natural adhesives in the wood industry -...
TRANSCRIPT
![Page 1: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/1.jpg)
Natural adhesives in thewood industry
Dr. Ing. Bruno Gorrini
Montevideo, September 11, 2018
CAETS 2018
![Page 2: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/2.jpg)
Wood based adhesives: Today
• Petroleum based polymers
• The panel industry, is the larger user of products based on formaldehyde
• More than 50% of the formaldehyde produced in the world is used for the resin production and about 90 % of these resins are used in the production of wood based panels
![Page 3: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/3.jpg)
Petroleum – based polymers
• Good Properties
• Inexpensive
• Limited resource
• Non –renewable
• Environmental/healthissues
![Page 4: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/4.jpg)
Formaldehyde Wood based Adhesives
![Page 5: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/5.jpg)
Formaldehyde Emissions
• 2004 IARC classifies formaldehyde carcinogenic
• June 10, 2013 EPA implements national formaldehyde emissionsstandars (USA)
![Page 6: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/6.jpg)
Formaldehyde emission from Particle boards in Europe
E3
E2
E1
![Page 7: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/7.jpg)
Formaldehyde emission from Particleboards in Chile
30
20
10
6.5 6.5
4
PB MG HCHO / 100 GR
Pe
rfo
rato
rV
alu
e[m
g/1
00
gr]
1962 - 1980 1980 1995 2005 2012 2012 USA
Redrawn from Ramirez E., Biocomp, 2017
![Page 8: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/8.jpg)
Global Trend of Product Emissions Standards
Harmon D., 9th European Wood-based Panel Symposium, 2014
![Page 9: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/9.jpg)
Influence of the Emissions Levels in PB Production
![Page 10: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/10.jpg)
Approaches for emission reduction by adhesives
• Control of synthesis and formulations• Lowering Formaldehyde/urea Molar Ratio• Scavengers ( urea solution or dry urea)• Formaldehyde catchers ( low molar ratio resins)• Introduction of crosslinkers (melamine) • Post treatments ( Ammonia solutions, etc.)
UF and MF adhesives
![Page 11: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/11.jpg)
Approaches for emission reduction by adhesives
• Phenol- formaldehyde resins✓ Provides emissions down to Ultra Low emitting formaldehyde level ( ULEF)
• PF Modification (soy)✓ Provides emissions down to Ultra Low emitting formaldehyde level ( ULEF)
• Introduction of Non added formaldehyde adhesives ( pMDI)✓ Adhesive itself has not emitable formaldehyde✓ Emission of the board Will depend on emission potential of Wood substrate
![Page 12: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/12.jpg)
Challengue for the Wood Industry
• Increased pressure to be sustainableForest Stewardship Council (FSC)
• Environmental Product DeclarationsLife –cycle enviromental impact of products
• Building Rating Schemeso Credits for renewable energy, efficiency , sustainabilityo Material & products play a important role
![Page 13: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/13.jpg)
Natural Adhesives: Challengue and Oportunity
• Biobased Wood adhesives with the same bonding performance and samecost or lower than syntetic adhesives (UF or PF adhesives)
• Sustainable adhesives should not only be available at low costs, but also need to be easily distributable, fast reacting, and have a long pot life.
• Key factor is to achieve the same production speed ( press factor)
![Page 14: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/14.jpg)
▪ Recent government legislative changes to minimize the health effects relating to product emissions of volatile organic chemicals (VOCs), most notably formaldehyde
▪ The use of renewable materials as a cost effective replacement for petrochemical components of adhesives.
▪ Price volatility of petroleum based adhesives
▪ There are some organizations that believe that any formaldehyde is unacceptable
Key drivers for the use of Bioadhesives
![Page 15: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/15.jpg)
Volatility Price : Methanol Contract Prices
![Page 16: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/16.jpg)
Volatility Price : Phenol Contract Prices 2001-2018 U
S$/t
on
US GOLF ICIS lor average Price
![Page 17: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/17.jpg)
Biobased Polymers
Bio-based polymers are materials which are produced from renewable resources
Starch , Protein, Lignin, Tannin, etc..
