Universidade
Federal de Santa Maria
REGET, Santa Maria, v.
23, Ed. Especial, e9, 2019
DOI:
https://doi.org/10.5902/2236117038531
Submissão:
12/06/2019 Aprovação: 12/06/2019 Publicação:
25/06/2019
Production
and evaluation of particleboard made of sawdust and sugarcane bagasse with
polyurethane resin based on castor oil
Produção
e avaliação de painéis de partículas de serragem e bagaço de cana
com poliuretano a base de óleo
de mamona
Raissa Pravatta PivettaI
Ana
Laura Soler Cunha BuzoII
Estéfani Suana SugaharaIII
Sérgio Augusto de Mello da SilvaIV
I Graduanda, Departamento de Engenharia Civil, Universidade Estadual Paulista - UNESP,
Ilha Solteira, SP, Brasil.
raissa_ppivetta@hotmail.com
II Mestrandas, Departamento de Engenharia Civil, Universidade Estadual
Paulista - UNESP, Ilha Solteira, SP, Brasil. analaurasolercunha@gmail.com
III Mestrandas, Departamento de Engenharia Civil, Universidade Estadual
Paulista - UNESP, Ilha Solteira, SP, Brasil. estefanisugahara@hotmail.com
IV Doutor, Departamento de Engenharia Civil, Universidade Estadual Paulista -
UNESP, Ilha Solteira, SP, Brasil.
Abstract
Among the goals
for sustainable development in Brazil, studies have been conducted to better
use of industrial and agricultural waste to promote adequate final disposal of
these and generate new materials that minimize the exploitation and use of
natural resources. In this work, the proposal is to make and evaluate boards
with nominal density of 0.80 g.cm-3 using sugar cane bagasse, sawdust and
polyurethane resin derived from castor oil. Thus, three treatments with
different percentages of particles and 10% of PU-castor were proposed for the
preparation of boards that were pressed with a pressure of 50 kgf.cm-2, a temperature of 100 °C and a
pressing time of ten minutes. The boards were
evaluated for their physical properties (density, moisture content and
swelling) and mechanical (static flexure and perpendicular traction) according
to NBR 14810: 2-2013 and presented average values density of 936 to 937 kg.m-3,
swelling after 24 hours of 5.0 to 7.2%, modulus of resistance to static bending
of 22 to 23 MPa and perpendicular traction of 0.71 to 0.87 MPa. The results obtained
with the tests indicate the great potential of use of sugarcane bagasse and
sawdust to produce boards of high density particles.
Keywords: Particleboards; Wood waste; Agroindustrial waste
Dentre as metas para um desenvolvimento sustentável, no Brasil são realizados
estudos para melhor aproveitamento de resíduos industriais e agrícolas de forma
a promover adequada disposição final destes e gerar novos materiais
que minimizem a exploração
e o uso de recursos naturais. Neste trabalho, propõe-se confeccionar e avaliar painéis de partículas com densidade nominal
de 0,80 g.cm-3 empregando-se
bagaço de cana-de-açúcar, serragem e adesivo poliuretano bicomponente derivado de óleo de mamona. Assim, foram propostos
três tratamentos com porcentagens diferentes de partículas e 10% de PU-Mamona
para confecção de painéis
que foram prensados com pressão de 50 kgf.cm-2, temperatura
de 100 °C e tempo de prensagem de dez
minutos. Os painéis foram avaliados
em suas propriedades
físicas (densidade, umidade e inchamento) e mecânicas (flexão estática e tração perpendicular)
de acordo com a NBR 14810:2-2013 e apresentaram valores médios de densidade de 936 a 937 kg.m-3,
Inchamento após 24h de 5,0 a 7,2%, módulo de resistência à flexão estática de 22 a 23 MPa e resistência
à tração perpendicular de 0,71 a 0,87 MPa. Os resultados obtidos
com os ensaios indicam o grande potencial de utilização de bagaço de cana
e serragem para produção de
painéis de partículas de alta densidade.
Palavras-chave: Painéis de partículas; Resíduos de madeira; Resíduos agroindustriais
1
Introduction
The exponential
growth of the world population with the rise in industrial activities had the
effect of increasing the demand for raw materials and also of the generation of
waste. Waste is material discarded in production and consumption chains that,
due to technological or market limitations, end up not having use or economic
value, and may cause negative impacts to the environment when handled improperly
(NOLASCO, 1998).
