EP4705252A1 - A binder composition, a method for producing a binder composition, its use, and an insulating wool product - Google Patents

A binder composition, a method for producing a binder composition, its use, and an insulating wool product

Info

Publication number
EP4705252A1
EP4705252A1 EP24715847.0A EP24715847A EP4705252A1 EP 4705252 A1 EP4705252 A1 EP 4705252A1 EP 24715847 A EP24715847 A EP 24715847A EP 4705252 A1 EP4705252 A1 EP 4705252A1
Authority
EP
European Patent Office
Prior art keywords
weight
binder composition
lignin
composition
amount
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24715847.0A
Other languages
German (de)
French (fr)
Inventor
Nina PYKÄLÄINEN
Sanna VALKONEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
UPM Kymmene Oy
Original Assignee
UPM Kymmene Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by UPM Kymmene Oy filed Critical UPM Kymmene Oy
Publication of EP4705252A1 publication Critical patent/EP4705252A1/en
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
    • C03C25/34—Condensation polymers of aldehydes, e.g. with phenols, ureas, melamines, amides or amines
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
    • C08H6/00—Macromolecular compounds derived from lignin, e.g. tannins, humic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/54—Silicon-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C08L61/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C08L61/04, C08L61/18 and C08L61/20
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/005—Lignin
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D161/00—Coating compositions based on condensation polymers of aldehydes or ketones; Coating compositions based on derivatives of such polymers
    • C09D161/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C09D161/04, C09D161/18 and C09D161/20
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J161/00—Adhesives based on condensation polymers of aldehydes or ketones; Adhesives based on derivatives of such polymers
    • C09J161/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C09J161/04, C09J161/18 and C09J161/20
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J197/00—Adhesives based on lignin-containing materials
    • C09J197/005—Lignin
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process

