COST Young Researchers' Forum at the FTP-c8 Conference, 12 March 2013, Barcelona, Spain RECYCLING OF WOOD BASED COMPOSITES USING MILD HYDROTHERMAL TREATMENTS Dr. CHARALAMPOS LYKIDIS Researcher Hellenic Agricultural Organization "Demeter" Institute of Mediterranean Forest Ecosystems and Forest Products Technology Laboratory of Wood Anatomy and Technology Greek General Secretariat For Research & Technology Association of Local Authorities of the Prefecture of Thessaloniki Aristotle University of Thessaloniki 1. INTRODUCTION The problem LOSS OF FORESTS INCREASE OF WOOD DEMAND/PRICE INCREASE OF WOOD WASTE World population and cumulative deforestation, 1800 to 2010 (FAO, 2012) Region 1000 ha/year % 1990-2000 2000-2010 1990-2000 2000-2010 Europe +877 +676 +0,09 +0,07 Asia -595 +2235-0,10 +0,39 Africa -4067-3414 -0,56-0,49 North & Central America -289-10 -0,04 0,00 South America -4213-3997 -0,45-0,45 Oceania -41-700 -0,02-0,36 World -8327-5211 -0,20-0,13 Annual change in forest area by region (FAO, 2010)
1. INTRODUCTION The problem LOSS OF FORESTS INCREASE OF WOOD DEMAND/PRICE INCREASE OF WOOD WASTE Trend of wood price (EPF, 2006) 1. INTRODUCTION The problem LOSS OF FORESTS INCREASE OF WOOD DEMAND/PRICE INCREASE OF WOOD WASTE Million tonnes/year 37 36 35 34 33 32 31 30 222 220 218 216 214 212 210 208 206 Million tonnes/year 29 2004 2006 2008 2010 204 Recyclable wastes Total Waste Waste generated by households (Eurostat, 2013)
1. INTRODUCTION 5% 4% 3% 29% 26% Hardboard Insulating Board MDF Particle Board Plywood Veneer Sheets 33% Global production share of wood based panels for 2011 (FAOSTAT, 2013) 1. INTRODUCTION 5% 4% 3% 29% 59% 26% Hardboard Insulating Board MDF Particle Board Plywood Veneer Sheets 33% Mainly UF bonded boards Global production of wood based panels (WBP) (FAOSTAT, 2008)
1. INTRODUCTION MANAGEMENT OF WBP WASTE Leaching and emissions of pollutants LandFilling Reuse Composting, substrates etc Uncontrollable burning of waste Fuel RECYCLING Pollution of underground and surface water 1. INTRODUCTION MANAGEMENT OF WBP WASTE Leaching and emissions of pollutants LandFilling Reuse Composting, substrates etc Uncontrollable burning of waste Fuel RECYCLING Pollution of underground and surface water
1. INTRODUCTION MANAGEMENT OF WBP WASTE Emission of polutants LandFilling Reuse Composting, substrates etc Fuel RECYCLING Pollution of underground and surface water Uncontrollable burning of waste Reduction of CO2 emissions Protection of forests Reduction of waste 1. INTRODUCTION MANAGEMENT OF WBP WASTE Emission of polutants LandFilling Reuse Composting, substrates etc Fuel RECYCLING 1970 SANDBERG Pollution of underground and surface water Uncontrollable burning of waste PFLEIDERER HESCH Crushing 2001 W.K.I. ROFFAEL FIBRESOLVE Use of hydrothermal treatments
2. AIM Investigation of : The potential for recovery of wood by used particleboards and MDF using mild hydrothermal treatments (up to 150 C) The utilization of recovered coatings, particles and fibers in the production of recycled boards 3. MATERIALS AND METHODS SAMPLING OF OLD FURNITURE SEPARATION OF INORGANIC MATERIALS hinges, handles etc boards 800Kg sample