Forest-based
industries in Brazil generate a significant amount of waste during the
operational phases, from logging to the final product. In the study carried out
by Cerqueira et al. (2012) it was verified that the main wastes generated by
sawmills are sawdust (36.17%), firewood (25.53%), woodcuts (23.40%) and wood
chips (12.77%) and that for every 1.720 m3 of wood processed
annually, 396.6 m3 of waste is generated, thus creating a scenario
of low technological level and bad use of wood due to the large amount of waste
generated. This volume shows the great potential of using these materials to
produce particleboard.
According to the
Brundtland Report (1988), sustainable development must be understood as a
transformation process in which resource exploitation, investment direction, technological
development orientation and institutional change meet the needs of the present
without compromising the future generations to meet their own needs.
In this way, the
lumber sector focused on improving environmental performance using new inputs, such
as in the process of producing boards with biodegradable adhesives and various
vegetable residues such as tree pruning, bark, sugarcane, wood chips and other.
The use of lignocellulosic residues in the production of agglomerates has been
considered sustainable by reducing the use of natural wood and extending the
life of landfills (SANTOS et al., 2014).
Particleboards,
compared to solid wood, have greater dimensional stability, lower weight and
lower cost. In the manufacturing process, it is observed a lower energy
expenditure with less production time and less effort, and it is possible to
increase special properties such as thermal and acoustic (SILVA, 2016).
Thus, since
industry depends on the environment directly and indirectly, reducing the
maximum possible demand for raw material is crucial for the survival of the
market in a resource-constrained world. The benefits are not only environmental
but also economical, reducing costs and reliance on external suppliers (SARAVIA-CORTEZ
et al., 2013).
According to data
from National Food Supply Company - CONAB, in Brazil, the estimated sugarcane
harvest for 2017/2018 will be 646.4 million tons, which represents, for the
country, approximately 181 million tons of sugarcane bagasse, since, according
to Silva et al. (2007), each processed ton of sugar cane generates a total of
280 kg of waste.
Generally,
sugarcane bagasse is burned for energy production for industrial use, but given
its physicochemical characteristics, and because it is a renewable source of
raw material, it is being used in a wide field of research.
The production of
particleboard with lignocellulosic residues is an alternative that provides
added value to this by-product, making it possible to meet the growing demand
of the wood boards industry, as well as contributing to a decrease in the use
of wood and consequently the pressure on forests, reducing the cost of
producing the boards, making them more competitive in the economic scenario
(MENDES et al., 2010).
NBR 14810-1
(ABNT, 2013) defines adhesive or resin as a substance used with the purpose of
adhering wood particles to a board, which may have an organic or inorganic
origin. The main resins used in the wood board industry are synthetic ones
which, according to some studies, have presented some unsatisfactory points due
to the low resistance to the action of humidity and the release of formaldehyde
gas when heated, which damages the environment. Therefore, it is necessary to
find a substitute with the same quality and performance as the traditional
resins (ZAU et al., 2014).
In addition,
there is a worldwide trend towards the use of biodegradable, non-polluting
products from renewable sources. According to Araújo (1992), this trend has
advanced research, leading to the discovery of a polyurethane
derived from castor oil, presented as a resin in the bicomponent formulation.
Therefore, in
order to develop sustainable products and the use of industrial and
agricultural byproducts that can add value to these materials and promote an
adequate final disposal that avoids the burning of material, this work has the
objective to evaluate the applicability of residues in the manufacture of
agglomerated boards using sawmill waste, sugarcane bagasse and alternative
resin derived from castor oil.
2
Materials and methods
2.1
Materials
For the
preparation of the boards, particles collected from sawmills and sugar and
alcohol industries located at the region of Ilha Solteira (São Paulo) were used
and three treatments were proposed (Table 1), using sugarcane bagasse residues
in association with the sawing of several native woods.
Table 1 - Proposed
treatments for confection of agglomerated boards
|
Treatments |
Bagasse (%) |
Sawdust (%) |
Resin (%) |
|
T1 |
100 |
0 |
10 |
|
T2 |
80 |
20 |
10 |
|
T3 |
60 |
40 |
10 |
For particle
agglutination, a bicomponent polyurethane derived from
castor oil (PU-Castor) was used in the ratio of 10% to the dry mass of the
particles.
