Final Report Summary - ECOPRESSWOOD (Formaldehyde free Bio-Based thermosetting resin for wood pressed products) Executive Summary:ECOPRESSWOOD project was officially started on the 1st of March 2014. The project was structured into eight work packages and the planned duration was 36 months, ending on the 28th of February 2017. In this section, the objectives planned for whole project will be presented, as described in the Description of Work.In order to define an efficient process for production and characterization of biobased resin, the consortium performed several desk researches for increasing its knowledge on use those biobased resins in free-formaldehyde wood panels. During those months, INSPIRALIA has been synthesized three types of bio-based resins. One is based on polyester and polyacrylate with short-medium molecular weight. This bio-resin has been scaled up and sent to the RTD members of Ecopresswood to be tested. In order to include other types of monomers and crosslinkers, the 2nd bio-resin is based on polyester with higher molecular weight. In order to fulfil requirements of viscosity and to include water in the formulation, the last one is a polyurethane water based dispersion synthesized from bio-based polyester synthesized previously.After the characterization of the bio-based resin formulations and taking into account their properties (viscosity, solid content, stickiness, etc.), the bio-based selected was polyester polyacrylate resin composed by 75% of acrylate oil, 25% of maleinized oil and 20% of reactive diluent, glycerol dimethacryl. In the last months, INSP have implemented different actions according to feedback of other RTDs. Some parameters of the resin were modified in order to transfer lab technology of synthesis to pilot plant and scale up process, e.g. decrease the viscosity. In addition, INSPIRALIA supported CHIMAR in all the scale up production as well as they provided their equipment to characterize the monomers synthesized in CHIMAR facilities.In parallel, CETEM has incorporated the nanoparticles into the bio-based resin in order to evaluate the effect of them in the dispersions and in the properties of the resin. The most suitable results have been obtained with silica nanoparticles, so it has been decided to manufacture some particleboards with this nanoparticle. However, the mechanical and hygroscopic properties were slightly better than particleboards without oxide ceramic nanoparticles. Cellulose nanoparticles were also study as an alternative to oxide ceramic nanoparticles. In addition, CETEM performed laboratory particleboards samples in order to optimize the production process. They have achieved the reduction of the curing time to 20 s/mm and as well as fix the curing temperature in 120ºC, using the catalyst Luperox P. Meanwhile, FHG-WKI has been carried out a full characterization of the new resin formulations, taking into consideration the processability of the resin. Viscosity, solid content, stickiness, etc. are some of the properties measured by FHG.The conclusions obtained were that PA resin was the most suitable one, and they have been working with it in the development of the WP5. In this work package, FHG optimized the production process of each wood panel type using the new bio-based resins and after their manufacture, each one has been characterized in order to ensure them industrial requirements in terms of mechanical and hygroscopic properties. In addition, they carried out the study of the panel emissions.For the exploitation and dissemination of the Ecopresswood resin some key stakeholders and channels have been identified by the SME associations and the rest of the partners. Some strategic goals, main tasks and a list of activities. Moreover, regarding the dissemination of the project different actions have been undertaken like the development of the project website, presentation of a poster in some fairs and events.From the point of view of management and, considering the planned work plan, the main objectives for this period were to complete all the tasks on work package 1,2,3,4,5,6,7 and 8.Project Context and Objectives:The ECOPRESSWOOD project has been devised to take advantage of the waste generated by the biodiesel industry to develop “formaldehyde free” wood based panels that combine bio-based chemistry, nanotechnology and process engineering.Currently, the resins used in pressed wood product are composed by petroleum based products containing formaldehyde. The shift in classification by the International Agency for Research on Cancer (IARC) of formaldehyde from group 2A, substance “probably carcinogenic to humans” to group 1, “carcinogenic to humans, it has enhanced the trend of the last decades towards the reduction of formaldehyde content in wood products until the complete avoidance of its use in a short/medium term, is expected and continued.In Ecopresswood, a new bio-based free formaldehyde resin has been developed that will be used for manufacturing wood panels with emission levels of natural wood. To be cost competitive and environmentally friendly, the new bio-based resin is produced from residues of food industry and biodiesel.This provides biodiesel and food industries an excellent way for recycling and revalorizing their waste and bio-resin manufacturers, saving waste treatment cost, a new bio based product with a great market potential and opportunity of new clients within the woodworking industry.Project Results:In order to define an efficient process for production and characterization of bio-based resin, the consortium performed several desk researches for increasing its knowledge on use those bio-based resins in free-formaldehyde wood panels. During the first reporting period, different type of resin chemistries were developed by INSPIRALIA in order to meet the Ecopresswood project