Phenolated Lignins as Reactive Precursors in Wood Veneer and Particleboard Adhesion

Effect of Lignin Structure Characteristics on the Performance of Lignin Based Phenol Formaldehyde Adhesives

As the second most abundant biopolymer, lignin remains underutilized in various industrial applications. Various forms of lignin generated from different methods affect its physical and chemical properties to a certain extent. To promote the broader commercial utilization of currently available industrial lignins, lignin sulfonate (SL), kraft lignin (KL), and organosolv lignin (OL) are utilized to partially replace phenol in the synthesis of phenol formaldehyde (PF) adhesives. The impact of lignin production process on the effectiveness of lignin-based phenolic (LPF) adhesives is examined based on the structural analysis of the selected industrial lignin. The results show that OL has more phenolic hydroxyl groups, lower molecular weight, and greater number of reactive sites than the other two types of lignins. The maximum replacement rate of phenol by OL reaches 70% w/w, resulting in organosolv lignin phenolic (OLPF) adhesives with a viscosity of 960 mPa·s, a minimal free formaldehyde content of 0.157%, and a shear strength of 1.84 MPa. It exhibits better performance compared with the other two types of lignin-based adhesives and meets the requirements of national standards.

Green Phenolic Resins from Oil Palm Empty Fruit Bunch (EFB) Phenolated Lignin and Bio-Oil as Phenol Substitutes for Bonding Plywood

Lignin is a natural biopolymer with a complex three-dimensional network and it is rich in phenol, making it a good candidate for the production of bio-based polyphenol material. This study attempts to characterize the properties of green phenol-formaldehyde (PF) resins produced through phenol substitution by the phenolated lignin (PL) and bio-oil (BO), extracted from oil palm empty fruit bunch black liquor. Mixtures of PF with varied substitution rates of PL and BO were prepared by heating a mixture of phenol-phenol substitute with 30 wt.% NaOH and 80% formaldehyde solution at 94 °C for 15 min. After that, the temperature was reduced to 80 °C before the remaining 20% formaldehyde solution was added. The reaction was carried out by heating the mixture to 94 °C once more, holding it for 25 min, and then rapidly lowering the temperature to 60 °C, to produce the PL-PF or BO-PF resins. The modified resins were then tested for pH, viscosity, solid content, FTIR, and TGA. Results revealed that the substitution of 5% PL into PF resins is enough to improve its physical properties. The PL-PF resin production process was also deemed environmentally beneficial, as it met 7 of the 8 Green Chemistry Principle evaluation criteria.

A Critical Review on Wood-Based Polymer Composites: Processing, Properties, and Prospects

Waste recycling is one of the key aspects in current day studies to boost the country's circular economy. Recycling wood from construction and demolished structures and combining it with plastics forms wood-polymer composites (WPC) which have a very wide scope of usage. Such recycled composites have very low environmental impact in terms of abiotic potential, global warming potential, and greenhouse potential. Processing of WPCs can be easily done with predetermined strength values that correspond to its end application. Yet, the usage of conventional polymer composite manufacturing techniques such as injection molding and extrusion has very limited scope. Many rheological characterization techniques are being followed to evaluate the influence of formulation and process parameters over the quality of final WPCs. It will be very much interesting to carry out a review on the material formulation of WPCs and additives used. Manufacturing of wood composites can also be made by using bio-based adhesives such as lignin, tannin, and so on. Nuances in complete replacement of synthetic adhesives as bio-based adhesives are also discussed by various researchers which can be done only by complete understanding of formulating factors of bio-based adhesives. Wood composites play a significant role in many non-structural and structural applications such as construction, floorings, windows, and door panels. The current review focuses on the processing of WPCs along with additives such as wood flour and various properties of WPCs such as mechanical, structural, and morphological properties. Applications of wood-based composites in various sectors such as automotive, marine, defense, and structural applications are also highlighted in this review.

Effects of Alcell Lignin Methylolation and Lignin Adding Stage on Lignin-Based Phenolic Adhesives

To investigate the effects of lignin methylolation and lignin adding stage on the resulted lignin-based phenolic adhesives, Alcell lignin activated with NaOH (AL) or methylolation (ML) was integrated into the phenolic adhesives system by replacing phenol at various adhesive synthesis stages or directly co-polymerizing with phenolic adhesives. Lignin integration into phenolic adhesives greatly increased the viscosity of the resultant adhesives, regardless of lignin methylolation or adding stage. ML introduction at the second stage of adhesive synthesis led to much bigger viscosity than ML or AL introduction into phenolic adhesives at any other stages. Lignin methylolation and lignin adding stage did not affect the thermal stability of lignin based phenolic adhesives, even though lignin-based adhesives were less thermally stable than NPF. Typical three-stage degradation characteristics were also observed on all the lignin-based phenolic adhesives. Three-ply plywoods can be successfully laminated with lignin based adhesives, and it was interesting that after 3 h of cooking in boiling water, the plywoods specimens bonded with lignin-based phenolic adhesives displayed higher bonding strength than the corresponding dry strength obtained after direct conditioning at 20 °C and 65% RH. Compared with NPF, lignin introduction significantly reduced the bonding strength of lignin based phenolic adhesives when applied for plywood lamination. However, no significant variation of bonding strength was detected among the lignin based phenolic adhesives, regardless of lignin methylolation or adding stages.

