UFC's, also known as urea-formaldehyde precondensates, are nowadays primarily used as additive to a urea melt before granulation or prilling to improve the properties of the urea granules. UFC is also used, but in a minor amount, as a starting material for the production of urea formaldehyde resins.

According to the state of the art urea formaldehyde resins are produced by using urea granules and an aqueous formaldehyde solution as starting materials. These starting materials often are transported over large distances to the plant for production of the urea formaldehyde resins. The transport of the formaldehyde solution involves environmental and safety hazards. Therefore, a plant for production of the urea formaldehyde resins is often located in the vicinity of a formaldehyde plant.

To produce a urea formaldehyde resin the urea granules are dissolved in water and/or in an aqueous formaldehyde solution.

A disadvantage from the process according to the state of the art is that the urea granules have to be prepared and transported over large distances and thereafter the urea has to be dissolved in water again to be able to prepare the resin.

The invention aims to eliminate the aforementioned disadvantage.

This aim is achieved by the preparation of a UFC by combining a formaldehyde-containing stream with a urea-containing aqueous stream that is supplied from a urea plant.

By preparing the UFC in such a way the water in the urea-containing aqueous stream does not have to be evaporated to be able to form granules or prills from the urea stream. Also the formation of prills or granules is no longer necessary. In this way a lot of energy, investments and labour costs, used for the evaporation of the water and the formation of prills or granules, can be saved.

An other advantage of the process according to the invention is that the UFC that is prepared is stable for a long period of time and can, without substantial any environmental or safety hazards be transported over large distances.

A further advantage is that, when prepared in this way, it is economically feasible to produce large quantities of UFC, so that UFC becomes available as a raw material for the production of UF-resins.

A UFC is a urea-formaldehyde precondensate, which is an aqueous solution containing urea and formaldehyde in a free and/or dissolved and/or reacted form. A UFC has a low viscosity which makes it suitable for storage in tanks and transportation by pumps. A UFC contains a molar excess of formaldehyde relative to the amount of urea, so that the UFC remains stable for a long period and is suitable for transportation over long distances. The UFC may contain traces of other compounds.

Examples of such compounds are unreacted starting products or by-products from the synthesis of formaldehyde and/or urea, such as, for instance, methanol, C02, NH3.

Since urea and formaldehyde are highly water-soluble, and since the mutual molar ratio between urea and formaldehyde (U/F) in the UFC may vary between a molar ratio of 0.5 and 0.001, the mutual ratios between water, formaldehyde and urea in the UFC may vary as well.

The quantity of water in the UFC can vary between 5 wt% and 50 wt%, more preferably between 10 wt% and 40 wt%, still more preferably between 15 wt% and 30 wt%.

The formaldehyde-containing stream comprises formaldehyde.

Formaldehyde in the framework of the invention refers to the compound itself or compounds from which formaldehyde may be released, such as paraformaldehyde.

Paraformaldehyde is an oligomeric form of formaldehyde. Paraformaldehyde may be a solid, but is preferably an aqueous solution. The degree of polymerisation of paraformaldehyde in an aqueous environment is an equilibrium reaction, which is adjustable by choosing the concentration and temperature. This is known to those skilled in the art. The degree of polymerisation in paraformaldehyde is preferably no more than 11.

The formaldehyde-containing stream may be gaseous, but also liquid.

The formaldehyde-containing stream preferably consist primarily of formaldehyde, as in the case of a gaseous stream of formaldehyde originating from a formaldehyde plant.

The formaldehyde-containing stream can also be in liquid form, as in the example of an aqueous solution of formaldehyde, customarily referred to as formalin. In practice formalin often contains between 20 wt% and 60 wt% of formaldehyde and between 0 wt% and 15 wt% of methanol. The formaldehyde-containing stream may also contain traces of other compounds. Examples of such compounds are unreacted starting

products or by-products from the synthesis of formaldehyde such as, for instance, methanol, but also stabilisers.

In a preferred embodiment of the invention the formaldehyde- containing stream is gaseous and originates from a formaldehyde plant wherein formaldehyde is prepared by a process known per se; this is commonly done in a catalyzed reaction at high temperature with methanol as a feedstock. The advantage of this is that the formaldehyde-containing stream may be fed directly from the formaldehyde plant to the combination step according to the invention.

The urea-containing aqueous stream contains urea and water. The urea content in the stream may vary and lies between wide limits, usually between 50 and 95 wt%. The quantity of water in the urea-containing aqueous stream is usually between 50 wt% and 5 wt%. The urea-containing aqueous stream may also contain traces of other compounds. Examples of such compounds are unreacted starting products or by-products from the synthesis of urea, such as, for instance, ammoniumcarbamate, C02, NH3.

In the light of the generally unwanted interaction between NH3 and formaldehyde it is preferable to limit the weight quantity of NH3 in the urea-containing aqueous stream such that the weight quantity of NH3 in the urea-containing aqueous stream is less than 5%, preferably less than 1%.