3. MATERIALS AND METHODS SAMPLING OF OLD FURNITURE SEPARATION OF INORGANIC MATERIALS hinges, handles etc boards 800Kg sample Cut to 50x50mm specimens 3. MATERIALS AND METHODS PARTICLEBOARD SAMPLE COMPOSITION Veneer coated (36%) Melamine coated (42%) Not coated (22%)
3. MATERIALS AND METHODS HYDROTHERMAL RECOVERY APPARATUS 3. MATERIALS AND METHODS RECOVERY OF WOOD PARTICLES PRIOR TO RECOVERY TREATMENT AFTER RECOVERY TREATMENT
3. MATERIALS AND METHODS Particleboards RECOVERED MATERIALS particles >1,5mm particles <1,5mm coatings MDF MDF (prior to treatment) MDF (After treatment) Recovered Fibers 3. MATERIALS AND METHODS 3 Research phases 1. Preliminary investigation - effect of the hydrothermal recovery parameters on the quality of recovered wood 2. Determination of optimal recovery parameters (Lykidis and Grigoriou, 2011) 3. Laboratory production of recycled boards using recovered materials (wood and coatings) Η εφαρµογή των βέλτιστων συνθηκών για την ανάκτηση υλικών από χρησιµοποιηµένες (παλιές) ξυλοπλάκες και η χρήση των ανακτηµένων υλικών στην παραγωγή νέων (ανακυκλωµένων) µοριοπλακών σε µίξεις µε βιοµηχανικά (φρέσκα) ξυλοτεµαχίδια. Η µελέτη της επίδρασης της διαδικασίας ανάκτησης στα χαρακτηριστικά και τις ιδιότητες των ανακτηθέντων υλικών και των παραγοµένων από αυτά µοριοπλακών Ο προσδιορισµός της επίδρασης της ποσοστιαίας συµµετοχής των ανακτηµένων από παλιές ξυλοπλάκες υλικών σε συνδυασµό µε ξυλοτεµαχίδια βιοµηχανίας στην ποιότητα των ανακυκλωµένων µοριοπλακών. Η διερεύνηση της επικινδυνότητας των αποβλήτων που προκύπτουν από τη διαδικασία της ανάκτησης. 18
3. MATERIALS AND METHODS 3 Research phases 1. Preliminary investigation - effect of the hydrothermal recovery parameters on the quality of recovered wood 2. Determination of optimal recovery parameters (Lykidis and Grigoriou, 2011) 3. Laboratory production of recycled boards using recovered materials (wood and coatings) Η εφαρµογή των βέλτιστων συνθηκών για την ανάκτηση υλικών από χρησιµοποιηµένες (παλιές) ξυλοπλάκες και η χρήση των ανακτηµένων υλικών στην παραγωγή νέων (ανακυκλωµένων) µοριοπλακών σε µίξεις µε βιοµηχανικά (φρέσκα) ξυλοτεµαχίδια. Η µελέτη της επίδρασης της διαδικασίας ανάκτησης στα χαρακτηριστικά και τις ιδιότητες των ανακτηθέντων υλικών και των παραγοµένων από αυτά µοριοπλακών Ο προσδιορισµός της επίδρασης της ποσοστιαίας συµµετοχής των ανακτηµένων από παλιές ξυλοπλάκες υλικών σε συνδυασµό µε ξυλοτεµαχίδια βιοµηχανίας στην ποιότητα των ανακυκλωµένων µοριοπλακών. Η διερεύνηση της επικινδυνότητας των αποβλήτων που προκύπτουν από τη διαδικασία της ανάκτησης. 19 3. MATERIALS AND METHODS 3 Research phases 1. Preliminary investigation - effect of the hydrothermal recovery parameters on the quality of recovered wood 2. Determination of optimal recovery parameters (Lykidis and Grigoriou, 2011) A/A WATER UPTAKE/TEMPERATURE/DURATION 3. Laboratory production of recycled boards using recovered materials (wood and coatings) Η εφαρµογή 1 των βέλτιστων συνθηκών 30%/ για 150 C/ την ανάκτηση 20min υλικών από χρησιµοποιηµένες (παλιές) ξυλοπλάκες και η χρήση των ανακτηµένων υλικών στην παραγωγή 2 νέων (ανακυκλωµένων) 45%/ µοριοπλακών 110 C/ 75min σε µίξεις µε βιοµηχανικά (φρέσκα) ξυλοτεµαχίδια. Η µελέτη 3 της επίδρασης της διαδικασίας 45%/ ανάκτησης 130 C/ 20min στα χαρακτηριστικά και τις ιδιότητες των ανακτηθέντων υλικών και των παραγοµένων από αυτά µοριοπλακών 4 45%/ 150 C/ 10min Ο προσδιορισµός της επίδρασης της ποσοστιαίας συµµετοχής των ανακτηµένων από παλιές ξυλοπλάκες υλικών σε συνδυασµό µε ξυλοτεµαχίδια βιοµηχανίας στην ποιότητα 5 των ανακυκλωµένων µοριοπλακών. 60%/ 110 C/ 30min Η διερεύνηση της επικινδυνότητας των αποβλήτων που προκύπτουν από τη διαδικασία 6 της ανάκτησης. 60%/ 130 C/ 10min 7 60%/ 150 C/ 8min 20
