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Possibilities for Manufacturing Eco-friendly Medium Density Fibreboards from Recycled Fibres – a Review

Authors:

Abstract

The production of medium density fibreboards (MDF) is the second largest worldwide, preceded only by the production of plywood. A major advantage of this technology is the possibility for utilization of small-sized and low quality wooden raw material. However, the increased production and the expected average life cycle of panels of about 15-20 years result in significant amounts of post-consumer wood waste. Due to the content of synthetic adhesives the panels are not suitable for energy applications. On the other hand, their recycling and re-use will reduce the consumption of wood raw material. Significant amounts of lignocellulosic waste and residues also remain in the production and recycling of paper and cardboard. This article presents a review and analysis of the current state of research in the field of recycling lignocellulosic fibres and possibilities for their use in the production of MDF panels. Different methods for recycling with and without the use of chemical reagents in terms of quantitative yield, quality of panels and production costs, are presented.
ICWST 2019
30th
PROCEEDINGS
Zagreb, 12th 13th December 2019
• Faculty of Forestry, University of Zagreb, Croaa • Biotechnical Faculty, University of Ljubljana, Slovenia
• Faculty of Forestry and Wood Sciences, Czech University of Life Sciences Prague, Czech Republic
• WoodEMA i.a. • InnovaWood
IMPLEMENTATION
OF WOOD SCIENCE
IN WOODWORKING
SECTOR
30th
Internaonal
Conference on
Wood Science
and Technology
70th
Anniversary of
Drvna industrija
Journal
ICWST • 2019 • IMPLEMENTATION OF WOOD SCIENCE IN WOODWORKING SECTOR
30th International Conference on Wood Science and Technology - ICWST 2019 “IMPLEMENTATION OF
WOOD SCIENCE IN WOODWORKING SECTOR” & 70th Anniversary of Drvna industrija Journal
18
Possibilities for Manufacturing Eco-friendly Medium Density Fibreboards
from Recycled Fibres a Review
Antov, Petar1*; Savov, Viktor1
1 Department of Mechanical Wood Technology, Faculty of Forest Industry, University of Forestry, Sofia,
Bulgaria
*Corresponding author: p.antov@ltu.bg
ABSTRACT
The production of medium density fibreboards (MDF) is the second largest worldwide, preceded only
by the production of plywood. A major advantage of this technology is the possibility for utilization of
small-sized and low quality wooden raw material. However, the increased production and the expected
average life cycle of panels of about 15-20 years result in significant amounts of post-consumer wood
waste. Due to the content of synthetic adhesives the panels are not suitable for energy applications. On
the other hand, their recycling and re-use will reduce the consumption of wood raw material.
Significant amounts of lignocellulosic waste and residues also remain in the production and recycling
of paper and cardboard. This article presents a review and analysis of the current state of research in the
field of recycling lignocellulosic fibres and possibilities for their use in the production of MDF panels.
Different methods for recycling with and without the use of chemical reagents in terms of quantitative
yield, quality of panels and production costs, are presented.
Key words: wood-based panels; wood waste, cascading use of wood; recycled fibres; MDF
1. INTRODUCTION
The transition to a circular and low-carbon economy have posed new actions and
requirements towards a greater and more sustainable use of natural resources by sustainably
increasing the primary production and conversion of waste into value-added products, enhanced
production and resource efficiency. To meet these demands actions in a variety of areas are
required, from the sustainable management of forests, to the more resource efficient use of
wood in society (Antov et al., 2018). Cascading use of wood resources, defined as “the efficient
utilisation of resources by using residues and recycled materials for material use to extend total
biomass availability within a given system” is one of the leading principles for achieving this
goal (Stevulova et al., 2016, Vis et al., 2016). The wood-based industries produce significant
amounts of waste and residues. According to Mantau (2012) 26 million tonnes of post-
consumer wood (wood products that are disposed at the end of their life cycle, e.g. wooden
furniture, window frames and wood-based panels, packaging, doors, windows, various
construction materials, etc.) was generated in Europe in 2010. Currently, recovered wood is
used for relatively low value applications including energy generation, particleboard
manufacture, animal beddings and landscape uses (Irle et al. 2019).