Recent Developments in Lignin- and Tannin-Based Non-Isocyanate Polyurethane Resins for Wood Adhesives—A Review

This review article aims to summarize the potential of using renewable natural resources, such as lignin and tannin, in the preparation of NIPUs for wood adhesives. Polyurethanes (PUs) are extremely versatile polymeric materials, which have been widely used in numerous applications, e.g., packaging, footwear, construction, the automotive industry, the lighting industry, insulation panels, bedding, furniture, metallurgy, sealants, coatings, foams, and wood adhesives. The isocyanate-based PUs exhibit strong adhesion properties, excellent flexibility, and durability, but they lack renewability. Therefore, this study focused on the development of non-isocyanate polyurethane lignin and tannin resins for wood adhesives. PUs are commercially synthesized using polyols and polyisocyanates. Isocyanates are toxic, costly, and not renewable; thus, a search of suitable alternatives in the synthesis of polyurethane resins is needed. The reaction with diamine compounds could result in NIPUs based on lignin and tannin. The research on bio-based components for PU synthesis confirmed that they have good characteristics as an alternative for the petroleum-based adhesives. The advantages of improved strength, low curing temperatures, shorter pressing times, and isocyanate-free properties were demonstrated by lignin- and tannin-based NIPUs. The elimination of isocyanate, associated with environmental and human health hazards, NIPU synthesis, and its properties and applications, including wood adhesives, are reported comprehensively in this paper. The future perspectives of NIPUs’ production and application were also outlined.

2G waste lignin to fuel and high value-added chemicals: Approaches, challenges and future outlook for sustainable development

Lignin is produced as a byproduct in cellulosic biorefinery as well in pulp and paper industries and has the potential for the synthesis of a variety of phenolics chemicals, biodegradable polymers, and high value-added chemicals surrogate to conventional petro-based fuels. Therefore, in this critical review, we emphasize the possible scenario for lignin isolation, transformation into value addition chemicals/materials for the economic viability of current biorefineries. Additionally, this review covers the chemical structure of lignocellulosic biomass/lignin, worldwide availability of lignin and describe various thermochemical (homogeneous/heterogeneous base/acid-catalyzed depolymerization, oxidative, hydrogenolysis etc.) and biotechnological developments for the production of bio-based low molecular weight phenolics, i.e. polyhydroxyalkanoates, vanillin, adipic acid, lipids etc. Besides, some functional chemicals applications, lignin-formaldehyde ion exchange resin, electrochemical and production of few targeted chemicals are also elaborated. Finally, we examine the challenges, opportunities and prospects way forward related to lignin valorization.

Naphthalene Structures Derived from Lignins During Phenolation

Phenolation is a commonly used method to improve the reactivity of lignin for various applications. In this study, resinol lignin models (syringaresinol and pinoresinol) and eucalyptus alkali lignin were treated under acid-catalyzed phenolation conditions to investigate the products derived from resinol (β-β) structures of lignins. The phenolation products were characterized by means of GC-MS and NMR spectroscopy following separation using flash chromatography and thin-layer chromatography. A series of new naphthalene products were identified from phenolation of syringaresinol, and the corresponding guaiacyl analogs were also identified by GC-MS. The C1-Cα bond of these resinol compounds was cleaved to release syringol or guaiacol during phenolation. In addition, diphenylmethane products formed from phenol or phenol and syringol/guaiacol were found in the phenolation products. Comparatively, more naphthalene products were obtained by phenolation from syringaresinol than those obtained from pinoresinol. HSQC NMR characterization of the phenolated alkali lignin revealed that naphthalene structures formed in the phenolated lignin.

