Evaluation of phenol-formaldehyde OSB resins modified with lignin residues from acid-hydrolyzed waste newsprint

Lignin was extracted with ethanol and methanol from the residues of the Tennessee Valley Authority’s acid hydrolysis process of newsprint from municipal solid wastes. The lignin was characterized by molecular weight average and distribution. A lignin-phenol formaldehyde (LPF) resin was synthesized with the extracted lignin using 35 percent lignin replacement of phenol. The characteristics and molecular weight of the LPF resin were determined and compared with a control phenol-formaldehyde resin typically used in oriented strandboard (OSB) manufacture. Strandboards (OSB-type) were manufactured using liquid phenolic resins at two press times (4 and 5 min.) and two resin solids levels (3.5% and 4.5%) on an ovendry strand weight basis. The strandboards were tested for physical strength and dimensional stability properties. Properties of strandboards bonded with the LPF resins were comparable to those of the control-bonded strandboards. While the extraction process may be impractical for large-scale implementation, these results showed that lignin extracted from the residues of the acid hydrolysis process of waste newsprint can be used for partial substitution of phenol in binders used for bonding strandboards.

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