Following the European economic recovery, European wood-based composite production
increased by 2.8 % in 2016, to 74.7 million m3 (European Panel Federation, 2017;
UNECE/FAO, 2017). The consumption of fibreboard in Europe increased by almost 1 million
m3 in 2016. The annual consumption of medium-density fibreboard (MDF) in Europe increased
by 15 % in 2016 (Mantanis et al., 2018) as the main consumers of European MDF panels were
furniture (45 %) and laminate flooring (32 %) manufacturers (European Panel Federation,
2017). This increased production and consumption in the recent years could subsequently
generate significant quantities of waste wood-based panels at the end of their service life,
requiring recycling instead of landfilling or incineration, due to the new stricter environmental
30th International Conference on Wood Science and Technology - ICWST 2019 “IMPLEMENTATION OF
WOOD SCIENCE IN WOODWORKING SECTOR” & 70th Anniversary of Drvna industrija Journal
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legislation (Daian and Ozarska, 2009; Kim and Song, 2014). Moreover, most of the industrially
produced wood composites are made with synthetic adhesives, which are cost-effective and
perform very well regarding bonding performance, mechanical properties, thermal stability and
water resistance (Jin et al., 2010; Jivkov et al., 2013a; Jivkov et al., 2013b; Yang et al., 2015)
but have one major disadvantage, namely the free formaldehyde emissions, especially in indoor
applications. This, together with the growing environmental consciousness related to
sustainability of raw materials and end products has significantly increased the scientific
interest towards the possibilities for recycling waste wood composites. The aim of this paper is
to summarize the current state of research in the field of technologies for recycling waste and
residues from wood composites in order to obtain fibres suitable for the production of MDF.
2. METHODS OF RECYCLING WASTE WOOD PANELS AND PRODUCTION OF
MDF
Recycling used wood composites for their subsequent reuse in the production of new panels
is a complex process which involves the disintegration of wood raw material, selection of an
appropriate adhesive system and optimization of the hot press regime. Therefore, it is essential
to understand the physical and chemical properties of wood and recycled materials, as well as
the interactions between wood, recycled material, adhesive and technological conditions.
Three different principle methods can be applied for disintegration of waste wood panels:
mechanical, thermo-hydrolytic and chemical, and combinations between them (Kharazipour
and Kües, 2007; Lykidis and Grigoriou, 2008; Karade, 2010; Kim and Song, 2014; Roffael,
2002; Roffael et al., 2002; Mantanis et al., 2004; Michanickl and Boehme, 1995a; Michanicki,
1997; Moezzipour et al., 2017a; Moezzipour et al., 2017b; Athanassiadou et al., 2005).
Mechanical disintegration severely damages the structure of wood fibres and the fibres
have poor wettability with urea-formaldehyde resins and phenol-formaldehyde resins, but better
wettability with isocyanate adhesives (Roffael and Schneider, 2003, Hameed et al., 2005). In
addition, disintegration in dry conditions leads to the formation of high quantities of dust and
fine particles and partial charring of surfaces of larger pieces occurs as well (Ihnát et al., 2017).
The thermo-hydrolytic disintegration, which uses steam and pressure to cleave the existing
bonds in wood composites, glued by hydrolysable adhesives, produces better quality fibres than
those of the mechanical disintegration. It is generally performed under pressure in the
temperature range of 120180 °C (Roffael and Kraft, 2004, Kharazipour and Kües, 2007).
Reclaiming fibres from the waste wood panels and residues with a twin extruder machine
(Athanassiadou et al., 2005), or a thermo-mechanic refiner (Roffael et al., 2010) or a steam
exploder resulted in a reduction of fibre length of about 30 % less than the virgin fibres because
they may be mechanically damaged by the refining devices (Hui et al., 2014; Qi et al., 2006).
A comparison of the physical and mechanical properties of the MDF panels manufactured
with the recycled fibres and the fresh fibres showed that a substitution of 15 % of the virgin
fibres by recycling fibres had no negative effect on the physical and mechanical properties of
the panels, but the replacement of 33 % virgin fibres resulted in a significant decrease in the
physical and mechanical properties (Ju and Roh, 2017; Roffael et al., 2016). MDF
manufactured with higher amounts of recycled fibres (67 and 100 %) could not be produced
without applying the hybrid bonding technology whilst MDF made from 100 % recycled fibres
showed significantly lower thickness swelling values as well as a serious drop in the
formaldehyde release compared with boards made from virgin wood fibres (Roffael et al.,
2016). It was considered this may be due to the effect of morphologic parameters and surface
contamination of the recycled fibres with the expired urea-formaldehyde used as a primary
adhesive in the production of the MDF panels.