2.2
Methods
Initially, the
waste passed through a manual selection, where the strange materials were removed,
and, after, the remaining materials were taken for processing in the knife mill
to adjust the particle size.
Then, the
sugarcane bagasse and sawdust particles were graded in an assay using NBR NM
248-2003 as a reference, in which a particulate stirrer with a vibratory system
was used to determine the modulus of fineness of the particulate mixture
according to the retained percentages of material in each sieve of the whole
set.
After grading,
the particles were selected using only the ones with dimensions between 2 and 6
mm in length, then the material was dried in the sun until a mean humidity of
10% was reached.
From the nominal
density of 0.80 g.cm-3, the masses of the
particles to be used in the production of the boards were calculated according by
the percentages defined for the proposed treatments, and then nine boards were
created with dimensions of 35 x 35 x 1 cm.
After the
preparation of the materials, the boards were created, as can be seen in the
sequence shown in Figure 1. The particles were homogenized in two stages to
provide greater uniformity of the PU-Castor resin in the mixture, initially the
polyol and then the prepolymer, where the homogenization was done first
manually and then using a rotational particle gluer.
The sequence of images
presented in Figure 1 illustrates the preparation of the boards starting with
the homogenization of the particles with PU-Castor, preparation of the
"particle mattress" in the "mattress forming" with press
pressure of 5 tons where the "mattress
forming" was subjected to the hydraulic press with a measured pressure of
50 kgf.cm-2 and a temperature of 100 °C for 10 minutes of pressing,
with initial time of 3 minutes with intervals of 30 seconds for relief of
pressure, in order to avoid the formation of gases and delamination of the boards.
Figure 1 - Sequence of confection of agglomerated
boards
|
|
|
|||||||||||||||
Source: Own author
Three boards were prepared for each treatment. After 72h they were
squared and from them, the test specimens were produced to evaluate the
physical and mechanical properties according to the essays from NBR 14810: 2-2013.
Ten test specimens measuring (50 x 50) mm were used for each test to
determine the physical characteristics. To calculate the density of the boards,
it was necessary to determine the dimensions of the test specimens with pachymeter
and micrometer and their respective masses. In the moisture
content test, the test specimens were
weighed on analytical balance before and after drying for 24 hours in an oven
at 100 ° C ±. And for the swelling test, the thickness at the point of intersection
of the diagonals was measured before and after the test specimens were
submerged in deionized water for 24 hours.
In the mechanical characterization of the boards, the EMIC universal
testing machine was used. Thus, for the static flexural test, ten specimens
were used in the dimensions (20 times the thickness + 50 mm) x 50 mm that were
positioned on two supports of the universal machine, the length of the span
being ten times the thickness of the body (200 mm minimum). To determine the
tensile strength perpendicular, ten test specimens were prepared in the
dimensions (50 x 50) mm, which were fixed with Super Bonder in metallic
supports.
3
Results and discussion
In this item, it
is presented the values obtained with the tests to characterize the physical
properties: density, moisture content, swelling after 24 hours, and the mechanical
properties: modulus of resistance to static bending (MOR) and perpendicular traction.
The values obtained were compared with the requirements established by standard
NBR 14810-2 (ABNT, 2013).
Based on the
tests for the granulometric composition of the materials, the fineness modules
of sugarcane bagasse (3.0) and sawdust (5.2) were determined, that is, the
particles of treatments T1, T2 and T3 are contained in a length range of 2 to 6
mm.
3.1
Physical Properties
Table 2 presents
the mean values determined for density, moisture content, swelling after 24h.
Table
2 - Determined physical properties
|
NBR
14810-2:2013 |
550
a 750 (kg.m-3) |
5
a 13 (%) |
18
(%) |
|
Treatment |
Density
|
Moisture
content |
Swelling
24h |
|
T1(100x0) |
937 |
9,7 |
7,1 |
|
T2(80x20) |
937 |
10,3 |
7,2 |
|
T3(60x40) |
936 |
10,0 |
5,0 |
The analysis of
the results obtained with the tests to characterize the apparent density of the
treatments T1, T2 and T3, indicate, in accordance with NBR 14810-2: 2013, that the
boards can be classified as high density. According to Torquato (2008), high
density boards have better machining and consequently satisfactory finishing.