Definitions

  • the present disclosure relates to a method for producing a binder composition .
  • the present disclosure further relates to a binder composition and to its use .
  • the present disclosure further relates to an insulating wool product .
  • An insulating wool product such as mineral wool can be produced by spaying a binder on a melted fiber matrix .
  • binders for insulating wool production are sodium silicates , polyesters , melamine urea formaldehyde , polyamides , furane-based resins , and others , phenolic resin (PF) -based binders .
  • PF-resin has a high free formaldehyde ( FA) content affecting the emissions of the final product unless a relevant amount of urea is used .
  • the inventors have therefore recogni zed the need to produce a binder composition to be used for producing an insulating wool product in a more sustainable manner .
  • a method for producing a binder composition comprises : i ) polymeri zing crosslinking agent and polymeri zable substance in an aqueous composition by mixing and heating at a temperature of 60 - 95 °C for preparing a pre-composition, wherein at least 30 weight- % of the polymeri zable substance originates from lignin, and ii ) mixing the pre-composition with silane , wherein silane is used in an amount of 0 . 1 - 0 . 9 weight- % based on the total dry weight of the binder composition, to form a binder composition having a free formaldehyde content of at most 0 . 5 % .
  • binder composition comprising crosslinking agent polymeri zed with polymeri zable substance , and silane , wherein :
  • the binder composition comprises silane in an amount of 0 . 1 - 0 . 9 weight-% based on the total dry weight of the binder composition
  • the binder composition has a free formaldehyde content of at most 0 . 5 % .
  • an insulating wool product comprising a fiber matrix and a binder composition, wherein the binder composition comprises crosslinking agent polymeri zed with polymeri zable substance , and silane , wherein :
  • the binder composition comprises silane in an amount of 0 . 1 - 0 . 9 weight-% based on the total dry weight of the binder composition
  • the binder composition has a free formaldehyde content of at most 0 . 5 %.
  • Fig . 1 illustrates the results of example 4
  • Fig . 2 illustrates the results of example 5
  • Fig . 1 illustrates the results of example 4
  • Fig . 2 illustrates the results of example 5
  • Fig . 3 illustrates the results of example 6 .
  • the present disclosure relates to a method for producing a binder composition .
  • the method comprises : i ) polymeri zing crosslinking agent and polymeri zable substance in an aqueous composition by mixing and heating at a temperature of 60 - 95 °C for preparing a pre-composition, wherein at least 30 weight- % of the polymeri zable substance originates from lignin, and ii ) mixing the pre-composition with silane , wherein silane is used in an amount of 0 . 1 - 0 . 9 weight- % based on the total dry weight of the binder composition, to form a binder composition having a free formaldehyde content of at most 0 . 5 % .
  • the present disclosure further relates to a binder composition
  • a binder composition comprising crosslinking agent polymeri zed with polymeri zable substance , and silane , wherein :
  • the binder composition comprises silane in an amount of 0 . 1 - 0 . 9 weight-% based on the total dry weight of the binder composition
  • the binder composition has a free formaldehyde content of at most 0 . 5 % .
  • the binder composition may be an aqueous binder composition .
  • the present disclosure further relates to the use of the binder composition as disclosed in the current specification for producing an insulating wool product .
  • the method may thus be used for producing a binder composition for producing an insulating wool product .
  • an insulating wool product comprising a fiber matrix and a binder composition, wherein the binder composition comprises crosslinking agent polymerized with polymerizable substance, and silane, wherein:
  • the binder composition comprises silane in an amount of 0.1 - 0.9 weight-% based on the total dry weight of the binder composition
  • the binder composition has a free formaldehyde content of at most 0.5 weight-%.
  • the binder composition as disclosed in the current specification has the added utility of being a more environmentally friendly solution to be used for producing an insulating wool product.
  • silane is used in an amount of 0.2 - 0.7 weight-%, or 0.3 - 0.5 weight-%, based on the total dry weight of the binder composition.
  • the binder composition comprises silane in an amount of 0.2 - 0.7 weight-%, or 0.3 - 0.5 weight-%, based on the total dry weight of the binder composition.
  • Silane has the added utility of promoting adhesion to achieve high strength and good moisture resistance in an insulating wool product.
  • the method comprises mixing in ii) the pre-composition also with a scavenger and/or a hardener.
  • the binder composition comprises also a scavenger and/or a hardener.
  • the scavenger is selected from urea, ammonia, dicyandiamide, melamine, tannin such as tannin extracts, gallic acid, sodium hydrogen sulfite (NaHSOs) , sodium sulfite (Na2SOs) , sodium metabisulphite (Na2S20s) , ammonium hydrogen sulfite, polyamides, dextrose, amine, ammonia sulfite, ammonium salts, ammonium hydroxide, ammonium carbonate, ammonium bicarbonate, oxygenated sulfur salts, sodium sulfite, sodium bisuifate, sodium metabisulfite, melamine, cyanoguanidine, guanamine, caprinogu
  • the hardener is selected from sulphates and/or phosphates. In one embodiment, the hardener is selected from ammonium sulphate and/or ammonium hydroxide. In one embodiment, the hardener is ammonium sulphate. In one embodiment, the hardener is selected from alkaline metal sulphate, alkaline metal phosphate, alkaline earth metal sulfates and/or alkaline earth metal phosphates. Also, a mixture of at least two hardeners may be used.
  • the method comprises mixing in ii) the pre-composition also with urea and/or ammonium sulphate.
  • the binder composition comprises also urea and/or ammonium sulphate.
  • the urea may be used for producing a binder composition with a suitably low viscosity value.
  • the urea may further be used for increasing the dry solids content of the binder composition.
  • urea is used in an amount of 0 - 9 weight-%, or 0.1 - 9 weight-%, or 0.5 - 8 weight-%, or 1 - 7 weight-%, or 2 - 6 weight-%, or 3 - 5 weight-%, based on the total wet weight of the binder composition.
  • the binder composition comprises urea in an amount of 0 - 9 weight-%, 0.1 - 9 weight-%, or 0.5 - 8 weight-%, or 1 - 7 weight-%, or 2 - 6 weight-%, or 3 - 5 weight-%, based on the total wet weight of the binder composition.
