Development of a bio-based high pressure laminate (HPL) by partial replacement of phenol with hardwood kraft lignin: design, optimization and scaling-up

Abstract

This work involved the design, optimization and scaling-up of the Hx process of a eucalyptus KL for resol synthesis and HPL production. Variables such as pH, temperature, and order of conditioning of reagents were studied during the laboratory optimization of the Hx to favor dissolution and increase KL reactivity. Scaling-up was performed at Centro S.A., San Francisco, Córdoba, Argentina. The hydroxymethylated KL (HL) was employed for the substitution of 30 wt% P in resol synthesis. The lignin-phenol-formaldehyde (LPF) and conventional PF resins were characterized and employed for the industrial impregnation of Kraft-type paper and subsequent curing. Tensile and flexural tests of HPL were performed. Also, boiling water resistance test was performed.