Corn distiller’s dried grains with solubles (DDGS) is mostly marketed as a livestock feed due to its high protein content of 30%. Recently, the proteins in DDGS have shown potential to act as binding agents along with melamine-urea-formaldehyde resin. However, it is unknown if DDGS can be chemically functionalized as a natural binder to replace synthetic resin in particleboard. In this study, several formulations were tested using various concentrations of acetic acid and sodium hydroxide treatments with combinations of temperature, DDGS concentrations, particle sizes, and wax. FTIR results indicated that DDGS proteins were decoupled through acid or alkali treatments, and acid treated DDGS in particleboards displayed higher improvements in internal bond strength as well as the moisture resistance of the particleboards. These results suggest that acid or alkali treated DDGS has potential to act as a natural binder for manufacturing medium-density particleboard.

The content of this diploma thesis is to explore the possibility of utilization of wastes generated in the production of cement-bonded particleboards in terms of their application as secondary raw materials back into the production. At first an attention was focused on a fine-grained waste containing wood particles with cement matrix produced during the final adjustment of boards. Further, fly ash generated from the combustion of wood chips in the biomass boiler is assessed. In the theoretical part the different types of waste generated in the production of cement-bonded particleboards are characterized, including their methods of creation, production, use or disposal of the current and other proposals for utilization in the future. The research papers dealing with applications of various wastes in the production of cement composites with organic fibers were also studied. In the experimental part of the thesis the characteristics of each type of waste generated in the production of cement-bonded particleboards are evaluated using laboratory analyses and their pretreatment methods for another use are designed. Subsequently performed the laboratory verification capabilities of secondary raw materials from wastes in cement-bonded particleboards identifying and evaluating basic physico–mechanical characteristics of boards with modified composition.

京都大学 / 新制・課程博士 / 博士(農学) / 甲第25018号 / 農博第2578号 / 新制||農||1103(附属図書館) / 京都大学大学院農学研究科森林科学専攻 / (主査)教授 梅村 研二, 教授 矢野 浩之, 教授 村田 功二 / 学位規則第4条第1項該当 / Doctor of Agricultural Science / Kyoto University / DFAM

More than one billion vehicle tires reach the end of their useful service life annually. Less than a quarter of rubber waste is reused or recycled in some way. Interest has grown in working to discover means by which to incorporate rubber tire waste into construction materials. This study sought to delve into the use of micronized rubber powder (MRP) as an acoustic agent within particleboard and concrete. In addition, work was conducted to characterize the effect that MRP has on the strength and flexural properties of concrete. Furthermore, research sought to provide insight into how pine biomass, a forest products industry waste, would interact with MRP in concrete as it relates to strength and acoustic properties. As expected, particleboard that contained MRP resulted in lower strength but higher flexibility. Acoustic testing revealed that there was minimal sound absorption improvement at some frequencies and less absorption at low and high frequencies. Sound transmission loss was slightly improved by the addition of MRP to the particleboard. Adding pine biomass and MRP to concrete yielded much lower compressive strength as compared to plain concrete. Visual inspection of the sound absorption coefficient curves over the full range of test frequencies identified limited, if any, advantage for the addition of MRP or biomass. Some ranges of frequencies offered minimal improvement. There appeared to be no appreciable sound absorption advantage to adding MRP, pine biomass, or the combination of the two into concrete mix proportions. Modulus of rigidity was decreased as compared to plain concrete when MRP, pine biomass, or a combination of both were incorporated into the concrete mixture as volume replacement for aggregate. Visual observation revealed that flexural failure for the MRP or pine beams were less sudden and less catastrophic than the plain concrete samples. Modulus of elasticity was decreased as compared to plain concrete when MRP, pine biomass, or a combination of both were incorporated into the concrete mixture as volume replacement for aggregate. The more flexible and ductile concrete produced with MRP and biomass provides a combination of properties that serve to lessen the propagation of cracks throughout the specimen.

