Thermal Stability and Fire Retardant Properties of Polyamide 11 Microcomposites Containing Different Lignins

Kraft Lignin: A Valuable, Sustainable Resource, Opportunities and Challenges

Kraft lignin, a by-product from the production of pulp, is currently incinerated in the recovery boiler during the chemical recovery cycle, generating valuable bioenergy and recycling inorganic chemicals to the pulping process operation. Removing lignin from the black liquor or its gasification lowers the recovery boiler load enabling increased pulp production. During the past ten years, lignin separation technologies have emerged and the interest of the research community to valorize this underutilized resource has been invigorated. The aim of this Review is to give (1) a dedicated overview of the kraft process with a focus on the lignin, (2) an overview of applications that are being developed, and (3) a techno-economic and life cycle asseeements of value chains from black liquor to different products. Overall, it is anticipated that this effort will inspire further work for developing and using kraft lignin as a commodity raw material for new applications undeniably promoting pivotal global sustainability concerns.

Pyrolysis Kinetics of Lignin-Based Flame Retardants Containing MOFs Structure for Epoxy Resins

This study describes the preparation of a lignin-based expandable flame retardant (Lignin-N-DOPO) using grafting melamine and covering 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) using the Mannich reaction. Then, through in situ growth, a metal-organic framework (MOF) HKUST-1 (e.g., Cu3(BTC)2, BTC = benzene-1,3,5-tricarboxylate)/lignin-based expandable flame retardant (F-lignin@HKUST-1) was created. Before that, lignin epoxy resin containing phosphorus (P) and nitrogen (N) components had been created by combining epoxy resin (EP) with F-lignin@HKUST-1. Thermogravimetric analysis was used to examine the thermal characteristics of epoxy resin (EP) composite. The findings indicate that the thermal stability of EP is significantly affected by the presence of F-lignin@HKUST-1. Last but not least, the activation energy (E) of EP/15% F-lignin@HKUST-1 was examined using four different techniques, including the Kissinger-SY iteration method, the Ozawa-SY iteration method, the Lee-Beck approximation-iteration method, and the Gorbatchev approximation-iteration method. It was discovered that the activation energy was significantly higher than that of lignin. Higher activation energy suggests that F-lignin@HKUST-1 pyrolysis requires more energy from the environment, which will be significant about the application of lignin-based flame retardants.

Antimicrobial and Flame-Retardant Coatings Prepared from Nano- and Microparticles of Unmodified and Nitrogen-Modified Polyphenols

The purpose of this study was to elucidate the structures and functional properties of tannin- and lignin-derived nano- and microparticles and the coatings prepared from them. Nanoparticles prepared from technical lignins and water-insoluble tannin obtained from softwood bark showed large differences in the suspension testing of antibacterial efficacy against methicillin-resistant Staphylococcus aureus (MRSA) bacteria. A common factor among the most effective lignin nanoparticles was a relatively low molar mass of the lignin, but that alone did not guarantee high efficacy. Tannin nanoparticles showed good antibacterial activity both in suspension testing and as coatings applied onto cellulose. The nanoparticles of nitrogen-modified tannin and the small microparticles of nitrogen-modified kraft lignin exhibited promising flame-retardant parameters when applied as coatings on cellulose. These results illustrate the potential of nano- and microsized particles of unmodified and chemically modified polyphenols to provide functional coatings to cellulosic substrates for environments and applications with high hygiene and fire safety requirements.

Flame retardance-donated lignocellulose nanofibers (LCNFs) by the Mannich reaction with (amino-1,3,5-triazinyl)phosphoramidates and their properties

Nitrogen/phosphorus-containing melamines (NPCM), a durable flame-retardant, were prepared by the successive treatment of ArOH (Ar = Br_nC₆H_5−n, n = 0, 1, 2, and 3) with POCl₃ and melamine monomer. The prepared flame-retardants were grafted through the CH₂ unit to lignocellulose nanofibers (LCNFs) by the Mannich reaction. The resulting three-component products were characterized using FT-IR (ATR) and EA. The thermal behavior of the NPCM-treated LCNF fabric samples was determined using TGA and DSC analyses, and their flammability resistances were evaluated by measuring their Limited Oxygen Index (LOI) and the UL-94V test. A multitude of flame retardant elements in the fabric samples increased the LOI values as much as 45 from 20 of the untreated LCNFs. Moreover, the morphology of both the NPCM-treated LCNFs and their burnt fabrics was studied with a scanning electron microscope (SEM). The heat release lowering effect of the LCNF fabric against the water-based paint was observed with a cone calorimeter. Furthermore, the mechanical properties represented as the tensile strength of the NPCM-treated LCNF fabrics revealed that the increase of the NPCM content in the PP-composites led to an increased bending strength with enhancing the flame-retardance.

LCNFs were grafted with nitrogen/phosphorus-containing melamines to achieve potent flame-retardance and converted to PP-composites of improved mechanical properties.

