Market and product

1. The Necessity of the Research

In the rapidly growing domestic and international wood-based panel industry, Urea-Formaldehyde (UF) resin remains the dominant adhesive. However, its primary drawback is the emission of formaldehyde—a substance hazardous to human health. Facing increasingly stringent international environmental standards (E1, E0, CARB, etc.), controlling formaldehyde levels has become a matter of survival for UF resin manufacturers.

Currently, formaldehyde scavengers (additives) are entirely dependent on imports, which reduces production autonomy and inflates costs. To address this, the project focuses on a highly urgent and practical direction: synthesizing Ethylene-urea domestically and developing an integrated additive formula for UF resin. This aims to secure raw materials and upgrade the quality of adhesive products to meet international standards.

2. Research and Application Process

Research Object: Ethylene-urea—an organic compound capable of reacting with free formaldehyde in UF resin to reduce emission levels. The project covers the entire process from synthesizing Ethylene-urea and formulating additives to integrating them into UF resin production and verifying their performance through industrial plywood trials.

2.1. Research Methodology

• Utilizing global scientific theories and data as a technical foundation.
• Consulting with experts to refine the research methodology.
• Applying modern analytical techniques such as FTIR, NMR, HPLC, and DSC to evaluate product quality.
• Conducting direct performance comparisons between resins with and without Ethylene-urea additives.

2.2. Scientific and Practical Basis

UF resin is favored for its low cost and excellent bonding strength, but it emits high levels of formaldehyde—classified by the WHO as a Group I carcinogen. Using Ethylene-urea as an additive is a sustainable scientific approach that both effectively scavenges formaldehyde and enhances the mechanical properties of the resin. For Vietnam's wood export industry, mastering this synthesis technology is a breakthrough strategy to lower costs and increase competitive advantage.

2.3. Research Content

• Comprehensive review of related scientific literature.
• Establishing the technological process for synthesizing Ethylene-urea and conducting pilot production.
• Designing an additive system formula that meets EU standards.
• Optimizing the UF resin production process with integrated additives.
• Pilot production of UF resin and plywood, followed by quality assessment based on international standards.

2.4. Key Results and Achievements

1. Optimized Synthesis: Refined the reaction parameters for Ethylene-urea synthesis, making it suitable for industrial scaling.

2. Structural Verification: Confirmed molecular structure and purity (reaching 99%) using FTIR, ¹H-NMR, ¹³C-NMR, HPLC, and DSC.

3. Pilot Production: Successfully produced 60 kg per batch with a stable process, yielding quality comparable to imported products.

4. Optimal Formula: Developed an additive system with the ideal ratio of Ethylene-urea and other enhancers (Melamine, PVA, starch, Hexamine).

5. Standardized Procedures: Created guidelines for using additives across different quality levels (E2, E1, E0), easily integrated into existing production lines.

6. Industrial Application: Produced industrial-scale UF resin meeting E1 and E0 standards for immediate use in plywood manufacturing.

7. International Validation: Plywood produced with this resin passed all mechanical and emission tests conducted by the international organization Intertek.

8. Academic Contribution: Results were published in the Journal of Chemistry.

9. Recognition: Recognized as an Industry-level Initiative by the Vietnam National Chemical Group (Vinachem).

3. Significance and Impact

Internal Efficiency: The application of these research results helped the Center increase its high-quality resin output from 2,500 tons/year (2020) to 6,000 tons/year from 2022 to the present—a growth of over 60%. It has also reduced costs and increased competitiveness by eliminating dependence on imported additives.

Socio-Economic and Environmental Impact: The project contributes significantly to the sustainable development of the adhesive and wood-based panel industry. By meeting high standards like E1, E0, and CARB, Vietnamese wood products can access demanding markets such as the EU, Japan, and the USA. Furthermore, this technology aligns with the national strategy for "green-clean-friendly" industrial development.