targets. In the second period, after the initial testing of the proposed chemistries, Ecopresswood consortium decided to select the 100% solids resins as best performing solution and more robust and reliable chemistry. Different actions were implemented by Inspiralia according to feedback of other RTDs regarding results. Some parameters of the resin were modified in order to transfer lab technology of synthesis to pilot plant and scale up process, e.g. decrease the viscosity.In parallel, CETEM studied the effect of adding oxide ceramic nanoparticles (previously selected in the first period) to the new bio-based resins in order to prove and assess the effects they produced when they were added in the Ecopresswood resin. Finally, it has been concluded that silica nanoparticles are the most suitable due to the good results obtained at the hour of being incorporate them into the resin and it cost in comparison with the other nanoparticles.Meanwhile, laboratory particleboards samples have been performed trying to optimize the production process using the bio-based resin. CETEM has achieved the reduction of the curing time to 20 s/mm and as well as the reduction of the curing temperature to 120ºC by the use of catalysts.Meanwhile, FHG-WKI has been carried out a full characterization of the new resin formulations, taking into consideration the processability of the resin. Viscosity, solid content, stickiness, etc. are some of the properties measured by FHG.The conclusions obtained were that 100% solids resin was the most suitable one, and they have been used in the development of the WP5. In this work package, FHG optimized the production process of each wood panel type using the new bio-based resins and after their manufacture; each one has been characterized in order to ensure their industrial requirements in terms of mechanical and hygroscopic properties. In addition, they carried out the study of the panel emissions.Finally CHIMAR has scaled up the production process of the new bio-based resin with successful results due to the close collaboration of the rest of the partners, especially Inspiralia. Then, a pilot-scale production and validation of the production process of plywood panels by Millpanel. These manufactures were carried out in FHG-WKI facilities. For the exploitation and dissemination of the Ecopresswood resin some key stakeholders and channels have been identified by the SME associations and the rest of the partners. Some strategic goals, main tasks and a list of activities. Moreover, regarding the dissemination of the project different actions have been undertaken like the development of the project website, presentation of a poster in some fairs and events.Potential Impact:Ecopresswood project will benefit two different European industrial sectors: the woodworking industries and the biomass industry. All participant SME-AGs comprise a network of 2500 SMEs, 91 Big Enterprises and 45 associations from the furniture, woodworking and biomass sector that will potentially benefit from the results of the ECOPRESSWOOD project.Regarding the benefit for the SMEs in the woodworking industry, they will benefit from direct commercialization of the new wood based panels with formaldehyde emission at natural wood levels. The total market of wood panels in 2011 was €24.8 billion with a total production of 60 million of m3 and an average growth of 3.4% per annum.132 Therefore, the total market in 2018 (first selling year) will be 31,3€ billion and a production of 75,8 million m3.For the case of SMEs in the European Biomass industry. The Ecopresswood resin will benefit to bio-based resin producers with revenues from commercialization. The biodiesel producers will directly benefit from selling their residues as the starting material for resin synthesis.ECOPRESSWOOD project will have a significant environmental impact through minimising formaldehyde emissions from wood products. In indoor environments, like in prefabricated houses made of UF-fibreboards, formaldehyde concentration in air can even reach 800μg/m3. The use of the new bio-based resin, instead of UF, will have the potential to reduce indoor formaldehyde emissions until the background level, 1 μg/m3. The European woodworking industry is now facing increasing environmental regulations and bio-resins appear to offer the only solution for minimising environmental impact of glued wood products. Bio-resins can now be used as natural, sustainable alternatives to traditional petro-chemical derived materials such as formaldehyde and isocyanate based resins in the manufacture of composite products. The new bio-based resin that will be developed in ECOPRESSWOOD project will become important for the present and future ‘green’ credibility of engineered wood products. Moreover, the proposed solution would offer no compromise at end of life so the products may be safely recycled and reused. ECOPRESSWOOD project will contribute to jobs both by securing existing jobs in largely rural areas of Europe and by creating new jobs. The total potential on new jobs created in Europe by ECOPRESSWOOD could even reach 50,000 if all of the 607 SMEs in the European woodworking sector were commercializing the new wood panels. There will be also a societal impact through the improved health and safety of wood products both in manufacture and in long term use. The new developed wood pressed products will improve the safety to the consumer by avoiding harmful chemicals. Societal benefits on a large scale will also be won throughout the European Union by an increased share of wood and wood-based materials used in the construction sector.This will directly affect the sustainability of society by shifting towards a renewable resource which is neutral in the perspective of carbon dioxide release to the atmosphereList of Websites:www.ecopresswood.com