The objective of this study was to investigate the effects of melamine and ether contents on the curing and performance properties of UF resins as binders for wood composites. Various UF and UMF resins were synthesized with three different synthesis procedures. These resins were examined by 13C NMR, rheometer, and other methods and evaluated as particleboard binders. Three-layer particleboards were prepared with the resins catalyzed with various catalysts and levels, applied in face and core layers. The board test results were compared. Only about half of added melamine had reacted with formaldehyde. UMF resins were found to be catalyzed with stronger catalysts at suitable levels depending on melamine levels and on which layer of particleboard the UMF resins are to be applied. Even catalyzed with a stronger catalyst, the curing rates of UMF resins were still slower, and storage stabilities were shorter than UF resins, but the pot lives were longer, and internal bond strength and water resistance were higher. Moreover, resins synthesized with procedures 2 and 3 showed obviously longer storage times, longer pot lives, and longer gel times, and the particleboards bonded with these resins showed significant improvements in internal bond strength and water absorption values but the formaldehyde contents increased. The increased formaldehyde content test values indicated that linear methylene-ether groups in UF resins decompose in the hot-pressing of boards to emit formaldehyde, most of which is not captured back into the UF resin matrix. Uron-type methylene-ether groups decompose in the hot-pressing of boards to participate in the curing process and enhance the bonding of boards, but it could also emit extra formaldehyde which may not be effectively captured by UF resins but more effectively by UMF resins if the amount of melamine is high enough because of the increased reactive capacities of melamine. The results of this research offered a new hypothesis that the linear methyleneether bonds in UF resins might be a major contributor of the high free formaldehyde contents of particleboards. Decreasing the linear methylene-ether groups contents might effectively bring down the formaldehyde content of boards.

O presente estudo teve como objetivo desenvolver, produzir e caracterizar painéis OSB-cimento-madeira residual com as espécies de eucalipto (Eucalyptus spp.) e pinus (Pinus spp.) com densidade 1250 kg/m³, bem como avaliar o efeito da cura com carbonatação acelerada nas propriedades dos painéis. O projeto foi desenvolvido em quatro etapas. Na Etapa 1 (Tratamentos nos strands de eucalipto e pinus) foi realizada a produção e a avaliação do efeito dos tratamentos de água fria, água quente e solução 2,5% de hidróxido de sódio, nas propriedades dos strands, bem como o estudo do efeito dos strands de eucalipto e pinus (sem e com tratamentos) na hidratação do cimento Portland aos 28 dias de idade. Após a avaliação dos strands, foi constatado que os que não receberam tratamento apresentaram melhor desempenho em comparação aos strands tratados. A etapa 2 (Determinação do teor ótimo de strands de madeira para painéis OSB cimento-madeira residual) visou produzir painéis OSB-cimento-madeira residual contendo os teores de 25%, 30% e 35% de strands em massa, seguindo a metodologia convencional de produção de painéis cimento-madeira (OSB-cimento-madeira) e avaliá-los por meio das propriedades, físicas, mecânicas e microestruturais. Os painéis OSB-cimento-madeira com os teores de 25%, 30% e 35% de strands apresentaram propriedades físicas próximas ao valor recomendado pela norma ISO 8335 como também para propriedades mecânicas de módulo de ruptura (MOR) e módulo de elasticidade (MOE). Na etapa 3 (Painéis OSB-cimento-madeira residual otimizados) foram ajustados os parâmetros de produção (teor de strands, teor de água, processo de mistura e pressão) e avaliadas as propriedades térmicas, físicas e mecânicas dos painéis OSB-cimento-madeira residual com 35% e 45% de strands (em massa). Foi observado que após o ajuste da água não evaporável (Wn), os valores de densidade aparente foram próximos ao valor proposto nos parâmetros produtivos. O teor de strands de 45% resultou em um aumento de aproximadamente 31% no MOR paralelo e de 93% no MOE perpendicular ao strand