Development of Wood Composites from Recycled Fibres Bonded with Magnesium Lignosulfonate

The potential of producing ecofriendly composites from industrial waste fibres, bonded with magnesium lignosulfonate, a lignin-based formaldehyde-free adhesive, was investigated in this work. Composites were produced in the laboratory using the following parameters: a hot press temperature of 210 °C, a pressing time of 16 min, and a 15% gluing content of magnesium lignosulfonate (on the dry fibres). The physical and mechanical properties of the produced composites were evaluated and compared with the European Standard (EN) required properties (EN 312, EN 622-5) of common wood-based panels, such as particleboards for internal use in dry conditions (type P2), load-bearing particleboards for use in humid conditions (type P5), heavy-duty load-bearing particleboards for use in humid conditions (type P7), and medium-density fibreboards (MDF) for use in dry conditions. In general, the new produced composites exhibited satisfactory mechanical properties: a bending strength (MOR) (18.5 N·mm−2) that was 42% higher than that required for type P2 particleboards (13 N·mm−2) and 16% higher than that required for type P5 particleboards (16 N·mm−2). Additionally, the modulus of elasticity (MOE) of composites (2225 N·mm−2) was 24% higher than that required for type P2 particleboards (1800 N·mm−2) and equivalent to the required MOE of MDF panels for use in dry conditions (2200 N·mm−2). However, these ecofriendly composites showed deteriorated moisture properties, i.e., 24 h swelling and 24 h water absorption, which were a distinct disadvantage. This should be further investigated, as modifications in the lignosulfonate formula used and/or production parameters are necessary.

Bio-Crude by Acidic Phenolation and Carbamation for the Preparation of Phenolic Thermosetting Resin and Its Application in Thermoresistant Laminates

Fir sawdust was liquefied in phenol solvent under acidic catalyst at 135, 150 and 165 °C, respectively; after neutralization, bio-crude was obtained where contained oil-like liquid and tiny powder-like residue. The bio-crude was chemically modified with urea at high temperature (e. g. > 130 °C) to form carbamate so as to improve chemical reactivity of bio-crude in phenolic resin synthesis. The carbamate-containing bio-crude was condensed with paraformaldehyde into thermosetting phenolic resin. Finally, this biomass-derived phenolic resin matrixed silica fabric laminates were processed. The uncured and thermally cured bio-based resins were characterized by the techniques of Differential Scanning Calorimetry (DSC), Fourier Transform Infrared spectrum (FT-IR), rheology and Thermogravimetric Analysis (TGA), and the laminates’ structure and mechanical performances were studied using the methods of Scanning Electron Microscopy (SEM), three point bending mechanical test and Dynamic Mechanical Analysis (DMA). The results showed: (1) the chemical reactivity of bio-crude was highly improved by carbamation; (2) biomass-derived thermosetting phenolic resin was thermally curable at 150–250 °C (with two exothermic peaks at 185 °C and 220 °C); (3) the char yield was about 47 %, which was not in apparent relationship with sawdust liquefaction temperatures; (4) flexural strength of silica fabric laminates at room temperature was around 357 MPa (similar with that of conventional phenolic laminate); (5) glass transition temperature of silica fabric laminate was above 270 °C (much higher than Tg of conventional phenolic resin laminate, which is normally at 215 °C). The biomass-derived phenolic resin is expected to be widely used as cost-effective and environment-friendly thermosetting resin in the application of high-performance composites.

Ammoxidized Fenton-Activated Pine Kraft Lignin Accelerates Synthesis and Curing of Resole Resins

Ammoxidation of pine kraft lignin in aqueous 5 wt % ammonia affords a novel type of phenol substitute that significantly accelerates resole synthesis and curing as demonstrated for 40 wt % phenol replacement. Compared to non-ammoxidized lignin, which already shortens significantly the cooking time required to reach a resole viscosity of 1000 Pa·s (250 vs. 150 s) and reduces the typical curing B-time by about 25% at 100 °C, the use of ammoxidized lignin has an even more pronounced impact in this respect. Activation of lignin by Fenton-type oxidation prior to ammoxidation further boosts both synthesis and curing of the resole. This is presumably due to the intermediary formation of polyvalent cross-linkers like N,N,N-tris (methylol) trimethylene triamine triggered by saponification of a larger fraction of nitrogenous moieties present in such a treated lignin (ammonium salts, amide-type nitrogen, urea) and reaction of the released ammonia with formaldehyde. Except for the fact that phenol replacement by ammoxidized lignin results in a somewhat less brittle cured adhesive polymer and higher elastic modulus, the aforementioned acceleration in curing could no longer be observed in the presence of wood, where a significantly delayed wood-adhesive bond formation was observed for the lignin-containing adhesives as evident from the automated bonding evaluation system.

Development of sustainable bio-adhesives for engineered wood panels – A Review

Stricter legislation on formaldehyde emissions as well as growing consumer interest in sustainable raw materials and products are the main driving factors behind research on bio-based adhesives, as alternatives to amino-based ones, for wood panels.