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Innovative, harmless additive, lowering curing-point temperatures, reducing surface tension in aminoresins, giving considerable raw material, energ y,financial savings in woods, laminates

Objective


The major industrial objective obtained with this research is to produce a series of innovative, non-toxic chemical additives which are capable of:
a. considerably reducing the surface tension of MUF resins (to increase their soaking effect and thus reduce the amount of MUF resins needed to bind each m³ of wood); this would lead to the use of MUF resins becoming more widespread, providing considerable environmental-technical benefits and energy savings (saved resins = saved energy);
b. reducing the surface tension - i.e. the soaking effect - of UF resins too, thereby reducing the cost of manufactured articles and making them more competitive (saved resins = saved energy);
c. reducing the curing point by 10-15°C, thereby recovering energy in the production of both laminates and reconstructed wood panels (chipboard, Mdf, plywood, blockwood)
d. replacing the use of catalysts used to harden the resins, seeking to improve the overall efficiency of the polymerisation.
e. The additive designed and produced by this research costs about 0.8 ECU per kg. and 1.5% of the weight of the resin is used in a 60% solution;
f. the effectiveness of this innovative additive has also benefited a whole range of the characteristics of manufactured articles, the most important of which are: improved mechanical resistance, improved resistance to water and minimised formaldehyde emissions
g. to obtain an additive which can also be sold as an independent chemical product to manufactured article producers. Together with resistance to water, this will increase the total resistance of the resins to moisture).
Objectives and content
The production of reconstructed wood panels and plastic
laminates offers low added value, requires a high
quantity of raw materials, energy and manpower, and has a
vast range of final applications (furniture, floorings,
cars, etc.) and huge markets. There are agglomerating
resins (aminoresins), used to achieve the technical
performances demanded by the market, which are
environment friendly: they are the MUF resins (melamine,
urea, formaldehyde), which are alternatives to or used
together with the UF resins (urea, formaldehyde) normally
used. However, they cost almost twice as much as UF
resins, and as they have less than half the agglomerating
capacity, double the amount is required. Another
important industrial objective is the saving of energy,
which accounts for approx. ' 2()% of the cost of
producing agglomerating resins (and above-all the energy
required for producing ammonia and subsequently
melamine), approx. 18% in the case of reconstructed wood
(particle-board, Mdf, plywood), and approx. 16% for
plastic laminates.
In brief, the industrial needs are: To reduce the
incidence of energy costs, minimise the quantity of
quality raw materials (agglomerating resins) and improve
the environmental aspect, so as to keep costs competitive
in a very large, varied market in great difficulty.
CONTENT OF THE PROPOSAL AND TECHNICAL APPROACH:
To develop-test a completely non-toxic additive which is
capable of producing the following benefits: - major
energy savings (up to 15-2()%) - considerable savings in
agglomerating resins (up to:3()% less MUF and 1()% less
UF) - lower formaldehyde emissions from articles bided
using aminoresins - reduced production cycles - improved
mechanical properties. the technical approaches for
achieving these objectives are:
to considerably reduce MUF resin surface tension (to
improve the dampening effect and thus reduce the amount
of MUF needed to bind a m3 of wood and to impregnate
paper, so that 30% less is required) allowing MUF resins
to be more widely used on the market (saved resin = saved
energy).
to lower the curing-point by l()-l5 C, giving
considerable recovery of energy in the production of both
laminates and reconstructed wood panels (particle-board,
Mdf fibreboard, plywood). At the same time the additive
will improve the properties of manufactured articles, in
particular mechanical and water resistance, and minimise
formaldehyde emissions.
SECTORS INVOLVED: the proposal is aimed at all the
industrial sectors in which aminoresins (melamine, urea
etc. resins) are used as binders, in particular plastic
laminates and reconstructed wood products [particleboard, plywood, listels, fibreboard (Hdf, Mdf . etc.].
STATE-OF-THE-ART:
No thorough, original, scientific and technological
studies have been carried out on this subject (there are
practically no related patents); the project envisages a
scientific-technological approach and systemisation of
the issues in question. Reference is made to a highly
original preliminary study made by two of the partners
which may produce a highly innovative patent.
ENVIRONMENTAL, SOCIAL AND EEC COMMUNITY IMPACT:
reduced formaldehyde emissions and need for raw materials
(agglomerating resins); certain savings in energy.
resulting in less environmental pressure overall;
appreciable energy savings at an EEC level (5()m m3 of
agglomerated materials and laminates are produced with
aminoresins in the EEC; a minimal saving at a local level
could produce considerable global savings).

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Saint Peter Srl
Address

12065 Monforte D'alba
Italy

Participants (7)

Arespan SpA
Italy
Address
Piazza I Maggio 1
14047 Mombercelli Asti
Institute of Researches and Testings M. Masini Srl
Italy
Address
Via Moscova 11
20017 Rhò Milano
Linopan SA
Belgium
Address
16,Ooigemstraat
8710 Wielsbeke
Liri Industriale Srl
Italy
Address
Via Vernea 2
10042 Nichelino
Mepa N.V.
Belgium
Address
25,Industriepark De Bruwaan
9700 Oudenaarde
Pina S.A.
Spain
Address
Calle Dr. Martinez Pardo
15310 Curtis
Società Europea Pannelli SpA
Italy
Address
Via Vajont
32010 Castello Lavazzo Belluno