Multifunctional lignin-based nanocomposites and nanohybrids

Significant progress in lignins valorization and development of high-performance sustainable materials have been achieved in recent years. Reports related to lignin utilization indicate excellent prospects considering green chemistry, chemical engineering, energy, materials and polymer science, physical chemistry, biochemistry, among others. To fully realize such potential, one of the most promising routes involves lignin uses in nanocomposites and nanohybrid assemblies, where synergistic interactions are highly beneficial. This review first discusses the interfacial assembly of lignins with polysaccharides, proteins and other biopolymers, for instance, in the synthesis of nanocomposites. To give a wide perspective, we consider the subject of hybridization with metal and metal oxide nanoparticles, as well as uses as precursor of carbon materials and the assembly with other biobased nanoparticles, for instance to form nanohybrids. We provide cues to understand the fundamental aspects related to lignins, their self-assembly and supramolecular organization, all of which are critical in nanocomposites and nanohybrids. We highlight the possibilities of lignin in the fields of flame retardancy, food packaging, plant protection, electroactive materials, energy storage and health sciences. The most recent outcomes are evaluated given the importance of lignin extraction, within established and emerging biorefineries. We consider the benefit of lignin compared to synthetic counterparts. Bridging the gap between fundamental and application-driven research, this account offers critical insights as far as the potential of lignin as one of the frontrunners in the uptake of bioeconomy concepts and its application in value-added products.

Renewable lignin-based surfactant modified layered double hydroxide and its application in polypropylene as flame retardant and smoke suppression

A novel and environmentally friendly lignin-based surfactant sodium lignosulfonate (SLS) modified layered double hydroxide (LDH) flame retardant (LDH-LS) was fabricated via co-precipitation method, and subsequently incorporated into polypropylene (PP) matrix to obtain the PP and LDH-LS composites (PP/LDH-LS) by melt blending method. The XRD, FT-IR and XPS results indicated that SLS had successfully modified LDH by adsorbing on the surface of the LDH nanosheet. The WCA and SEM results revealed that the hydrophobic property of LDH-LS had been evidently improved, and it displayed a more homogeneous dispersion than virgin LDH in the PP matrix. Furthermore, cone calorimetry tests (CCT) illustrated that the peak heat release rate (PHRR), total heat release (THR), and total smoke release (TSR) of PP/LDH-LS composites exhibited declines of 62.9%, 25.1%, and 43.3% compared with those of Neat PP, respectively. Besides, the PP/LDH-LS achieved a LOI value of 29.4% and a UL-94 V-0 rating, whereas the PP/LDH showed only a LOI value of 25.2% and a UL-94 V-2 rating at 20 wt% loading. These improvements of flame retardant properties can be attributed to that the well-dispersed LDH-LS and synergistic flame retardancy between LDH and SLS.

Flammability Tests and Investigations of Properties of Lignin-Containing Polymer Composites Based on Acrylates

In this paper flammability tests and detailed investigations of lignin-containing polymer composites' properties are presented. Composites were obtained using bisphenol A glycerolate (1 glycerol/phenol) diacrylate (BPA.GDA), ethylene glycol dimethacrylate (EGDMA), and kraft lignin (lignin alkali, L) during UV curing. In order to evaluate the influence of lignin modification and the addition of flame retardant compounds on the thermal resistance of the obtained biocomposites, flammability tests have been conducted. After the modification with phosphoric acid (V) lignin, as well as diethyl vinylphosphonate, were used as flame retardant additives. The changes in the chemical structures (ATR-FTIR), as well as the influence of the different additives on the hardness, thermal (TG) and mechanical properties were discussed in detail. The samples after the flammability test were also studied to assess their thermal destruction.

Development of Novel Polyamide 11 Multifilaments and Fabric Structures Based on Industrial Lignin and Zinc Phosphinate as Flame Retardants