3. MATERIALS AND METHODS 3 Research phases 1. Preliminary investigation - effect of the hydrothermal recovery parameters on the quality of recovered wood 2. Determination of optimal recovery parameters (Lykidis and Grigoriou, 2011) 3. Laboratory production of recycled boards using recovered materials (wood and coatings) Mixtures of recovered and fresh wood. Subsequent recycling processes Effect on board main properties Use of recovered coatings in the CL Use of recovered fibers in the SL 3. MATERIALS AND METHODS TYPES OF PRODUCED LABORATORY BOARDS Fresh : Recovered particles ratios Ratios of recovered fibers in surface layers 0:100 25:75 50:50 65:35 75:25 100:0 0% 10% 15% 100 75 50 35 25 0 100 Ι10 Ι15 Use of recovered coatings in the core layer Boards with recovered coatings in Core Layer 100% 75% 50% 100 75 50 0% Boards without recovered coatings 100% 75% 50% 0 100Χ 75Χ 50Χ
3. MATERIALS AND METHODS Determined properties of recovered wood ph (Sandermann - Rothkamm, 1959) Chemical composition Ash (ASTM D1102-84) Holocellulose (Wise et al. 1946, Seifert 1960, Fengel and Wegener 1976) Extractives Ethanol - toluene(astm D1107-96) Dichloromethane(ASTM D1108-96) Total extractives (ASTM D1105-96) Klason lignin (ASTM D1106-96) Determined properties of recycled boards Density (ΕΝ 323:1993) Mechanical properties Internal bond ΕΝ 319/1993) Surface soundness (ΕΝ 311:1992) MOR (ΕΝ 310:1993) MOE (ΕΝ 310:1993) Hygroscopic properties Water absorption 24h immersion (ΕΝ 317:1993) Thickness swelling after 24h immersion (ΕΝ 317:1993) Other properties Formaldehyde content (ΕΝ 120:1992) Color changes (CIE Lab) Statistical analysis (ANOVA) 4. RESULTS Wood properties Components and acidity of recovered wood 24
4. RESULTS - Board properties INFLUENCE OF RECOVERED MATERIAL PERCENTAGE ON THE MECHANICAL PROPERTIES OF THE BOARDS 4. RESULTS - Board properties INFLUENCE OF RECOVERED MATERIAL PERCENTAGE ON THE MECHANICAL PROPERTIES OF THE BOARDS Not significant differences (α=0,05)
4. RESULTS - Board properties INFLUENCE OF RECOVERED MATERIAL PERCENTAGE ON THE MECHANICAL PROPERTIES OF THE BOARDS >35% recovered material Significant IB degradation >75% recovered material Significant SS degradation Significant Improvement 4. RESULTS - Board properties INFLUENCE OF RECOVERED MATERIAL PERCENTAGE ON THE HYGROSCOPIC PROPERTIES OF THE BOARDS
4. RESULTS - Board properties INFLUENCE OF RECOVERED MATERIAL PERCENTAGE ON THE HYGROSCOPIC PROPERTIES OF THE BOARDS More recovered material better hygroscopic properties!! 4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE OF RECOVERED ΜΟΡΙΟΠΛΑΚΩΝ FIBERS PERCENTAGE ON THE MECHANICAL PROPERTIES OF THE BOARDS
4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE OF RECOVERED ΜΟΡΙΟΠΛΑΚΩΝ FIBERS PERCENTAGE ON THE MECHANICAL PROPERTIES OF THE BOARDS Not significant differences (α=0,05) 4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE OF RECOVERED ΜΟΡΙΟΠΛΑΚΩΝ FIBERS PERCENTAGE ON THE HYGROSCOPIC PROPERTIES OF THE BOARDS