30th International Conference on Wood Science and Technology - ICWST 2019 “IMPLEMENTATION OF
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The effect of recycled wood fibre content on the properties of MDF were also studied by
Lubis et al. 2018. After preliminary treating of waste MDF panels, the authors used a refiner
and hammer mill to isolate recycled fibres from two softwood tree species. Recycled MDF
panels were fabricated using the obtained refiner and hammer mill recycled fibres at quantities
of 0, 5, 10, 20, 30, 50, and 100 %. The highest internal bond strength of the recycled MDF was
determined at 10 % recycled fibre content, regardless of isolation method and wood species.
The mechanical properties, including modulus of rupture, modulus of elasticity, and screw
withdrawal resistance showed behaviors similar to the internal bond strength with increasing
the content of recycled fibres. However, the thickness swelling, water absorption, and
formaldehyde emission of the new MDF decreased with increasing recycled fibre content. As
a result of the performed statistical analysis it was determined that the minimum of 10 %
recycled fibres can be used to replace virgin fibres without deteriorating the MDF properties.
The improved properties of recycled MDF panels were attributed to the reinforcing effects of
recycled fibres covered with cured resins.
According to a study, conducted by Hwang et al. 2005, replacing virgin fibres with
recycled fibres adversely affected physical and mechanical properties of fibreboard. Bending
properties and dimensional stability were linearly dependent on virgin fibre ratios. All panels
with recycled fibre content above 40 % failed to meet any commercial requirement.
Another study investigated the effects of the addition of recycled fibres obtained from
surface laminated MDF panels with three different materials to the properties of three-layer
recycled MDF (Hong et al., 2018). Three types of surface laminates (low-pressure laminate,
polyethylene terephthalate, and polyester coating) were hammer milled, and then went through
a patent-pending fibre recovery system to obtain the recycled fibres that were added to the core
layer of the new recycled MDF at three contents (10, 20 and 30 %), blended with 12 % urea-
formaldehyde resin to hot-pressing. The best internal bond strength, modulus of rupture and
modulus of elasticity of the new recycled MDF panels were obtained at 20 % recycled fibre
content. The authors reported that increasing the recycled fibre content resulted in reduced
thickness swelling, water absorption, and formaldehyde emission.
Moezzipour et al., 2018 studied the performance of the electrical method in MDF wastes
recycling. To determine the practical aspect of the electrical method, the hydrothermal method
as a known recycling method was also studied. Recycled fibres were analyzed by determination
of the chemical composition of fibre and fibre classification. The results showed that some
changes in the chemical composition of recycled fibres occurred in comparison with the virgin
fibres, especially for the hydrothermal method where lignin content was significantly reduced.
Fibre classification test showed significant reduction in the length of the fibres recycled by
hydrothermal method as compared to other fibres. Investigations of the quality of manufactured
MDF boards showed that the electrical method performed better in comparison with the
hydrothermal method.
The pulp and paper industry generates large quantities of waste lignocellulosic materials
which can be recycled and used for fabrication of MDF panels. Pulp and paper sludge can be
recycled in the manufacture of MDF panels because it contains wood fibres. A comparative
research studied the properties of MDF made from virgin fibres mixed with different pulp and
paper sludge sources (Migneault et al., 2010). The investigated factors were mill pulping
processes, thermal-mechanical pulping, chemical-thermal-mechanical pulping, and kraft
pulping, and percentage of sludge mixed with virgin fibres (0, 25, 50, and 75 %). According to
the reported results the properties of MDF panels decreased mostly linearly with sludge content.
Panel properties negatively correlated with the proportion of non-fibrous material such as ash
and extractives. It was concluded that the amount of sludge that can be incorporated into MDF
without excessive decrease in panel quality depends on the pulping process. At 25 % sludge
content, all panels met the quality requirements for MDF used for interior applications.