em comparação com painéis fabricados com teores de 35%. A pressão empregada foi efetiva uma vez que proporcionou uma compressão adequada para ambos os painéis (eucalipto e pinus), não sendo evidenciado o \"efeito mola\". Na Etapa 4 (Cura com carbonatação acelerada em painéis OSB-cimento-madeira residual) em que foram avaliados os painéis OSB-cimento-madeira residual com 45% de strands submetidos a cura com carbonatação acelerada, durante 12 h foi observada uma redução do inchamento em espessura e da absorção de água. Os valores médios do MOR na direção paralela do strand e do MOE foram próximos aos requisitos mínimos estabelecidos pela EN300: 2006 - classe OSB/1. Para os painéis avaliados após o ensaio de envelhecimento acelerado de 100 ciclos de imersão e secagem, foi observado que o desempenho mecânico dos painéis carbonatados foi significativamente superior aos não carbonatados. Portanto, pode-se concluir que os painéis OSB-cimento-madeira residual produzidos com strands de eucalipto e pinus no teor de massa de 45% e curados com carbonatação acelerada apresentaram potencial como um novo material, visto que as propriedades físicas e mecânicas atendem ao estabelecido pela norma EN300:2006 para painel cimento-madeira convencional. / This project aims the development, production and characterization of OSB-cement-residual-wood particleboards using the wood species of eucalyptus (Eucalyptus spp.) and pine (Pinus spp.) with a density of 1250 kg/m³, as well as to evaluate the accelerated carbonation effects on the particleboard\'s properties. This project was conducted into four steps. In the step 1 (Tratamentos nos strands de eucalipto e pinus) it was realized the strands production and characterization. In this step, the study of the strands (eucalyptus and pine) on the Portland cement hydration at 28 days age was also investigated. The results shown that the strands without treatment perform better than those treated. In the step 2 (Determinação do teor ótimo de strands de madeira para painéis OSB cimento-madeira residual) a physical, mechanical and microstructural properties evaluation was conducted on the OSB-cement-residual-wood particleboards with strand contents of 25%, 30% and 35% (by weight) produced with the conventional cement-wood production method. The OSB-cement-residual-wood with all strand contents shown physical and mechanical (MOR and MOE) properties close to those recommend by ISO 8335. In the step 3 (Painéis OSB-cimento-madeira residual otimizados) production parameters were adjusted (strand contents, water content, mixture procedure and pressure) and the particleboards with 35% and 45% of strands thermal, physical and mechanical properties were assessed. The results of this step shown that after once adjusted the non-evaporable water (Wn) in the production, the apparent density values were close to those proposed in the production methods. The particleboards with a strand content of 45% shown an increase of approximately 31% in the parallel MOR and 93% in the MOE perpendicular to the strand compared to those particleboards made with 35%s strand content. It was also found that the pressure used to produce the particleboards (eucalyptus and pine) was effective once it was not evidenced the spring effect. In the step 4 (Cura com carbonatação acelerada em painéis OSB-cimento-madeira residual) the OSB-cement-residual wood with 45% of strands were subjected to accelerated carbonation cure for 12 h and the materials were evaluated. It was found a reduction in thickness welling and water absorption for the carbonated particleboard. The mean values of MOR in the parallel direction of the strand and the MOE were close to the minimum requirements established by the EN300: 2006 - OSB/1 class. For the particleboards evaluated after the accelerated aging test of 100 wetting and drying cycles, it was found that the mechanical performance of the carbonated particleboards was significantly higher than those non-carbonated. Therefore, it can be concluded that the OSB-cement-residual-wood particleboards produced with eucalyptus with 45% of strand and cured by accelerated carbonation presented potential as a new material, since the physical and mechanical properties meet the EN300: 2006 standard requirements for conventional cement-wood panel.

