Novel Bio-Binders For Use in Composite Wood Products

Transcription

Bio-Binders For Use In
Composite Wood Products
October 11, 2013
Alex Tseitlin – Senior Scientist, ECOSYNTHETIX
Charles Markessini – R&D Director, Chimar Hellas
“EcoSynthetix®”, “Sustainable Polymers For Planet Earth™” and biolax® are trademarks or registered trademarks of EcoSynthetix or its affiliates. All rights reserved.
Delivering success through our partnerships
Current
Applications
Current
Research
Industrial & Academic
Partners*
*plus more under confidentiality
Introduction to Chimar
FACTS & FIGURES:
36 Years in 37 Countries and 70+ Industrial sites
Combined capacity: > 1.0 million tons of liquid resin
24 strong team:
ACTIVITES:

Developer and supplier of technology for the industrial production and
APPLICATION of Formaldehyde-based resins and additives

Engineering services for formaldehyde and resin plants

R&D services for third parties

Technical support services for resin, WBP producers & OEMs

Specialty chemicals production upon request (Hardeners, FR, Wetting agents)
Applying natural materials for biolatex® polymers
Biopolymer Source
+ Chemicals
Patented
Formula
Proprietary Continuous
Manufacturing Process
Patented
Process
Biolatex®
Dry Polymer
Patented
Product
Transforming native starch into cross-linked small particles
Natural
Biopolymer
Granules
Historical Approaches
Dextrin fragments
Novel Patented Approach
Cross-linked particles
• Retains high molecular weight functionality at a viscosity suitable for a
range of industrial applications.
• Reversible ability to absorb liquid and swell creating insoluble gel.
• Reduced tendency to migrate and create mottle in topcoat application
1H-NMR
spectra confirming biolatex is chemically
unique from starch coating systems
1H
NMR spectra (D2O – room temperature)
Starch 2
Starch 1
Biolatex
Small functional particles with excellent rheology in
coatings and binding strength in structural materials.
Biolatex particle size distribution impact excellent
rheology and process-ability in many applications.
biolatex®
nanoparticle
emulsion
10 nm
SB
Acrylic
Emulsion
Emulsion
100 nm
1000 nm
10,000 nm
100,000 nm
1 µm
10 µm
100 µm
Particle Size Measurements
)
Measured by Dynamic Light Scattering
ISO : 13321 in conformance with GMP
Lab: Particle Technology Labs Date: July 1, 2013
Native Corn
Starch
Unique properties of biolatex binders
 No added formaldehyde
 Compatibility with numerous chemistries
 Safe handling
 Delivered in dry powder – easily dispersed
 Dispersion of polymer particles in water
 - OR- Direct dispersion into an aqueous solutions
 Stabilized by hydroxyl-groups at the surface
 One liter aqueous dispersion at 35% solids contains:

18
~1x10
particles
2
 Surface area ~40 000 m
 Excellent coating and binding mechanics
Small particles provide unique benefits
Tailored functionality through chemical modifications
Applications:
( - Glucose - )n