According to Kelly (1977) cited by Iwakiri (2005), boards of higher density
have greater mechanical resistance.
According to the
moisture content, Table 2 shows that the determined values are in accordance
with the requirements of NBR 14810-2: 2013. According to Bertolini (2011), the
ideal moisture content of the boards made with PU-Castor must be in the range
of 8 to 10%, in the treatments T1, T2 and T3 the particles were with a humidity
of 10 %.
As for the test
for swelling evaluation after 24h, it is observed that the values obtained for
all boards meet the minimum standards that define boards for use in humid
conditions, whose limit is 13%. This assay makes it possible to infer the
efficiency of the PU-Castor within the board when subjected to immersion in
water. According to Fiorelli et al. (2011), industrially marketed boards are
meticulously subjected to this type of test for satisfactory quality control.
The swelling
values obtained for the boards of the T2 and T3 treatments may be related to
the proposed particle size composition, the adhesion between the particles, the
reduction of voids within the boards and, consequently, better resistance to
swelling.
In the research
conducted by Iwakiri et al. (2012), for wood boards agglomerated with sawdust
residues and 8% urea formaldehyde resin the results of swells obtained varied
between 10.97% and 22.37%, being therefore larger than those obtained in this
work with boards s made with PU-Castor, which shows the efficiency of the
enveloping and adhesion between the particles and, consequently, greater
resistance to swelling.
3.2
Mechanical Properties
Table 3 shows the
MOR and perpendicular traction values. These values were compared with the
minimum values required by the NBR, whose use is justified by the similarity of
the product developed in the present study with a board of wood particles.
Table
3 - Determined values for resistance properties of the boards
|
NBR 14810-2:2013 |
18 (MPa) |
0,45 (MPa) |
|
Tratamento |
MOR |
Perpendicular traction |
|
T1 |
22 |
0,77 |
|
T2 |
22 |
0,71 |
|
T3 |
23 |
0,87 |
When analyzing
the values obtained in the modulus of resistance to static bending (MOR) and
resistance to perpendicular traction of the boards (Table 3), it is observed
that all treatments reached values higher than the minimum required by NBR
14810-2: 2013.
In relation to
MOR, it is verified that the average values reached are close to those obtained
by Fiorelli et al. (2011), Battistelle et al. (2009), Contreras et al. (2006),
Silva et al. (2008), Widyorini et al. (2005), Okino et al. (1997), in
researches with cane bagasse particles and synthetic resins. Regarding perpendicular
traction, it can be observed that the mean values reached are higher than those
obtained by Battistelle et al. (2009) and Okino et al. (1997). These results
confirm that the PU-Castor resin has adhesive potential for the manufacture of boards, that the manufacturing process used was adequate and
that the amount of resin used provided effective results to produce boards of
high density particles.
4
Final Thoughts
Sugarcane bagasse
is a large-scale agroindustrial by-product that has great potential for use in
particle board production, given the positive results obtained with the
physical and mechanical tests that, for the boards of the three treatments, maintained
within the specifications of the standard. The production of boards adds value
to this waste that is a renewable source of raw material.
It was verified
that the proposed composition of the mixture to produce the boards was
efficient, independent of the wood species contained in the sawdust, because,
when analyzing the values obtained with the physical and mechanical tests of
the boards, it was verified that the use of these wastes enables the production
wood boards according to the normative requirements.
The PU-Castor for
the swelling property was presented efficient, with better results in relation
to the urea formaldehyde resin. Thus, PU-castor oil is an effective alternative
to the property of waterproofing, in addition to being biodegradable and
renewable source of raw material.
Regarding the
mechanical properties of the boards and according to ABNT NBR 14810-1 and 2:
2013, the results obtained make it possible to classify the boards as
"Type P4", ie "Structural boards for use in dry conditions".
In this context,
it is evident that the use of residues, in the case of sugarcane bagasse,
sawdust and the use of PU resin, besides the environmental contribution, it is
a viable alternative for the manufacture of agglomerated boards that can be used
in the production of furniture and in various applications in civil
construction.
Acknowledgments
The authors are
grateful to the Postgraduate Program of the Faculty of Engineering of Ilha
Solteira, Universidade Estadual Paulista, CNPq and Capes for the support
provided to the development of this work.
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