30th International Conference on Wood Science and Technology - ICWST 2019 “IMPLEMENTATION OF
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Antov et al. (2019) studied the possibilities for utilization of low quality lignocellulosic
paper mill waste, which had undergone only mechanical recycling, in the production of
insulation boards with and without surface layer, using a technology, similar to the production
of dry-process fibreboards. Several design variants of insulation boards with recycled
lignocellulosic fibres were developed and manufactured in laboratory conditions. The main
mechanical properties were determined in order to analyze the possibilities of application of the
boards. It was determined that the experimental boards had very good water resistance and
sound insulation properties. As a typical porous material the boards had better sound insulation
properties at higher sound frequencies. However, the low bending strength values represent an
impediment for standalone application of the boards which can be overcome by surface
treatment with phenol formaldehyde resin or inclusion of a secondary material such as paper or
veneer.
Nourbakhsh et al. (2010), investigated the use of old newsprint fibres as a raw material for
laboratory MDF panels. The authors determined the effect of old newsprint fibres mixed with
virgin aspen fibres and the press time (3, 4, and 5 min) on the properties of MDF panels. Panels
were produced using aspen fibres in surface layer and combination of aspen fibres and old
newsprint fibres in the core layer. The authors concluded that old newsprint can be considered
as a potentially suitable raw material for manufacturing MDF panels without having any
significant adverse influence on the panel exploitation properties.
Recycled fibres still contain cured resin residues and exhibit high formaldehyde emissions
in recycled MDF panels (Roffael et al., 2016). A research, carried out by Lubis et al. 2018
studied the removal of cured urea-formaldehyde resins from MDF panels by hydrolysis, finding
that almost 75 % of cured resins were removed from MDF after acid hydrolysis, 50 % after
neutral hydrolysis, and 25 % after alkaline hydrolysis. This indicates that 2575 % cured urea-
formaldehyde resins remain in the recycled fibres, depending on hydrolysis conditions.
Grigsby et al. (2014a) investigated the levels of cured urea-formaldehyde resins in MDF
panels by water extraction. The authors reported a significant difference in water extractable
resin components between cured pure resin and that from MDF panels.
The mechanical properties of MDF panels depend on the properties of the wood fibres
(Ganz et al., 2006; Lee et al., 2006), fibre orientation or mat structure (Sliseris et al., 2017), the
adhesive system (Grigoriou, 2000), quantity and distribution of adhesives on fibre surface
(Doosthoseini et al., 2010) as well as hot-pressing technological parameters (Gul et al., 2017).
The fibre length and its distribution are related with fibre bulk density, affecting the
construction of internal mat structure of MDF (Lu et al., 2007; Townshend et al., 2015), and
all mechanical properties could be improved by increasing fibre length (Benthien et al., 2017).
In addition, the morphological and chemical characteristics of the fibres are also major factors
affecting the properties of MDF panels (Grigsby and Thumm, 2004; Roffael et al., 2010).
3. CONCLUSIONS
The technical possibilities to utilize different wood panel waste and residues in new
products determine the physical boundary conditions for cascading use of wood resources.
Despite the presented different methods and technologies for recycling waste wood-based
composites and their reuse in the production of MDF panels, there are still many difficulties
and drawbacks for their wide application at an industrial scale. These technical barriers should
be addressed by future research and development activities aiming to further develop recycling
in wood panel industry, including extensive research on solutions for closing the material loop.
Strong efforts are also needed to address the recent imbalance between material and energy uses
of industrial residues, where more significant potential for wood cascading exists.
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Acknowledgements: This research was supported by the project No. НИС-Б-1002/03.2019
‘Exploitation Properties and Possibilities for Utilization of Eco-friendly Bio-composite Materials’,
implemented at the University of Forestry, Sofia, Bulgaria.
Conflicts of Interest: The authors declare no conflict of interest regarding the publication of this
paper.
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... Regarding the current excessive dependence of the construction and production industry on hydrocarbon-containing materials occurring within Earth's crust; taking into account the abundance of waste and industrial by-products, it is necessary to make greater use of the advantages of biomaterials with a low carbon footprint [145][146][147][148][149][150][151][152]. The following conclusions can be drawn from the reviewed content presented: The challenge of unconventional materials is the technique of fastening elements [143,144]. ...