Biobased lignin represents one of the possible materials for next-generation flame retardant additives due to its sustainability, environmental benefits and comparable efficiency to other flame retardant (FR) additives. In this context, this study presents the development of FR polyamide 11 (PA11) multifilament yarns and fabric structures containing different industrial lignins (i.e., lignosulfonate lignin (LL), and Kraft lignin (KL)) and zinc phosphinate (ZnP). The combination of ZnP and lignin (KL or LL) at different weight ratios were used to prepare flame retarded PA11 blends by melt mixing using a twin-screw extruder. These blends were transformed into continuous multifilament yarns by the melt-spinning process even at a high concentration of additives as 20 wt%. The mechanical test results showed that the combination of KL and ZnP achieved higher strength and filaments showed regularity in structure as compared to the LL and ZnP filaments. Thermogravimetric (TG) analysis showed the incorporation of lignin induces the initial decomposition (T_5%) at a lower temperature; at the same time, maximum decomposition (T_max) shifts to a higher temperature region and a higher amount of char residue is reported at the end of the test. Further, the TGA-FTIR study revealed that the ternary blends (i.e., the combination of LL or KL, ZnP, and PA11) released mainly the phosphinate compound, hydrocarbon species, and a small amount of phosphinic acid during the initial decomposition stage (T_5%), while hydrocarbons, carbonyls, and phenolic compounds along with CO₂ are released during main decomposition stage (T_max). The analysis of decomposition products suggests the stronger bonds formation in the condensed phase and the obtainment of a stable char layer. Cone calorimetry exploited to study the fire behavior on sheet samples (polymer bulk) showed an improvement in flame retardant properties with increasing lignin content in blends and most enhanced results were found when 10 wt% of LL and ZnP were combined such as a reduction in heat release rate (HRR) up to 64% and total heat release (THR) up to 22%. Besides, tests carried out on knitted fabric structure showed less influence on HRR and THR but the noticeable effect on postponing the time to ignition (TTI) and reduction in the maximum average rate of heat emission (MARHE) value during combustion.

Towards lignin derived thermoplastic polymers

Lignin is the second most abundant biobased material found on earth. It is produced mainly as a byproduct of pulp and paper industry and biorefineries. Despite its abundance, lignin valorization is not achieved on a large scale. Recently, there has been a growing demand for using the renewable and biodegradable raw materials in the commodity polymers. Potential use of lignin as a component in thermoplastic polymers is a promising approach for its value-added utilization. Given the vast applications of thermoplastic materials, there is lack of comprehensive review on lignin based thermoplastic polymers in literature. This review focuses on the utilization of lignin as functional and structural component of the thermoplastic polymers which requires structural modifications of lignin pertaining to the polymeric system. First, various lignin modifications were discussed in view of controlling the homogeneity, reactivity, processability and compatibility of lignin for successful thermoplastic copolymer synthesis and blend processing. Then, various copolymerization methodologies of lignin applicable for thermoplastic monomers are reviewed. Lastly, the lignin based thermoplastic blends are discussed which covers the lignin blends with various thermoplastic polymers and the chemical modifications required to improve its compatibility in polymer matrix. Some of the promising potential applications and future perspectives to achieve the goal of lignin-based commercial thermoplastics polymers are addressed.

Influence of Ammonium Polyphosphate/Lignin Ratio on Thermal and Fire Behavior of Biobased Thermoplastic: The Case of Polyamide 11

Flame retardancy of polymers is a recurring obligation for many applications. The development trend of biobased materials is no exception to this rule, and solutions of flame retardants from agro-resources give an advantage. Lignin is produced as a waste by-product from some industries, and can be used in the intumescent formation development as a source of carbon combined with an acid source. In this study, the flame retardancy of polyamide 11 (PA) is carried out by extrusion with a kraft lignin (KL) and ammonium polyphosphate (AP). The study of the optimal ratio between the KL and the AP makes it possible to optimize the fire properties as well as to reduce the cost and facilitates the implementation of the blend by a melting process. The properties of thermal decomposition and the fire reaction have been studied by thermogravimetric analyzes, pyrolysis combustion flow calorimetry (PCFC) and vertical flame spread tests (UL94). KL permits a charring effect delaying thermal degradation and decreases by 66% the peak of heat release rate in comparison with raw PA. The fire reaction of the ternary blends is improved even if KL-AP association does not have a synergy effect. The 25/75 and 33/67 KL/AP ratios in PA give an intumescence behavior under flame exposure.

Valorization of Industrial Lignin as Biobased Carbon Source in Fire Retardant System for Polyamide 11 Blends

In this study, two different types of industrial lignin (i.e., lignosulphonate lignin (LL) and kraft lignin (DL)) were exploited as charring agents with phosphorus-based flame retardants for polyamide 11 (PA11). The effect of lignins on the thermal stability and fire behavior of PA11 combined with phosphinate additives (namely, aluminum phosphinate (AlP) and zinc phosphinate (ZnP)) has been studied by thermogravimetric analysis (TGA), UL 94 vertical flame spread, and cone calorimetry tests. Various blends of flame retarded PA11 were prepared by melt process using a twin-screw extruder. Thermogravimetric analyses showed that the LL containing ternary blends are able to provide higher thermal stability, as well as a developed char residue. The decomposition of the phosphinates led to the formation of phosphate compounds in the condensed phase, which promotes the formation of a stable char. Flammability tests showed that LL/ZnP ternary blends were able to achieve self-extinction and V-1 classification; the other formulations showed a strong melt dripping and higher burning. In addition to this, cone calorimetry results showed that the most enhanced behavior was found when 10 wt % of LL and AlP were combined, which strongly reduced PHRR (-74%) and THR (-22%), due to the interaction between LL and AlP, which not only promotes char formation but also confers the stability to char in the condensed phase.