The urea-containing aqueous stream is supplied from a urea synthesis plant. A urea synthesis plant normally comprises a urea synthesis section and on or more recovery sections, followed by an evaporation and finishing section.

Examples of finishing sections are prilling or granulation sections. A urea synthesis section refers to a section in which NH3 and CO2 or compounds thereof such as ammonium carbamate, are reacted to form urea. Water is released in this equilibrium reaction. The stream that leaves the synthesis section is a synthesis solution ; this is an aqueous solution which contains, besides urea, other compounds such as non-reacted starting materials. If, as has been customary until now, the intention is to obtain urea in a virtually pure form, the synthesis solution undergoes a number of follow-up operations in one or more recovery sections. Examples of such follow-up operations known per se are decomposition and separation steps such as stripping, whether or not in combination with pressure reduction and with the aim of removing unwanted starting products and by-products, and concentration steps with the aim of reducing the water content. In the framework of the present invention the synthesis solution and/or one or more urea-containing aqueous streams from the recovery section may serve as

a urea-containing aqueous stream so long as the water content is higher than 5 wt% and preferably higher than 10 wt%. Thus, there are various possibilities of removing a urea-containing aqueous stream from the urea plant: either directly (from the synthesis section) or from or after one or more of the recovery sections. Normally the water content in the urea-containing aqueous stream is too low after it has passed the evaporation section of a urea plant.

It is possible to combine one or more streams that are removed at various places from the urea plant after the synthesis section to the urea-containing aqueous stream.

It is possible to feed the whole quantity of urea which leaves the urea synthesis section and/or recovery section (s) in the form of the urea-containing aqueous stream to the combination step according to the invention. It is also possible to feed a proportion of the quantity of urea which leaves the urea synthesis section and/or recovery section (s) in the form of the urea-containing aqueous stream to the combination step according to the invention.

Preferably the urea-containing aqueous stream is more than 5 wt% of the total stream which leaves the urea synthesis section; more preferably more than 10 wt% or 15 wt%, still more preferably more than 20 wt%. Preferably the urea-containing aqueous stream is less than 95 wt% of the total stream which leaves the urea synthesis. section; more preferably less than 75 wt%, still more preferably less than 50 wt%.

Given that at least a proportion of the synthesis solution does not undergo all follow-up operations for obtaining virtually pure urea, the process according to the invention offers a possibility of debottlenecking a urea plant without the capacity of all components, for instance the evaporation and finishing section, needing to be increased. The invention therefore also relates to a process for debottlenecking a urea plant wherein the urea plant comprises a synthesis section, one or more recovery sections, an evaporation section and a finishing section, wherein the capacity of the urea synthesis section is increased comparatively more than that of at least one of the recovery sections and/or of the evaporation and finishing section. Capacity of a section here refers to the maximum possible throughput (measured in volume or mass) in that section.

The process of the invention may be carried out in a plant for the preparation of a UFC, comprising: a urea synthesis section wherein a urea-containing aqueous stream is formed;

optionally a recovery section wherein compounds other than urea may be removed wholly or partially from the urea-containing aqueous stream, wherein the plant includes a combination section wherein the urea-containing aqueous stream is contacted with a formaldehyde-containing stream so that the UFC is formed and means of conveyance with which a formaldehyde-containing stream is supplied to the combination section and at least a proportion of the urea-containing aqueous stream from the urea synthesis section and/or from the recovery section is supplied to the combination section.

In the combination step, the formaldehyde-containing stream and the urea-containing aqueous stream are contacted with each other so that the UFC is formed. In that process there occurs to a greater or lesser degree a reaction, usually an condensation reaction, between formaldehyde and urea. The said reaction generally proceeds spontaneously. Thus, many processes and conditions are suitable for implementation of the combination step. A special catalyst is not generally necessary.

The combination step may be carried out both batch-wise and continuously. The combination step may be carried out at atmospheric pressure but if desired also at increased or reduced pressure. Usually atmospheric pressure will be chosen for reasons of economy. The temperature during the combination step may vary between wide limits and usually is between 50°C and 150°C, preferably the temperature is between 60°C and 100°C, more preferably between 70°C and 90°C.

If the formaldehyde-containing stream is gaseous, the combination step may for example be carried out by passing the formaldehyde-containing stream through the urea-containing aqueous stream in for example a vessel or an absorption column. Such an absorption column is used in known processes for the preparation of formaldehyde so as to prepare formalin from a gaseous formaldehyde stream with the aid of water. It is possible in one embodiment of the invention to carry out the combination step in a process for the preparation of formaldehyde which comprises an absorption column, by feeding the urea-containing aqueous stream from the urea synthesis section instead of water to the absorption column.