... Regarding the current excessive dependence of the construction and production industry on hydrocarbon-containing materials occurring within Earth's crust; taking into account the abundance of waste and industrial by-products, it is necessary to make greater use of the advantages of biomaterials with a low carbon footprint [145][146][147][148][149][150][151][152]. The following conclusions can be drawn from the reviewed content presented: ...
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Mycelium-based composites (MBCs) have attracted growing attention due to their role in the development of eco-design methods. We concurrently analysed scientific publications, patent documents, and results of our own feasibility studies to identify the current design issues and technologies used. A literature inquiry in scientific and patent databases (WoS, Scopus, The Lens, Google Patents) pointed to 92 scientific publications and 212 patent documents. As a part of our own technological experiments, we have created several prototype products used in architectural interior design. Following the synthesis, these sources of knowledge can be concluded: 1. MBCs are inexpensive in production, ecological, and offer a high artistic value. Their weaknesses are insufficient load capacity, unfavourable water affinity, and unknown reliability. 2. The scientific literature shows that the material parameters of MBCs can be adjusted to certain needs, but there are almost infinite combinations: properties of the input biomaterials, characteristics of the fungi species, and possible parameters during the growth and subsequent processing of the MBCs. 3. The patent documents show the need for development: an effective method to increase the density and the search for technologies to obtain a more homogeneous internal structure of the composite material. 4. Our own experiments with the production of various everyday objects indicate that some disadvantages of MBCs can be considered advantages. Such an unexpected advantage is the interesting surface texture resulting from the natural inhomogeneity of the internal structure of MBCs, which can be controlled to some extent.
... A solution to this problem should be sought by optimizing the use of the available natural resources, searching for alternative lignocellulosic raw materials, and promoting the more effective reuse, recycling, and upcycling of wood and wood-based materials [2][3][4][5]. The increased use of recycled wood and woodbased composite materials in a variety of end uses is a viable approach to supporting the woodworking and furniture industries' ongoing green transition to a circular and biobased economy, reducing their reliance on petroleum-derived products and lowering the industrial carbon footprint [6,7]. ...
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Unlike the recycling of particleboards, the recycling of medium-density fiberboards (MDF) is not a widespread industrial practice, and currently, most waste MDF panels are landfilled or incinerated after the end of their life cycle. Therefore, it is of great importance to develop cost-effective methods for MDF recycling. The extraction of resins used for bonding the panels, mostly urea–formaldehyde (UF) resins, is carried out mainly with hydrolysis. Hydrothermal hydrolysis is a more environmentally friendly and cheaper recycling technique compared to acid hydrolysis and allows obtaining a high yield of recycled fibers. The aim of this research work was to investigate and evaluate the effect of hydrolysis regime applied on its efficiency and on the properties of the recycled MDF fibers. For this purpose, thermal hydrolysis was carried out in an autoclave with saturated steam as a heat carrier. The main novelty of the research is the preliminary preparation of the recyclable MDF in samples with dimensions close to those of pulp chips. The effect of hydrolysis regime characteristics, i.e., process time and temperature on the properties of recycled MDF wood fibers, was studied. The hydrolysis temperatures used were 121 °C (saturated steam pressure of 0.2 MPa) and 134 °C (saturated steam pressure of 0.3 MPa); for each temperature, three durations were applied—30, 45, and 60 min. After hydrolysis, the resulting fiber fraction was refined using a hammer mill. The fractional and elemental composition of the recycled fibers obtained were evaluated. The hemicellulose content after each hydrolysis treatment was also determined. The chemical oxygen demand (COD) was defined as an indicator of wastewater contamination and as an indirect indicator of the quantitative yield of the process. The results revealed no significant changes in the elemental composition of the recycled fibers, and the hydrolysis regimes used showed no decrease in pentosan content. The recycled MDF fibers exhibited similar fiber morphology and fractional composition, being shorter than fibers from industrial pulp. The increased temperature and time of hydrolysis resulted in a significant increase in COD values. Based on the obtained results, with a view to the slightest contamination of wastewater (as determined by COD), the most promising hydrolysis regime was at a temperature of 121 °C and a time of 30 min. It should be emphasized that for a confirmation of this statement, the properties of MDF panels fabricated with fibers recycled in different regimes should be subsequently investigated.
