worldwide. Market Data
• Major potential barriers to accessing these markets are: product shelf life, trade restrictions, MSDS restrictions, obtaining contract manufacturing agreements, stringent quality control and potential environmental impact concerns. • Major Manufacturers include: – Astra Chemtech Private Limited (India) – Wilsonart (USA) – 3M (USA) – Conpro Chemicals Private Limited (India) – IPS (USA) • Major sources for supplying turnkey operations and equipment are from China, Taiwan, US, India and EU. • Manufacturing adhesives are a relatively competitive business. There are several hundred small and a few mega manufacturers and suppliers. Manufacturers' technologies for specific products are proprietary. Adhesives
Estimated Requirements *
1,000 – 3,000 sq m US$800,000 – 4,000,000 US$200,000 – 1,000,000 3,000 gallons per week Manpower requirement Utility Requirements 400 kW electricity 40 tpd water Potential Markets T&T, SA, CA, Africa, US, Middle East Other Input Materials Urea formaldehyde * depending on plant size and level of automation Adhesives Processing Equipment
Technical parameters: Packing Packaged as Per Customer as per Customer Request Complete Set of Chemical Alkyd Resin, Acrylic Resin, Machine Material Alkyd Resin, Phenolic Resin, Hotmelt Glue, Heat, React, Dilute Resin Production Equipment
Coatings
Coatings
• Melamine-formaldehyde resins are used in specially formulated resin systems to produce highly durable coatings. • Typical melamine-modified coatings applications include: o Vehicle body panels o Household appliances o Drink cans o Coils of metal sheeting • Benefits of melamine-modified coatings include: o Good color retention o Wear resistance o Scratch resistance o Glossy finish Market Data
• An increased demand for multiple speciality and fire retardant high performance and nano formula coatings in the automobile, aircraft, construction, household and other industrial uses has resulted in an increase in overall global production for speciality coatings. • Overall global market demand is good with increasing demand expected from this Region, the US, South and Central America, Africa and EU • Forecast projected growth for the next 10 years is about 5% per annum. • Market drivers in the future will include creative use of the internet or e- marketing, innovations in the industry and good economics. Due to the many different formulas for speciality coatings, current retail prices for coatings could vary from the average store pricing to that used by NASA for space travel requirements. • The historical demand for coatings has increased considerably over the • Specific target markets are worldwide with emphasis on the Region, South and Central America, Africa and the US markets. Market Data
• Major potential barriers to accessing these markets are: product shelf life, trade restrictions, MSDS restrictions, obtaining contract manufacturing agreements, quality control and potential environmental impact concerns. • Manufacturing coatings, with multinational dominance in the industry, is a relatively competitive business. There are several hundred small and some mega manufacturers and suppliers. Manufacturers' technologies for specific products are proprietary. • Major manufacturers include: – Akzo Nobel (Netherlands) – Sherwin-Williams (USA) – PPG (USA) – Materis (France) – Benjamin Moore (USA) • Major sources for supplying turnkey operations and equipment are from China, Taiwan, US, India and EU. Coatings
Estimated Requirements *
US$300,000 – 1,500,000 US$75,000 – 375,000 4,000 gallons per week Manpower requirement Utility Requirements 300 kW electricity 40 tpd water Potential Markets T&T, SA, CA, Africa Other Input Materials * depending on plant size and level of automation Coatings
Interior Wall Paint Mixing Machine Flow Diagram of Melamine Coating
Manufacturing Plant
Typical Plant Requirements
Paint Type
Equipment
Quantity Electricity
Ready Mixed Paint, 1. HMB-3020E 30HP Mixer. Red Iron Oxide Anti- 2. HMD-30AL Vertical Type Bead Mill. Corrosion Primer, 3. HMC-405 Vibra-Filter Machine. Lacquer Paint, Enamel, 4. HME-101 1" Air Feeding Pump. Car Baking Enamel, 5. HMK-800 (800 litre) Mixing Tank. Polyurethane Paint. Position
Staffing requirement
Chemical Engineer Formula Technician Product Testing Operator Assistant Worker Packaging Worker Laminates
Laminates
• Melamine laminate is a protective, heat and scratch resistant covering for furniture and other surfaces. • Melamine laminate is a tough material that is resistant to moisture and chemicals. It does not scratch easily, and it is a flame retardant. • Melamine laminate also has antibacterial properties, making it a hygienic material for use in the kitchen. Market Data