4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE OF RECOVERED ΜΟΡΙΟΠΛΑΚΩΝ FIBERS PERCENTAGE ON THE HYGROSCOPIC PROPERTIES OF THE BOARDS Significant deterioration Significant deterioration 4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE ΜΟΡΙΟΠΛΑΚΩΝ OF RECOVERED COATINGS ON THE MECHANICAL PROPERTIES OF THE BOARDS 34
4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE ΜΟΡΙΟΠΛΑΚΩΝ OF RECOVERED COATINGS ON THE MECHANICAL PROPERTIES OF THE BOARDS Not significant IB deterioration when using up to 50% recovered material without coatings 35 4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE ΜΟΡΙΟΠΛΑΚΩΝ OF RECOVERED COATINGS ON THE HYGROSCOPIC PROPERTIES OF THE BOARDS
4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ INFLUENCE ΜΟΡΙΟΠΛΑΚΩΝ OF RECOVERED COATINGS ON THE HYGROSCOPIC PROPERTIES OF THE BOARDS (Not significant differences =0,05) significant differences =0,05) 4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ ΜΟΡΙΟΠΛΑΚΩΝ FORMALDEHYDE CONTENT OF BOARDS
4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ ΜΟΡΙΟΠΛΑΚΩΝ FORMALDEHYDE CONTENT OF BOARDS More recovered material less free formaldehyde!! 4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ ΜΟΡΙΟΠΛΑΚΩΝ FORMALDEHYDE CONTENT OF BOARDS More recovery repeats less free formaldehyde!!
4. RESULTS - Board properties Ι ΙΟΤΗΤΕΣ ΑΝΑΚΥΚΛΩΜΕΝΩΝ ΜΟΡΙΟΠΛΑΚΩΝ FORMALDEHYDE CONTENT OF BOARDS Use of coatings no difference 4. RESULTS - Board properties TOTAL COLOR CHANGES ( Ε* values)
4. RESULTS - Board properties TOTAL COLOR CHANGES ( Ε* values) Color changes not detected by the human eye 4. RESULTS - Board properties TOTAL COLOR CHANGES ( Ε* values) Color changes marginally detected by the human eye Color changes detected by the human eye
5. MAIN CONCLUSIONS Substitution of fresh particles by recovered material (including the crushed recovered coatings in the core layer) up to 35% no significant negative influence on all of the main properties of the boards. Subsitution up to 50% (after removing the coatings) no significant negative influence on all of the main properties of the boards. More recovered material, less board formaldehyde content replacement of recovered particles in the surface layers by recovered fibers by 10 and 15% no significant change in mechanical, but considerably downgraded hygroscopic properties replacement of fresh particles by old particleboard recovered material to 50% no colour differences perceptible by the human eye. 6. FURTHER RESEARCH Other factors influencing the recovery efficiency? In depth investigation of the chemical changes induced to wood by the recovery process (FTIR analysis of recovered materials, influence of the chemical changes in the bonding efficiency etc) Risk assesment of waste materials produced by the recovery process possibilities of reusing? Using recovered fibers for other products (WPC?)
6. FURTHER RESEARCH Prototype 1L reactor for accurate treatments : - thermal/hydrothermal treatments at temperatures up to 225 C, - vacuum treatments up to 120mbar (abs) - pressure treatments up to 25bar - equipped with THM treatment component 6 My respect and thanks to prof. Athanasios Grigoriou (Aristotle University of Thessaloniki)
www.wbp-recycling.web.auth.gr www.fria.gr/woodtech