... This huge amount of oil palm trunk biomass could serve as an alternative lignocellulosic feedstock for the wood-based industries that are facing constantly increasing demand for natural wood resources. This cascading use of wood waste and by-products, together with the optimization of the manufacturing processes, represent key bioeconomy principles [5][6][7][8]. ...
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Due to its inferior properties, oil palm wood (OPW) extracted from the inner layer of the oil palm (Elaeis guineensis) trunk, referred as inner OPW in this study, is frequently regarded as a waste. Phenolic resin treatment and lamination of inner OPW with other hardwoods may be an excellent way to improve the properties of the inner OPW. In this study, inner OPW were treated with two different concentrations (15% and 20%) of low molecular weight phenol formaldehyde resin (LmwPF) and compressed at different compression ratios (10%, 20%, and 30%). The physical and mechanical properties of the modified inner OPW's were evaluated according to British Standards (BS) 373: 1957. The results revealed that inner OPW treated with the highest compression ratio (30%) and resin concentration (20%) exhibited the highest weight percent gain, polymer retention and density. In the following phase of the research, the treated inner OPW was used as the core layer in the fabrication of a three-layer laminated compreg hybrid composites, with untreated and treated sesenduk (Endospermum diadenum) wood serving as the face and back layers. The compression ratios of 10% and 20% and resin concentrations of 10% and 20% were used in this phase of study as laminated boards made with 30% compression ratio failed. The findings showed that resin concentration had a significant impact on both the inner OPW and the laminated compreg hybrid panels. Markedly, higher resin concentrations (20%) resulted in improved physical properties, i.e., thickness swelling and water absorption, as well as enhanced mechanical properties (modulus of rupture and modulus of elasticity). Although compression ratios had no significant effect on the properties of the laminated products, those compressed at higher compression ratios (20%) performed slightly better than the panels compressed at lower compression ratios (10%).
... In this study, a 4-parameter symmetric sigmoidal model was used to generate a curve so that the average lifespan of all MDF products was 14 years. Therefore, introducing sustainable production practices to recycle MDF would lead to the preservation of valuable wood raw materials (Lykidis, C and Grigoriou, A. 2008;Kim, M.H. andSong H.B. 2014, Antov, P. andSavov, V. 2019). Due to synthetic binders, MDF is prohibited from incineration in the EU, and individual efforts are made to prevent this type of waste from being disposed of in general landfills. ...
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Production of Medium Density Fibreboards (MDF) is one of the growing woodworking industries. It has been found that a quarter of the produced MDFs have a life cycle of up to five years, and by ten years, this amount has increased to fifty percent. There is no established industrial practice for recycling that type of waste. That, together with the fact that some countries have banned dumping these panels in landfills, poses significant challenges. There are currently two main research directions on MDF recycling, namely, with and without pre-treatment. In both cases, a deterioration in the properties of the panels is observed with an increase in the content of recycled fibres. Still, the share of cut fibres and formaldehyde emissions from the boards are reduced during the preliminary treatment, mainly by hydrolysis. In the present manuscript, a review and analysis of MDF recycling methods are performed. On that basis, conclusions and recommendations are derived.
... Compared to the new bio-based materials, wood-based materials bonded with traditional adhesives are still very extensively used by companies around the world. Most of these materials such as particleboard [13], plywood [14], medium density fiberboard [15], and oriented strand board [16] are prepared by gluing wood components with petroleum-derived adhesives. Urea-formaldehyde, melamineformaldehyde, and phenol-formaldehyde resins are examples of such adhesives [17][18][19][20]. ...
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... The reuse of the separated waste MDF fibers in production of new MDF is the most apparent possible recycling pathway. However, due to a combination of effects such as fiber shortening, changes in the chemical compositions of the fibers and resin residues found on their surface, a deterioration of the mechanical properties in comparison with MDF made from fresh wood can be observed when using hydrothermal or steam-based fractionation processes [19][20][21][22][23][24]. Recently, Moezzipour et al. [25] have reported that such negative effects on the fibers can be reduced using electrical heating instead of hydrothermal treatments, leading to improved mechanical properties of the newly produced MDF. ...