+ Renewable
+ Environment Friendly ( reduced CO2 emissions)
![Page 18: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/18.jpg)
Biobased Polymers
Disadvantages
• Availability
• Properties
• Uncertainties about health and safety
• Maturity
![Page 19: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/19.jpg)
Natural Wood Adhesives
Saccharide based
Starch
Cellulose
Hemicellulose
Protein based
Animal Glue
Casein
Soy Protein
Aromatic Based
Lignin
Tannin
Oil based
Castor oil
Canola oil
Others
Natural Rubber
Liquefied Wood
![Page 20: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/20.jpg)
Comparison of different Natural adhesives for Wood panel industry
Hemmila V. et al; RSC Adv., 2017, 7, 38604–38630
![Page 21: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/21.jpg)
Tannin based adhesives
• Plant-derived extractives , typically obtained from bark
• Natural polymeric polyphenol very reactive
• Reaction is 10-50x faster than phenol (with formaldehyde)
• Potential to replace phenol
![Page 22: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/22.jpg)
Industrial trial using tannin based adhesive in Plywood
Blending After prepress After Press Knife test
60% of Phenol replacement for radiata pine tannin
![Page 23: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/23.jpg)
Extruder Blender using Tannin based Adhesive
2.2 mm radiata Pine Veneer
![Page 24: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/24.jpg)
Resin stability for Plywood ProductionV
isco
sity
[cp
s]
Standard PF Resin
60% Tannin Resin
Days
Ready to use adhesive
![Page 25: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/25.jpg)
Wo
od
Fai
lure
[%]
Standard PhenolicResin
Resin with 60% Tannin
Industrial Trial Results.60% Phenol replacement for Tannin
• 176 gr/m2 extruder blender• 60 ton of resin trial• 18 mm board
![Page 26: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/26.jpg)
Use of Lignin
• Lignin is Nature´s second most abundant biopolymer
• Natural phenolic compound
• Major by- product of chemical pulping
• The Brown gold of bioeconomy era
• Lignin Price between 350-600 US$/ton (Phenol :1300 US$/ton]
15-31% lignin content in the wood
![Page 27: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/27.jpg)
Use of Lignin
Lignin are underutilized:• Low chemical reactivity• Heterogeneous structure• Diverse chemicals compositions• Isolation Processes ( Kraft, organosolv,sulfite,
soda and enzymatic hydrolisis)
Lignin Modifications to improve Reactivity• Methylolation of lignin• Liqueafaction of ligninbark in phenol
(phenolation)
![Page 28: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/28.jpg)
Lignin Structural Units
Lignin which have very high hydroxyl-phenyl (H-lignin) content are the best candidates to replace 100% of phenol in phenolic adhesive formulations
![Page 29: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/29.jpg)
Nejad, ICWPT 2017
Potential of 100% Phenol Replacement for Lignin
Laboratory Results
(): Standard Deviation
![Page 30: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/30.jpg)
Example of Industrial Production based on Lignin
UPM BioPiva™ lignin product 50% phenol replacement
Obtained from Sanna Valkonen, UPM Biochemicals, 11th International Conference on Wood Adhesives, 2017
![Page 31: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/31.jpg)
Other Natural adhesives
LigateTM adhesive
• Developed by Scion ( New Zealand)
• Totally biobased and using renewable materials ( Tannins- Lignin- Agri-Proteins)
• Adresssing indoor quality , Sustainability, Green chemistry drivers
• Suitable for Plywood, MDF, Particleboard , cross laminated lumber
![Page 32: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/32.jpg)
Protein based Adhesives
• Soy protein as an adhesive to manufacture wood products has seen a huge resurgence
• The soy protein is derived from the residual soy mealremaining after the removal of the oil
• Comercial technologies are available:• Soyad® : soy protein + cross-link with Aminopolyamide-epiclorohydrin (PAE)• SOYBABY* - OZERO* - (MDF-HDF-Laminated floor)
![Page 33: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/33.jpg)
PAE Resin – Soy Chemistry
Allen, 2009, Lake Tahoe, Wood Adhesive Conference
![Page 34: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/34.jpg)
NATURAL ADHESIVE PRODUCTION & NAF
Soy, 72%
Tannin, 165%
0%
20%
40%
60%
80%
100%
120%
140%
160%
180%
NAF Alternatives
Co
st In
cre
ase
Estimated Cost Increasing, using NAF adhesives [MDF and PB]
Cost Limit
MDI; 15%Redrawn from Ramirez E., Biocomp, 2017
![Page 35: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/35.jpg)
• Synthetic resins are coming under increasing restrictions due environmentalexposure regulations
• Bio-adhesives can now be used as natural, suistainable options to traditionalsynthetic adhesives
• High costs are a significant barrier to the development of bioresins
• Improvement in the performance of bio-adhesives is a key focus for existingresearch
• The future will be an environmentally friendly bioadhesive based on natural and renewable resources and produced under sustainable conditions
Conclusions
![Page 36: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/36.jpg)
Still many creative ideas are required for industrial application of Natural Adhesives
FORMALDEHYDE CASUALDEHYDE
![Page 37: Natural adhesives in the wood industry - ANIUcaets2018.aniu.org.uy/wp-content/uploads/2018/09/4... · 2018. 9. 21. · UPM BioPiva™ lignin product 50% phenol replacement Obtained](https://reader035.vdocuments.site/reader035/viewer/2022081620/6116d905009ca8031d400126/html5/thumbnails/37.jpg)
¡¡¡¡ THANK YOU !!!!