VIOBOND – sustainable binder: Upscaling new lignin-phenol-formaldehyde resin production with wood-based biorefinery lignin

Project Information

VIOBOND

Grant agreement ID: 101022987

DOI

10.3030/101022987

EC signature date 28 April 2021

Start date 1 September 2021

End date 31 August 2027

Funded under

• SOCIETAL CHALLENGES - Food security, sustainable agriculture and forestry, marine, maritime and inland water research, and the bioeconomy

Total cost

€ 34 995 627,19

EU contribution

€ 15 897 000,00

Coordinated by

LATVIJAS FINIERIS A/S
Latvia

Periodic Reporting for period 2 - VIOBOND (VIOBOND – sustainable binder: Upscaling new lignin-phenol-formaldehyde resin production with wood-based biorefinery lignin)

Reporting period: 2023-03-01 to 2024-08-31

Summary of the context and overall objectives of the project

The project builds a first-of-its-kind 45,000 t/a flagship plant producing industrial-scale lignin phenol-formaldehyde (LPF) resins where lignin partially substitutes fossil-based phenol and formaldehyde, providing valorisation and scaling up the use of lignin, reducing lignin-rich streams and increasing value of lignin at least five-fold compared to the current use of heating energy. The VIOBOND consortium combines extensive interdisciplinary experience in a full value-chain from fractionating wood-based biorefinery lignin to manufacturing several types of LPF resin for different purposes. VIOBOND flagship plant uses lignin from biorefinery production, and validates the use of waste from plywood production.
The main commercial end-use is conventional plywood panels where lignin substitutes fossil-origin and hazardous phenol and formaldehyde in resin. The VIOBOND flagship project demonstrates a business model for valorisation and transformation of lignin in Europe while also demonstrating scale-up and exploitation of the lignin-agnostic lignin-resin technologies for Southern Europe and globally for areas where there are not any wood-based pulp plants or biorefineries.

The project has positive environmental and social impacts as lignin-based resins can be produced with low emissions and less waste, reducing dependence of synthetic fossil materials. It will reduce GHG emissions by replacing fossil-based chemicals and materials. This at the same time reduces waste and CO2 footprint. The production of the LPF resin in the flagship plant could avoid potentially over 118 000 t CO2 per year when the whole value-chain is considered. Moreover, VIOBOND, by focusing on the sustainable lignin sources into LPF, will contribute to the circular economy industry and boosting the bio-economy and natural carbon sinks building blocks.

VIOBOND project creates new consumer products from lignin, substantially increasing lignin applications and thus improving the business cases for both resin producers and biorefineries. The more detailed overall objectives of the project are related to the constructing a novel commercially viable, first-of-its-kind lignin phenol-formaldehyde resin plant on a large scale and operate it successfully, resin application, and environmental and sustainability objectives. VIOBOND project aims to demonstrate that the new LPF plywood resin results in higher quality plywood or enable to use of cheaper wood veneer than conventional plywood processes and that novel LPF specialty resins can be used in consumer products that meet the identified application market demands.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The VIOBOND project has made significant progress from its inception to the end of the second reporting period. The primary objective is to scale the production of lignin-phenol-formaldehyde (LPF) resin using biorefinery lignin. Key achievements include the successful characterization and optimization of lignin supply from biorefinery operations, the development of a novel LPF resin plant concept, and the commencement of construction and commissioning of the plant. Despite challenges such as the COVID-19 pandemic and geopolitical situation, significant preparatory tasks have been completed, including the relocation of the pipe bridge and the construction of the cooling tower.

The conclusions obtained during RP1 were successfully applied in the development of a large-scale resin factory concept, which will serve as the basis for starting work on the Flagship resin plant technical details. Pörner has completed the basic engineering of the flagship plant. The detailed plant design as well as the layout are currently in progress. In parallel, the suitability of lignin for flagship purposes was evaluated at three levels. LSIWC has modeled the potential behavior of lignins in the resin production. Based on the analysis, the most relevant analyses were selected and methods to measure these properties were developed. Next, Latvijas Finieris made resins mixtures with different compositions to find out which lignins and lignin procedures are suitable for resins. This way, the model forecasting lignin’s behavior in the resins could be validated. The achieved results show that the average degree of substitution of fossil-based phenol and formaldehyde with lignin is at least 50-70%.

Mirka tested lignin as an additive in a standard phenolic resin formulation for abrasives. The results showed that using lignin as a filler is not a feasible option for Mirka. However, the VIOBOND resins worked relatively well for coating abrasive material. Saint-Gobain has done preliminary analysis of the properties required for LPF resins in the mineral wool manufacturing process. UVIC started to perform a Sustainability Assessment and an LCA study on the whole VIOBOND value chain to demonstrate the sustainability and circularity of VIOBOND products compared with their fossil-based counterparts. They aim to optimize and propose mitigation and improvement measures using an iterative eco-design approach.
The VIOBOND project has actively promoted its activities and results through various channels, including social media, conferences, and publications. The project has also engaged with stakeholders through events and meetings, ensuring the dissemination of project results to a wide audience.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The current state-of-the-art resins involve fossil-origin production routes, presenting harmful health effects. Alternative biobased solutions are limited. The VIOBOND project has already achieved significant progress beyond state of the art. The high-efficiency LPF resin process has been demonstrated through the integration of advanced dispersing technologies, enabling high substitution rates of phenol with lignin. Novel lignin refining concepts have been developed, producing refined lignin grades with significantly low molecular weight, which have great potential for high-value applications. Advanced safety measures and environmental compliance have been integrated into the plant design to ensure sustainable plant operation.

The expected results until the end of the project include the commercialization of the novel LPF resin, providing a sustainable alternative to fossil-based resins. The commercialization of this technology is expected to reduce reliance on fossil resources and enhance the sustainability of the resin industry. The project is also expected to create new job opportunities and stimulate economic growth in the biorefinery and resin production sectors. The use of local renewable raw materials will contribute to a more sustainable and circular economy. The project has the potential to significantly reduce the environmental impacts by replacing fossil-based phenol with renewable lignin.

In conclusion, the VIOBOND project has made significant strides in developing and commercializing a novel LPF resin production process. The project has achieved key milestones, including the characterization and optimization of lignin supply, the development of a novel resin plant concept, and the commencement of construction of the plant. The project aims to reduce reliance on fossil resources, and enhance the sustainability of the resin industry. The project has also actively promoted its activities and results, ensuring the dissemination of project results. Despite challenges, the project has continued to make progress and is expected to achieve its objectives by the end of the project period.

Overall view on the new resin plant concept