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In this study, different methods, including acid hydrolysis (phosphoric and formic acid), thermo-hydrolysis, and microwave methods were tested for recycling of fiberboards made of 100 % beech and 70 % beech + 30 % pine wood fibers, which are widely sold in the market. The impacts of the using methods on the fibers were investigated with the help of a device that determines the fiber dimensions according to optical principles. In a laboratory setting, test boards were constructed using recycled fibers, and the changes in certain physical and mechanical qualities were studied. As a result, it was determined that recycled fibers obtained from microwave and thermo-hydrolysis fibers could be effectively used in fiberboard production. However, the proportion of fibers, longer than 1.24 mm, was decreased by about 30 % with the phosphoric acid method for MDF samples composed of 100 % beech fiber. The fiberboards could not be obtained from fibers recycled through acid hydrolysis except for phosphoric acid method with 100 % beech fibers.
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The large global production quantity of medium-density fiberboard (MDF) creates equal quantities of waste MDF, which consequently requires research on the recycling of MDF. This work was conducted to study the effect of recycled fiber (RF) content on the recycling properties of MDF. After pretreating waste MDF, a refiner and hammer were used to isolate refiner RFs (RRFs) and hammer mill RFs (HRFs) from two softwood species. This work also characterized the physical, chemical, and morphological features of RFs and virgin fibers (VFs). RRF and HRF contents of 0, 5, 10, 20, 30, 50, and 100% were used to fabricate recycled MDF (rMDF) panels. All RFs had shorter fiber lengths and higher fines contents than VFs had. The presence of N from urea–formaldehyde resins was confirmed by multiple analyses; more N was distributed in RFs than in VFs. The highest internal bonding (IB) strength of the rMDF occurred at 10% RF, regardless of isolation method and wood species; IB strength decreased afterward. The mechanical properties, including modulus of rupture, modulus of elasticity, and screw withdrawal resistance of rMDF, showed behaviors similar to the IB strength with increasing RF content. However, the thickness swelling, water absorption, and formaldehyde emission of rMDF samples decreased with increasing RF content. Statistical analysis indicates that the minimum of 10% RFs can be used to replace VFs without diminishing the properties of rMDF. The improved properties of rMDF were ascribed to the reinforcing effects of RFs covered with cured resins.
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In this work, the adhesive systems used today in the European industries of particleboard, medium density fibreboard (MDF), and oriented strand board (OSB) are discussed. The structure of particleboard, MDF and OSB markets in Europe in relation to the types of adhesives and product specifications are presented as well. It is noticeable that new markets for wood-based panels like particleboard and fibreboard, known as non-furniture markets, are growing in Europe at a fast rate. It was concluded that most of the technological changes concerning the adhesive systems applied and additives have been realised from the need for niche panel products, the obligation to reach even lower formaldehyde emissions, and the necessity to decrease production costs due to the stringent competition in the market of wood-based panels
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The article describes a method of preparing particles from waste particle boards (chipboards) and oriented strand boards (OSBs). Their reuse is the main target of recycling. Method of their destruction was determined in this work. Agglomerated materials disintegrated after an initial destruction were further processed under specified conditions with regard to the material humidity, type of materials, contained adhesives and given characteristics of final particles-wood chips. Wood particles obtained were characterized by a fractional composition and amount of residual formaldehyde as an important parameter for the reuse of waste materials in production of furniture boards. New chipboards and pulp for production of middle density fiberboards (MDFs) will be provided from such defined particles.
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High global production of medium-density fiberboard (MDF) in recent years could generate an equal quantity of waste MDF at the end of its service life, requiring recycling of waste MDF instead of landfilling or incineration. This study investigated effects of the addition of recycled fiber (RF) obtained from surface laminated MDFs with three different materials to the properties of three-layer recycled MDF (rMDF). Three types of surface laminates such as low-pressure laminate, polyethylene terephthalate, and polyester coating were hammer milled, and then went through a patent-pending fiber recovery system to obtain the resultant RFs that were added to the core layer of rMDF. These RFs at three contents (10, 20, and 30%) were blended with 12% of urea-formaldehyde (UF) resin prior to hot-pressing. Statistical analysis showed that the best internal bonding strength, modulus of rupture, and modulus of elasticity of rMDF panels were obtained for LPL-rMDF with a 20% RF content. Thickness swelling, water absorption, and formaldehyde emission of rMDF were reduced by increasing the RF content. These findings suggest that a minimum RF content of 20% can be replaced with virgin fibers for the rMDF manufacture, indicating the feasibility of recycling waste laminated MDF into three-layer rMDF. ARTICLE HISTORY
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Wood recycling is common practice in most countries. Currently, recovered wood is used for relatively low value uses including energy generation, particleboard manufacture, animal beddings and landscape uses. This paper gives an overview of two research projects that aim to generate high-value products from recovered wood and thereby encourage even higher rates of wood recycling. One project is concerned with the extraction of nano-crystalline cellulose from waste MDF and the other produces laminated beams from recovered wood.