• Trinidad and Tobago is not a timber rich country, and would need to import wood to use for large scale laminate production. The laminated board business is still flourishing worldwide, especially in the US and in timber rich Brazil and Southern Africa. • Overall global market demand is positive with increasing demand expected from this Region, the US, South and Central America, Africa and EU markets. • Forecast projected growth for the next 10 years is approximately 1.5% per annum. • The future market will be driven by creative internet or e- marketing, innovations in the industry and economics. Local experience and creative ingenuity could be used to create local unique laminate patterns. However, it should be noted that laminate production is a very competitive business. • The historical demand for laminates has been relatively flat over the last ten years. Market Data
• Specific target markets are worldwide with emphasis on the Region, South and Central America, Africa and the US • There are no major potential barriers to accessing these • Manufacturing laminates with multinational dominance in the industry will be very competitive. Most manufacturers' technologies for the product are proprietary. • Major manufacturers include: – Golden Laminates Ltd, India Ltd. (India) – Anpco Products (USA) – Fuzhou Yilida wood Industry Co. Ltd (China) – Xiamen Nan Hua Wen Co .Ltd (China) – Changzhou Chaomei Wood Co. Ltd (China) • Major sources for supplying turnkey operations and equipment are from China, Taiwan, US, India and EU. Laminates
Estimated Requirements*
US$300,000 – 1,500,000 US$75,000 – 375,000 3,000 - 10,000 sq m per day Manpower requirement Utility Requirements 700 kW electricity 60 tpd water Potential Markets T&T, SA, CA, Africa, US, Middle East Other Input Materials Urea formaldehyde, wood, paper * depending on plant size and level of automation Laminates
Technical parameters Mode Specification Minimum Board Length Overall Dimensions Paper Laminating Machine
Plasticizers
• Plasticizers are additives that increase the plasticity or fluidity of the material to which they are added. These can include plastics, cement, concrete, wallboard, and clay. • Plasticizers for concrete increase the workability of the wet mix, or reduce the water required to achieve the desired workability, and are usually not intended to affect the properties of the final product after it hardens. • Plasticizers for wallboard increase fluidity of the mix, allowing lower use of water and thus reducing energy to dry the board. • Plasticizers for plastics soften the final product increasing its flexibility. Market Data
• While newly engineered plasticizers are frequently emerging in almost every industry, many plasticizer users usually stick to traditional formulas. Countries like Trinidad and Tobago could encourage local bulk buyers to contract traditional plasticizer blends from a local manufacturer. • Due to the overall global market downturn, the use of concrete plasticizers has declined to a great extent as a result of the decrease in construction activity throughout the world. • Forecast for projected growth for the next 15 years appears to be somewhat flat. Developing economies like India and China are major producers of plasticizers. Due to the low labour costs in these countries, inexpensive traditional plasticizers are being exported from those markets. • The future market would be driven by product quality, adequate delivery mechanisms, creative internet or e-marketing, innovations in the industry and world economics. • The historical demand for concrete plasticizers has dropped considerably over the last ten years due to a decline in construction activities. Market Data
Specific target markets are worldwide with emphasis on the Region, South and Central America, Africa and the US and EU markets. Major potential barriers to accessing these markets are: product shelf life, trade restrictions, MSDS restrictions, obtaining contract manufacturing agreements and quality control. Manufacturing plasticizers, with Asian dominance in the industry makes it a very competitive business. There are several hundred small and some mega manufacturers and suppliers. Manufacturers' technologies for specific products are proprietary. Major manufacturers include: – Beijing Hengan Admixture Co. Ltd. (China) – Hunan Pioneer Building Material Co. Ltd. (China) – Shandong Tongsheng Building Maetrials Co, Ltd. (China) – Suzhou Sunbo Chemical Building Materials Co., Ltd. (China) Major sources for supplying turnkey operations and equipment are from China, Taiwan, US, India and EU. Plasticizers
Estimated Requirements *
US$300,000 – 1,500,000 US$60,000 – 300,000 2,000 gallons per day Manpower requirement Utility Requirements 250 kW electricity 20 tpd water Potential Markets T&T, SA, CA, Africa, US, Middle East, Europe Other Input Materials Sulphur Compounds * depending on plant size and level of automation The Way Forward
• Engage stakeholders including Business Chambers and State Entities for marketing and distribution of profiles. • Approve a site for locating melamine based • Develop Business Plans for melamine derivative projects. DOWNSTREAM ENERGY PROJECTS IN
DEVELOPMENT BY NEC
Global Chemical Business
Current Global Chemical Production: US$3.4 Trillion (2009)
Consumer Products Specialty Chemicals Other Ind. Chem.