Os painéis compensados e aglomerados são produtos com aplicação difundida, principalmente, na indústria moveleira e no setor da construção civil. Na fabricação destes produtos, tradicionalmente, são usadas as resina a base de fenol-formaldeído e uréia-formaldeído. Porém, há uma constante busca por inovações que visem o aproveitamento dos recursos disponíveis no nosso País. Uma resina alternativa, a resina poliuretana a base de mamona, desenvolvida no Instituto de Química de São Carlos, da Universidade de São Paulo, é um polímero oriundo de recurso natural e renovável. Com base nisto, este trabalho apresenta um estudo sobre a utilização desta resina na manufatura de painéis compensados e aglomerados. Os compensados foram produzidos com lâminas da espécie Eucalyptus saligna e os aglomerados com uma composição de Eucalyptus gradis, Eucalyptus urophilla e Pinus elliottii. Ambos os painéis foram prensados a temperatura de 60&#176C e 90&#176C. Nos compensados foram analisadas duas gramaturas, 180 g/m2 e 200 g/m2. Nos aglomerados industrializados são acrescentadas às partículas de madeira, percentagem de emulsão de parafina, com o objetivo de melhorar suas propriedades higroscópicas. Sendo assim, neste estudo, foram analisados aglomerados manufaturados com e sem a adição de parafina. O desempenho dos painéis foi avaliado por meio de ensaios físico-mecânicos recomendados pela Associação Brasileira de Normas Técnicas. Nos compensados, os ensaios de resistência da colagem ao esforço de cisalhamento, foram conduzidos segundo recomendações da European Standard. Os resultados apontam para a eficiência de ambos os painéis, quando comparados com valores de propriedades de painéis exigidos por documentos normativos, nacionais e internacionais, e valores encontrados na literatura, para painéis desta natureza. Os resultados mostraram que a resina poliuretana a base de mamona pode ser considerada uma alternativa promissora na manufatura de compensados e aglomerados. / Plywood and particleboard are products with spread application, mainly, in furniture industry and building site sector. Those products are produced traditionally with phenol-formaldehyde and urea-formaldehyde resins. However, there is a constant research for innovations which aim the use of available resources in our country. An alternative resin, the castor oil-based polyurethane resin, developed at the São Carlos Institute of Chemistry, University of São Paulo, is an environmentally friendly vegetal oil-based polymer, harmless to humans. This study involves the use of castor oil-based polyurethane resin to manufacture plywood and particleboard. Playwood panels were produced with Eucalyptus saligna veneers and particleboards with a composition of Eucalyptus grandis, Eucalyptus urophilla and Pinus elliotiii particles. Both panels were pressed to 60&#176C and 90&#176C temperature. Playwood panels were analyzed in two glue around 180 g/m2 e 200 g/m2. Percent of paraffin emulsion is increased in wood particles in industrialized particleboards, to improve their hygroscopic properties. Thus, in that research, particleboards manufactured with and without paraffin addition were analyzed. Plywood and particleboard performances were evaluated based on the results of physical and mechanical tests recommended by the Brazilian code. The plywood\'s glue-shear strength tests were conducted according to European Standard in plywood. Results appear to the efficiency of both panels, when compared to demanded property values by national and international normative documents and values found in the literature, to those panels. The results showed that the castor oil-based polyurethane resin is promising glue for plywood and particleboard manufacture.

Orientador: Sérgio Augusto Mello da Silva / Resumo: Um dos grandes desafios da última década é o aproveitamento de subprodutos objetivando-se proteger o meio ambiente e agregar valor ao produto final. A fabricação de painéis com madeira reconstituída vem registrando constante crescimento, sendo o Eucalipto a espécie de madeira exótica de reflorestamento mais utilizada no Brasil para a produção de painéis aglomerados. Considerando-se que na Cidade de Franca, no interior do Estado de São Paulo, a indústria calçadista gera grande quantidade de resíduos durante o processo de corte de couro para a montagem de calçados com um significativo volume de resíduos descartados em aterros sanitários. Na maioria dos casos, não ocorre seu reaproveitamento; sendo assim, considerou-se, nesse trabalho, o aproveitamento desses resíduos na produção de painéis aglomerados. Para produção dos painéis e avaliação das propriedades físicas e mecânicas, propuseram-se três tratamentos com proporções diferentes entre partículas de eucalipto e partículas provenientes de resíduos de couro aglutinadas com resina poliuretana bicomponente à base de óleo de mamona em prensa hidráulica, com controle de temperatura e pressão. Após avaliação das propriedades físicas e mecânicas dos painéis, com base no documento normativo brasileiro ABNT NBR 14810/2013, realizou-se a Análise de Variância (ANOVA) e Teste de Tukey. De modo geral, os valores obtidos para as propriedades dos painéis atenderam aos valores mínimos propostos pela NBR; entretanto, com base nos resultados o... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: One of the biggest challenges of the last decade is the use of by-products aiming to protect the environment and add value to the final product. The manufacture of panels with reconstituted wood has been steadily growing, with Eucalyptus being the most commonly used exotic reforestation wood in Brazil for the production of particle board. Considering that in the city of Franca, in the interior of the state of São Paulo, the footwear industry generates a large amount of waste during the leather cutting process to assemble footwear with a significant volume of waste disposed of in landfills. In most cases, reuse does not occur; Thus, this research considered the use of these residues in the production of particle board. For the production of panels and evaluation of physical and mechanical properties, It was proposed three components with different proportions between eucalyptus and waste residues bonded with bicomponent castor oil-based polyurethane resin in hydraulic press, with temperature and pressure control. After evaluating the physical and mechanical properties of the panels, based on the Brazilian normative document ABNT NBR 14810/2013, it was performed the analysis of variance (ANOVA) and Tukey test. In general, the values obtained for the properties of the panels met the minimum values proposed by the NBR; However, based on the results obtained by the statistical analysis, it was found that there was a need for adjustments in the parameters for making the panels. / Mestre

Orientador: Cristiane Inácio de Campos / Resumo: O segmento de painéis à base de madeira tem apresentado crescente expansão e competitividade, especialmente com aplicações na indústria moveleira e construção civil. No entanto, para garantir a competitividade os produtos devem apresentar propriedades equivalentes aos concorrentes. Neste contexto o estudo dos materiais ganha espeço, principalmente incorporando o uso da nanotecnologia para melhorar as características dos painéis, ampliando suas aplicações. Com base no exposto definiu-se o objetivo do presente estudo que foi avaliar as propriedades físicas e mecânicas dos painéis MDP a partir da adição de porcentagens distintas (0%, 25%, 50% e 100% em relação à água) de solução aquosa de nanocelulose associada ao adesivo ureia-formaldeído, essa geralmente utilizada na produção dos painéis. Os resultados obtidos permitiram concluir que não houve diferença estatística significativa nas propriedades de densidade e teor de umidade dos painéis em nenhuma das porcentagens adicionadas em comparação ao painel testemunha. A análise de imagens a partir de microscopia eletrônica de varredura permitiu observar uma superfície mais polida, com menor presença de irregularidades o que torna o painel mais adequado para o recebimento de revestimentos. Os testes mecânicos indicaram que não houve diferença estatística significativa para os testes de flexão estática, adesão interna e arrancamento de parafuso. Observou-se que houve uma tendência de redução das propriedades de adesão interna, resistê... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The wood-based panel segment has shown increasing expansion and competitiveness, especially with furniture industry and civil construction applications. However, to ensure competitiveness the products must present equivalent properties to competitors. In this context, the study of materials is gaining momentum, mainly incorporating the use of nanotechnology to improve the panels characteristics, expanding their applications. Based on the foregoing, the aim of the present study was to evaluate the physical properties of MDP panels by adding nanocellulose (in different percentages 0%, 25%, 50% and 100% regarding the water total) to the urea-formaldehyde adhesive in this type of panel production. The results showed that there was no significant statistical difference in the properties of density and moisture content of the panels in any of the percentages added in comparison to the control panel. The analysis of images from scanning electron microscopy allowed to observe a more polished surface, with less presence of irregularities which makes the panel more suitable for the reception of coatings. The mechanical tests indicated that there was no significant statistical difference for the tests of static flexion, internal adhesion and screw pulling. It was observed that there was a tendency of reduction of the internal adhesion properties, resistance and rigidity of the panels with the increase of the percentage of nanocellulose. However, for the bolt pull tests, a trend of impro... (Complete abstract click electronic access below) / Mestre