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Annually, a large volume of medium density fiber board (MDF) wastes are generated which consists of used furniture and other constructed items, the parts obtained from trimming and edge cutting of boards in MDF producer factories and cutting of boards during conversion processes. In this study, changes in the chemical properties of wood fibers after hydrothermal recycling of MDF wastes as an important aspect of recycling process which may be effective on quality of recycled MDF boards was investigated. Hydrothermal recycling was done at 3 different temperature (105, 125 and 150 °C) in which subsequently defibrillation step was performed. Recycled fibers were analyzed by determination of chemical composition of fibers, pH value and possible existence of UF resin residues on the surface of recycled fibers. Gel time of UF resin in the mixture of fibers was measured. Additionally, laboratory MDF boards with dimension of 35 × 35 × 12 mm and density of 0.7 g/cm³ were manufactured. Practical properties of MDF boards were studied according to EN standard. Significant quality fall off was observed in recycled MDF boards as compared to original ones. Also, the results showed that some chemical changes were occurred in fibers after recycling process which may be effective on properties of new (recycled) MDF boards. FT-IR results confirmed the presence of UF resin residues on the surface of recycled fibers which considered as reason for deterioration in properties of recycled MDF boards. Also, the results obtained from gel time measurements confirmed the negative effect of recycled fibers on the curing of UF resin.
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This research was performed to use recycling wood fiber from waste MDF as raw materials for manufacturing of interior decorative accessories. Virgin fiber of Pinus rigida for manufacturing MDF and recycling fiber from manufactured MDF with virgin fiber were dyed by using reactive dyes (Bis-monochlorotriazine and Vinyl sulfone type), vat dyes (Anthraquinone type), direct dyes (Diazo type) such as red, yellow and blue, and natural dyes using gardenia or sappan wood, and they were examined to evaluate their dyeing properties and sunlight fastness. The hue of virgin fiber and recycling fiber were 4.2YR, and 4.4YR, respectively, which showed red-yellowish color. The recycling fiber looked a little darker than the virgin fiber, where L∗ values of the recycling fiber showed a little lower. Reactive, vat and direct dyes dyed well both the virgin and recycling fibers. The recycling fiber showed a little higher values of colour yield and a little lower in L∗, but it seemed that there was no significant difference. The Hue values of the recycling fiber and the virgin fiber dyed with sappan wood were 4.4YR and 4.0YR, showing no difference between/after dyeing. However the Hue values of the recycling fiber and the virgin fiber dyed with gardenia were 7.4YR and 6.9YR, respectively. Those values were much higher than the values of the fibers dyed with other chemical dyes. But the fibers dyed with gardenia showed poor sunlight fastness. © 2017, Korean Society of Wood Science Technology. All rights reserved.
Article
This study focused on the removal of cured urea–formaldehyde (UF) resins by hydrolysis of medium-density fiberboard (MDF) at different temperatures and times for MDF recycling. Five aqueous solutions, i.e., two acids, two alkalis, and water, were used for MDF hydrolysis to obtain extract solutions and solid residues for the analysis of mass balance, nitrogen content, and resin removal. As expected, acidic solutions removed the greatest amount of cured resins, followed by water and alkaline. Moreover, temperature had a greater impact on hydrolysis than time. Fourier transform infrared spectra of MDF fibers before and after hydrolysis clearly showed the change in intensity of the amide group in UF resins. Reduction of the amide group was greater with increase in hydrolysis temperature than in time. Statistical analysis results suggested that the hydrolysis of MDF at 80°C for 2 h using oxalic acid solution was optimum condition for the removal of cured UF resins. However, water could be used as hydrolysis agent for the practice of MDF hydrolysis in the future.