Bulk Petrochemicals Source: ICIS/ACC
Industries in Focus for Development
Alternative
Plastics
Energy Efficiency
Energy Services
Common Utilities
Inorganic
Chemicals
Biochemical
and Agro-based
Products
Integrated Ammonia and Downstream Project
• Cabinet approved MHTL AUM II in February 2010 Major plants: • Integrated Downstream Ammonia Processing Facility to produce urea, ammonium sulphate and melamine urea formaldehyde (MUF) • Construction Employment • Operations Employment Status Feasibility Studies in progress. Methanol Downstream
In May 2011, NEC, in conjunction with The Ministry of Energy and Energy Affairs issued RFPs for the development of: •Methanol to Petrochemicals (MTP) (bid close: Sept 08, 2011) •Methanol to Olefins (MTO) (bid close: Nov 30, 2011) Fourteen (14) companies expressed interest in each RFP. Status •Five (5) proposals received for MTP project. •GORTT approved criteria used for evaluation of projects. •Evaluation team comprises officials from NEC, MEEA and NGC. •Evaluation of proposals for both projects are expected to be complete by end 2011. Prospective Derivative Industries from Acetic Acid
Acetic Anhydride Acetylsalicylic Acid Prospective Derivative Industries from Ethylene
Linear Alkyl Benzene Polyester Fibers Prospective Derivative Industries from Propylene
Propylene Glycol Food Applications Food Applications Biological Apps. Manufacturing Industries from
Polyethylene and Polypropylene
Polypropylene
 Carpeting
 Carpet Backing  Rope  Appliance Parts  Bottle Crates  Film Sheeting  Containers  Film Sheeting  Appliance Parts Inorganic Chemicals
CARISAL is proposing the construction of an integrated inorganic processing facility to produce:  calcium chloride  sodium hydroxide  sodium hypochlorite  hydrochloric acid Start of Construction: 2012 Natural gas used as a fuel as opposed to a raw material Minimal infrastructure requirements Relatively small capital expense Modest utility requirements Minimal land requirements Less complex to establish than organic industries Manufacturing/Service Industries
from Inorganic Chemicals
Bitumen Upgrader Project
Reliance is proposing the development of 75,000 bpd bitumen upgrading facility in Trinidad and Tobago. This facility would use imported asphaltine, together with resid oil (possibly from Petrotrin) to produce synthetic crude oil. This is proposed as the first train of a project which could eventually encompass four trains. Estimated capital investment of US$1.2 to 1.4 billion for Train 1 with the plant coming on stream possibly in 2015/2016 A Memorandum of Cooperation (MOC) was signed among Reliance, NEC and NGC in August/September 2011 in order to undertake a detailed feasibility study for the proposed project. CONCLUSION
Integrated
Petrochemicals &
Integrated
1970s/80s
and Service
Industries
2010 & Beyond
Gas Production
1960s/70s
Thank You

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