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No. of bitstreams: 1 Dissertação - Mirian Dayse Furtado Lima.pdf: 14927258 bytes, checksum: c5d6ad1eae22a73a98998965f51d8c8b (MD5) Previous issue date: 2012-07-06 / CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The wood processing industries use generates a timber of about 40% of the total volume of the processed timber, and the remainder in other words 60% are used in boilers and brickworks for a power generation, especially in some areas of North. However, the burning of waste wood there generating other residue, ash, whose destination is a landfill. This paper presents a study on the potential use of three types of tropical wood waste, Cumarurana (Dipteryx polyphylla), Cumaru (Dipteryx odorata) and Amapá (Brosimum parinariensis), the production of particleboard, using polyurethane resin based on castor oil as a binder. There was a chemical and physical characterization of the waste based on TAPPI standard. In the first stage waste Cumarurana panels (1000 and 1300 g) were produced by keeping the resin content 15%. The mechanical results of these panels were below the requirements of the NBR ABNT 14810-2 (2006). In the second stage panels Cumaru and Amapá were produced according to a factorial design, in different conditions of amount of residue (1000 to 1500g) and content of resin (10-15%) and these were characterized by tests based on the physical and mechanical standard NBR ABNT 14810-3 (2006). For panels Cumaru, the factorial design showed that the waste is a significant factor (95% confidence) at its maximum level (1500g) to increase the compaction ratio. Mechanical analysis (MOR, MOE and Face Screw) showed that both the residue and the resin are significant factors in the levels studied indicating that higher values are obtained at higher levels (1500 g, 15%). For all these tests the values obtained in 1500 g of panels are in accordance with normative standards. For the panels with waste Amapá by the experimental design, it was observed that the residue and the resin are significant factors, when the response variable and MOE and MOR, indicating that the best results are obtained using mechanical greater amount of waste. However, only the results of MOR for panels 1300 and 1500 g a 15% were above of the normative requirements. The internal adhesion tests were within the normative standards for both panels Cumaru and Amapá. / O processamento da madeira em indústrias madeireiras gera um aproveitamento de cerca de 40% do volume total das toras processadas, sendo que o restante, ou seja, 60% são utilizados em caldeiras e olarias para a geração de energia elétrica, principalmente em alguns locais da região Norte. No entanto, com a queima desses resíduos de madeira há a geração de outro resíduo, as cinzas, cuja destinação é o aterro. Este trabalho apresenta um estudo sobre o potencial uso de três tipos de resíduos de madeiras tropicais, Cumarurana (dipteryx polyphylla), Cumaru (Dipteryx odorata) e Amapá (Brosimum parinariensis), na produção de painéis aglomerados, utilizando resina poliuretana à base de óleo de mamona, como aglomerante. Fez-se a caracterização química e física dos resíduos baseadas na norma TAPPI. Na primeira etapa, painéis com resíduos de Cumarurana (1000 e 1300 g) foram produzidos mantendo o teor de resina em 15 %. Os resultados mecânicos desses painéis foram abaixo dos requisitos exigidos pela Norma NBR ABNT 14810-2 (2006). Na segunda etapa os painéis de Cumaru e Amapá foram produzidos seguindo planejamento fatorial, em diferentes condições de quantidade de resíduo (1000 a 1500g) e teor de resina (10 a 15%) e estes foram caracterizados através de ensaios físicos e mecânicos baseados na norma NBR ABNT 14810- 3 (2006). Para os painéis de Cumaru, o planejamento fatorial mostrou que o resíduo é um fator significante (95% confiança) no seu nível máximo (1500g) para aumentar a razão de compactação. Análises mecânicas (MOR, MOE e Arrancamento de Parafuso na Face) mostraram que tanto o resíduo quanto a resina são fatores significativos nos níveis estudados, indicando que maiores valores são obtidos em níveis mais altos (1500 g e 15%). Para todos esses ensaios os valores obtidos em painéis de 1500 g estão de acordo com os padrões normativos. Para os painéis com resíduo de Amapá, através do planejamento experimental, observou-se que o resíduo e resina são fatores significativos, quando a variável resposta é MOR e MOE, indicando que melhores resultados mecânicos são obtidos utilizando maior quantidade de resíduo. Porém, apenas os resultados de MOR, para painéis a 1300 g e 1500 g a 15% apresentaram-se acima dos requisitos normativos. Os testes de adesão interna apresentaram-se dentro dos padrões normativos, tanto para painéis de Cumaru quanto para Amapá.