Alternative Materials from Agro-Industry for Wood Panel Manufacturing—A Review

Particleboards with Recycled Material from Hemp-Based Panels

This research addresses the current need for sustainable solutions in the construction and furniture industries, with a focus on environmentally friendly particleboard. Particleboards were made from a mixture of virgin wood chips and hemp shives, which were then mechanically recycled and used to make new lightweight particleboards. Phenol-formaldehyde resin with 25% w/w phenol replacement by soybean flour (PFS) was used as the binder for the lignocellulosic materials. Laboratory analyses determined the resin properties, and FTIR confirmed the structure of the experimental PFS resin. The thermal properties of all the resins were evaluated using thermogravimetric analysis (TGA). The panels were manufactured using industrial simulation and tested for mechanical and physical properties in accordance with European standards. The FTIR study confirmed good adhesion, and the TGA showed improved thermal stability for the recycled biomass panels compared to virgin biomass panels. The study concludes that lightweight particleboards can be successfully produced from recycled hemp shive-based panels, providing a sustainable alternative to traditional materials in the construction industry.

Particleboard Creation from Agricultural Waste Residue of Seed Hemp

In this research, agricultural residue of seed hemp variety "Adzelvieši" was used to create hemp particleboard samples. Hemp was grown in three experimental fields where it was observed that after seed harvesting, 3.5 tonnes of hemp stems per hectare remained. The plants were processed with milling, cutting, and sieving equipment. Moisture content and particle size distribution were observed throughout raw material processing. Hemp boards were produced using the cold pressing method with 10% urea formaldehyde resin as the binder. The boards were made as 20 mm thick single-layer parts with a density range of 220 ± 30 kg/m3 and porosity of 86%. Board structural analysis was performed using optical microscopy and scanning electron microscopy methods. Mechanical strength was determined by performing bending strength, internal bond strength, and screw withdrawal tests. The thermal conductivity reached 0.047 ± 0.008 W/(mK). The results were compared with industrially produced hemp shive boards and materials in the developmental or production stage. The feasibility for the experimental production cycle proposed in the study is discussed.

Properties and Emissions of Three-Layer Particleboards Manufactured with Mixtures of Wood Chips and Partially Liquefied Bark

Partial liquefaction of residual biomass shows good potential for developing new materials suitable for making bio-based composites. Three-layer particleboards were produced by replacing virgin wood particles with partially liquefied bark (PLB) in the core or surface layers. PLB was prepared by the acid-catalyzed liquefaction of industrial bark residues in polyhydric alcohol. The chemical and microscopic structure of bark and residues after liquefaction were evaluated by means of Fourier Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscopy (SEM), while the particleboards were tested for their mechanical and water-related properties, as well as their emission profiles. Through a partial liquefaction process, some FTIR absorption peaks of the bark residues were lower than those of raw bark, indicating hydrolysis of chemical compounds. The surface morphology of bark did not change considerably after partial liquefaction. Particleboards with PLB in the core layers showed overall lower densities and mechanical properties (modulus of elasticity, modulus of rupture, and internal bond strength), and were less water-resistant as compared to the ones with PLB used in the surface layers. Formaldehyde emissions from the particleboards were 0.284-0.382 mg/m²·h, and thus, below the E1 class limit required by European Standard EN 13986:2004. The major emissions of volatile organic compounds (VOCs) were carboxylic acids as oxidization and degradation products from hemicelluloses and lignin. The application of PLB in three-layer particleboards is more challenging than in single-layer boards as PLB has different effects on the core and surface layers.

Particleboard Production from Paulownia tomentosa (Thunb.) Steud. Grown in Portugal

Paulownia wood has raised high attention due to its rapid growth and fire resistance. The number of plantations in Portugal has been growing, and new exploitation methods are needed. This study intends to determine the properties of particleboards made with very young Paulownia trees from Portuguese plantations. Single layer particleboards were produced with 3-year-old Paulownia trees using different processing parameters and different board composition in order to determine the best properties for use in dry environments. The standard particleboard was produced at 180 °C and a 36.3 kg/cm² pressure for 6 min using 40 g of raw material with 10% urea-formaldehyde resin. Higher particle size lead to lower-density particleboards, while higher resin contents lead to higher density of the boards. Density has a major effect on board properties with higher densities improving mechanical properties such as bending strength, modulus of elasticity (MOE) and internal bond, lower water absorption but higher thickness swelling and thermal conductivity. Particleboards meeting the requirements for dry environment according to NP EN 312 standard, could be produced with young Paulownia wood with acceptable mechanical and thermal conductivity properties with density around 0.65 g/cm³ and a thermal conductivity of 0.115 W/mK.

Cardanol-based adhesive with reduced formaldehyde emission to produce particleboards with waste from bean crops

Free formaldehyde is a carcinogen whose emission reduction in particleboard has been studied recently to mitigate this environmental and human health problem. One alternative to reduce the emission of formaldehyde in particleboards is by using adhesives produced from natural sources. Cardanol-formaldehyde is an environmentally friendly adhesive made with cashew nut liquid, a byproduct from the cashew chain. This work aimed to produce particleboard using cardanol-formaldehyde in place of urea. In addition, different proportions of bean straw wastes were used to replace pine wood. The combination of eco-friendly adhesive and lignocellulosic waste particles could result in a product that meets market demands while being environmentally nonaggressive. Cardanol-formaldehyde promoted a higher modulus of elasticity (MOE) (1172 MPa) and modulus of rupture (MOR) (4.39 MPa) about panels glued with urea-formaldehyde, which presented a MOE of 764 MPa and MOR of 2.45 MPa. Furthermore, the cardanol-formaldehyde adhesive promoted a 93% reduction in formaldehyde emission, with a reduction from 16.76 to 1.09 mg/100 g oven-dry board for particleboards produced with cardanol-formaldehyde, indicating potential as an adhesive in the particleboard industry.

Lignocellulosic Biomass of C3 and C4 Perennial Grasses as a Valuable Feedstock for Particleboard Manufacture

Looking for new alternative raw materials is one of the key issues in line with a bioeconomy approach, particularly for particleboard manufacturing. In this framework, this paper presents a comparison of some physico-mechanical properties and the formaldehyde contents of particleboards made with 30% substitution of grass biomass from six perennial grass species. Our studies indicate relatively high values of mechanical properties for particleboards made with the addition of biomass from grasses with the C₄ photosynthetic pathway: Miscanthus x giganteus and switchgrass (Panicum virgatum). Boards made with the addition of biomass from grasses with the C₃ photosynthetic pathway-tall wheatgrass (Elymus elongatus), tall fescue (Festuca arundinacea), and perennial ryegrass (Lolium perenne)-gave lower values of mechanical properties. The opposite results were obtained in the case of the formaldehyde content: the lowest value was measured for particleboards made with the addition of tall fescue biomass (0.1% less than the control), and the highest for switchgrass (0.9% greater than the control) and cordgrass (3.2% greater than the control). Future research should address the optimization of the manufacturing process of particleboards from perennial grasses, taking into account the needs and technical possibilities of the wood industry sector.