If the total quantity of water in the urea-containing aqueous stream and the formaldehyde-containing stream is inadequate for the desired application, it is advantageous to supply water to the combination step; it is also possible to add water to the UFC already formed.

The thus formed UFC may be applied in many different ways. For example in urea formaldehyde (UF) resins or in melamine urea formaldehyde (MUF)

resins. With these applications, if a molar excess of formaldehyde is present in the UFC, it may be necessary to supply urea to the UFC. As a result the formaldehyde : ureum ratio will drop so that in this way for example a UF resin may be prepared from a UFC. These steps are known to those skilled in the art.

The process according to the invention will be further elucidated by means of 2 figures and examples; without being limited thereto.

Figure 1 describes a process for the production of a UF resin according to the state of the art. Urea is produced in a urea plant on an other location than the location where the UF resin is produced. Urea is produced by adding C02and NH3 to the synthesis section (S) of a urea plant. The urea plant further comprises further a recovery section (R), an evaporation section (E) and a granulation section (G). The urea plant produces urea granules that can be stored and transported. On the same location as the location for the UF resin plant a formaldehyde plant is located, comprising a synthesis section (FH) and an absorption section (A). In the synthesis section air and methanol are introduced and formaldehyde is prepared at high temperature with the aid of a catalyst.

The formaldehyde is then transported to an absorption section where the gaseous formaldehyde is absorbed in water. This formaldehyde solution is then added to a UF- resin plant. The urea needed for the preparation of the resin is supplied by transport over a large distance from the urea plant and the dry urea granules are first dissolved in water. This aqueous urea solution is then added to the resin plant for the preparation of the UF resin.

Figure 2 describes a process for the production of an UF resin (UF) with a UFC prepared according to the invention as a starting material. The resin plant is located on a location that differs from the location of the urea plant and the formaldehyde plant that are needed for the production of the UFC. The UFC is transported to the plant for the preparation of UF resin. To the resin plant, optionally, also urea in the form of granules or an aqueous urea solution, is added. Urea is produced by adding C02 and NH3 to the synthesis section (S) of a urea plant. The urea plant further comprises further a recovery section (R) and thereafter the obtained urea- containing aqueous stream is added to the combination section according to the invention. In the formaldehyde synthesis section (FH) formaldehyde is is prepared at high temperature with the aid of a catalyst. The formaldehyde gas thus obtained is also added to the combination section according to the invention where it is absorbed in the urea-containing aqueous stream to prepare the UFC.

Example I A part of a urea-containing aqueous stream separated just before the evaporation section of a urea plant was added to the absorption column of a formaldehyde plant. The absorption column contained a formaldehyde-containing stream. The amount of formaldehyde-containing stream in relation to urea-containing aqeous stream was adjusted to 3: 1. The urea-containing aqueous stream contained 77 wt% urea and the formaldehyde-containing stream contained 50 wt% formaldehyde.

The stream leaving the absorption column was an UFC with a solid content of 56.8 wt% and a U/F molar ratio of 0.26.

Example II : batch production To prepare 1000 g of UF resin 779.7 g of the UFC of example I was added to a 2L reactor. The UFC contained 43.2 wt% water, 19,3 wt% urea and 37.5 wt% formaldehyde. The pH was adjusted to 8.0 with NaOH and 142.3 g of urea was added to obtain a U/F molar ratio of 0.5.

This solution was heated to 95 °C. After ten minutes at this temperature the pH was lowered to 5.0 with a solution of formic acid. When the pH reached 5.0 the condensation of the resin began and was continued untill a vicosity of about 300 mPa. s was reached.

Thereafter the pH of the solution was raised untill 8. 0 with a NaOH solution and 194.9 g urea was added to obtain a U/F molar ratio of 0.83. The temperature was raised to 80°C and 116.9 g of water was evaporated to adjust the solid content of the resin. Thereafter the solution was cooled to room temperature. The resin thus obtained is suitable for use as a glue in the woodprocessing industry.

Example III ; continuous production To prepare a resin continuously the UFC prepared according to Example I is dosed to a pipe reactor through two dosing points and there contacted with a urea-containing aqueous stream. The pipe reactor also contains dosing points for dosing NaOH and formic acid. Just after the entrance of the pipe reactor the UFC was brought to a temperature of 85 °C and a pH of 5.0. The ratio between the UFC stream and the urea-containing aqueous stream was adjusted in such a way that a U/F molar ratio was obtained of 0.5 in the first part of the reactor. The ratio between the UFC and the urea-containing aqueous stream was thus 1: 0.24.

At 80% of the reactor the pH was adjusted to 8.0 whereafter the ratio between the UFC and the urea-containing aqueous stream was changed to 1: 0.32.

At the end of the reactor a UF resin was obtained with a U/F molar ratio of 0.83 and a solid content of 70 wt. %. The resin thus obtained is suitable for use as a glue in the woodprocessing industry.