Wood
composites

Coatings

Insulation

Adhesives

Non-wovens
Independent Lab Evaluation:
Biobased Binders
Lab, pilot and industry trials
Lab Facility:
Chimar Laboratories
Accredited Test Lab
Thessaloniki, Greece
Lab
Commercial
Pilot
Industry
Lab evaluation settings
Panel product
Single layer particleboard
Panel size, mm x mm x mm
Panel density, kg/m3
440 x 440 x 16
660
Initial resin loading, %on dry wood
8
Paraffin wax loading, %on dry wood
0.5
Hardener loading (NH4)2SO4, %
Mat moisture, %
Resin type
3
11.5
UmF 096/066RS
Press temperature, oC
210
Wood mix: Scots pine, maritime pine & european black pine
Contour Plot of ΙΒ (MPa) vs Press Factor, s/mm; Substitution, %
ΙΒ (MPa)
< 0,20
0,20 – 0,25
0,25 – 0,30
0,30 – 0,35
0,35 – 0,40
0,40 – 0,45
> 0,45
Press Factor, s/mm
10,0
9,5
9,0
8,5
8,0
10
20
30
40
50
60
Substitution, %
70
80
Contour Plot of MOR (MPa) vs Press Factor, s/mm; Substitution, %
MOR (MPa)
<
9,5
9,5 – 10,0
10,0 – 10,5
10,5 – 11,0
11,0 – 11,5
11,5 – 12,0
12,0 – 12,5
> 12,5
Press Factor, s/mm
10,0
9,5
9,0
8,5
8,0
10
20
30
40
50
60
Substitution, %
70
80
Contour Plot of Swelling (%) vs Press Factor, s/mm; Substitution, %
Swelling
(%)
< 40
40 – 50
50 – 60
60 – 70
70 – 80
> 80
Press Factor, s/mm
10,0
9,5
9,0
8,5
8,0
10
20
30
40
50
60
Substitution, %
70
80
Contour Plot of Formaldehyde con vs Press Factor, s/; Substitution, %
Formaldehy d
content
< 3,5
3,5
– 4,0
4,0
– 4,5
4,5
– 5,0
5,0
– 5,5
> 5,5
Press Factor, s/mm
10,0
9,5
9,0
8,5
8,0
10
20
30
40
50
60
Substitution, %
70
80
Formaldehyde content in mg/100g O.D.B. according to EN 120 (Perforator Method)
Lab
Pilot
Commercial
Pilot Trial:
Industry
Alberta Innovates
Technology Futures =
“AITF”
Edmonton, Alberta
“AITF” production settings
Panel product
Single layer MDF
Panel size, mm x mm x mm
610 x 610 x 21.3
Panel density, kg/m3
800
12
0.5
Mat moisture, %
Resin type
0
9 -11
UF 096D
160
Press cycle, s
600
Wood mix: 60% lodgepole pine, 40% white spruce with a small % of balsam fir
Pilot test at “AITF”
Internal bond versus replacement
Pilot Test at “AITF”
MOR versus replacement
Lab
Commercial
Industrial Trial:
MDF Production
European Region
Pilot
Industrial
Industrial MDF production settings
Panel product
Single layer MDF
Ex-Press panel thickness, mm
Panel density, kg/m3 (lb/ft3)
19.5
700 – 720 (43.5 – 45.0)
11
0.5
1.5
Mat moisture, %
Resin type
UF 096D
Press cycle, s
9
240 – 220 – 210 –190
193.5
Wood mix: Scots pine (80%) and white poplar (20%)
Industrial MDF Internal Bond (IB)
0.85
Control
0.80
20% substitution
30% substitution
I.B., N/mm2
0.75
end Control
0.70
0.65
0.60
0.55
660
670
680
690
700
710
Density, kg/m3
720
730
740
750
760
Industrial MDF results
Control Start
Ex. #1
Ex. #2
Control End
0
20
30
0
Density, kg/m3
733
700
709
726
I.B., N/mm2
0.77
0.68
0.67
0.68
M.O.R., N/mm2
26.6
28.3
27.2
Moisture content, %
Formaldehyde emissions
Gas analysis, (mg·m-2·h-1)
Formaldehyde content at
6,5% MC mg/100g O.D.B.
4.4
4.4
4.6
4.2
4.1
3.3
7.9
8.7
7.4
% replacement
0.69N/mm2 is 100PSI
25.0N/mm2 is 3,626PSI
Discussion - Conclusions
• The biolatex bio binders showed excellent compatibility with
UF / UmF resins
• In lab, pilot and industrial scale
• Current applications:
– MDF
– Face PB
• Substitution ratio of two parts of UF / UmF by one part of
biolatex supports economic viability
• More R&D is on the way to further improve performance to
cost ratio and broaden application spectrum
Thank you
Novel Bio-Binders For Use In
Composite Wood Products
October 11, 2013
Alex Tseitlin – Senior Scientist, ECOSYNTHETIX
Charles Markessini – R&D Director, Chimar Hellas
“EcoSynthetix®”, “Sustainable Polymers For Planet Earth™” and biolax® are trademarks or registered trademarks of EcoSynthetix or its affiliates. All rights reserved.

Novel Bio-Binders For Use in Composite Wood Products

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