Periodic Reporting for period 2 - VIOBOND (VIOBOND – sustainable binder: Upscaling new lignin-phenol-formaldehyde resin production with wood-based biorefinery lignin)
Periodo di rendicontazione: 2023-03-01 al 2024-08-31
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.
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.
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.