  • Urea may be used to decrease the viscosity of the binder composition so that it may be sprayed on the fiber matrix when used for producing insulating wool.
  • no urea is used for producing the binder composition.
  • the binder composition comprises no urea.
  • total wet weight should in this specification be understood, unless otherwise stated, as the weight of both the dry matter and the liquid part, e.g. water, of the binder composition.
  • Ammonium sulphate when used in the binder composition for producing an insulating wool product, has the added utility of providing the insulating wool product a satisfactory tensile strength formed during the curing process.
  • ammonium sulphate is used in an amount of 0 - 15 weight-%, or 0.5 - 15 weight-%, or 1 - 14 weight-%, or 2 - 13 weight-%, or 3 - 12 weight- % , or 4 - 11 weight-%, or 5 - 10 weight-%, or 6 - 9 weight-%, based on the total dry weight of the binder composition.
  • ammonium sulphate is used in an amount of 0 - 7 weight-%, or 0.5 - 7 weight- % , or 1 - 6 weight-%, or 2 - 5 weight-%, or 3 - 4 weight- % , based on the total dry weight of the binder composition.
  • ammonium sulphate is used in an amount of 5 - 15 weight-%, or 6 - 14 weight-%, or 7 - 13 weight-%, or 8 - 12 weight-%, or 9 - 11 weight-%, based on the total dry weight of the binder composition.
  • the binder composition comprises ammonium sulphate in an amount of 0 - 15 weight- % , or 0.5 - 15 weight-%, or 1 - 14 weight-%, or 2 - 13 weight-%, or 3 - 12 weight-%, or 4 - 11 weight-%, or 5 - 10 weight-%, or 6 - 9 weight-%, based on the total dry weight of the binder composition.
  • the binder composition comprises ammonium sulphate in an amount of 0 - 7 weight-%, or 0.5 - 7 weight-%, or 1 - 6 weight-%, or 2 - 5 weight-%, or 3 - 4 weight-%, based on the total dry weight of the binder composition. In one embodiment, the binder composition comprises ammonium sulphate in an amount of 5 - 15 weight-%, or 6 - 14 weight-%, or 7 - 13 weight-%, or 8 - 12 weight-%, or 9 - 11 weight-%, based on the total dry weight of the binder composition.
  • no ammonium sulphate is used for producing the binder composition.
  • the binder composition comprises no ammonium sulphate.
  • the lignin used for preparing the binder composition may be selected from a group consisting of kraft lignin, steam explosion lignin, biorefinery lignin, supercritical separation lignin, hydrolysis lignin, flash precipitated lignin, biomass originating lignin, lignin from alkaline pulping process, lignin from soda process, lignin from organosolv pulping, lignin from alkali process, lignin from enzymatic hydrolysis process, and any combination thereof.
  • the lignin is wood based lignin.
  • the lignin can originate from softwood, hardwood, annual plants or from any combination thereof.
  • kraft lignin is to be understood in this specification, unless otherwise stated, lignin that originates from kraft black liquor.
  • Black liquor is an alkaline aqueous solution of lignin residues, hemi cellulose, and inorganic chemicals used in a kraft pulping process.
  • the black liquor from the pulping process comprises components originating from different softwood and hardwood species in various proportions .
  • Lignin can be separated from the black liquor by different , techniques including e . g. precipitation and filtration .
  • Lignin usually begins precipitating at pH values below 11 - 12 .
  • Different pH values can be used in order to precipitate lignin fractions with different properties .
  • These lignin fractions differ from each other by molecular weight distribution, e . g. Mw and Mn, polydispersity, hemicellulose and extractive contents .
  • the molar mass of lignin precipitated at a higher pH value is higher than the molar mas s of lignin precipitated at a lower pH value .
  • the molecular weight distribution of lignin fraction precipitated at a lower pH value i s wider than of lignin fraction precipitated at a higher pH value .
  • the precipitated lignin can be purified from inorganic impurities , hemicellulose and wood extractives using acidic washing steps . Further purification can be achieved by filtration .
  • flash precipitated lignin should be understood in this specification as lignin that has been precipitated from black liquor in a continuous process by decreasing the pH of a black liquor f low, under the influence of an over pressure of 200 - 1000 kPa, down to the precipitation level of lignin using a carbon dioxide based acidifying agent , preferably carbon dioxide , and by suddenly releasing the pressure for precipitating lignin .
  • the method for producing flash precipitated lignin is disclosed in patent application FI 20106073 .
  • the residence time in the above method is under 300 s .
  • the flash precipitated lignin particles having a particle diameter of less than 2 pm, form agglomerates , which can be separated from black liquor using e .
  • the advantage of the flash precipitated lignin is its higher reactivity compared to normal kraft lignin .
  • the flash precipitated lignin can be purified and/or activated if needed for the further processing .
  • the l ignin may be derived from an alkali process .
  • the alkali process can begin with liquidi zing biomass with strong alkali followed by a neutrali zation proces s . After the alkali treatment , the lignin can be precipitated in a similar manner as presented above .
  • the lignin may be derived from steam explosion .
  • Steam explosion is a pulping and extraction technique that can be applied to wood and other fibrous organic material .
  • biorefinery lignin is to be understood in this specification, unless otherwise stated, lignin that can be recovered from a refining facility or process where biomass is converted into fuel , chemicals and other materials .
  • supercritical separation lignin is to be understood in this specification, unless otherwise stated, lignin that can be recovered from biomass using supercritical fluid separation or extraction technique .
  • Supercritical conditions correspond to the temperature and pressure above the critical point for a given substance . In supercritical conditions , distinct liquid and gas phases do not exist .
  • Supercritical water or liquid extraction is a method of decomposing and converting biomass into cellulosic sugar by employing water or liquid under supercritical conditions . The water or liquid, acting as a solvent , extracts sugars from cellulose plant matter and lignin remains as a solid particle .
  • the lignin may be derived from a hydrolysis process .
  • the lignin derived from the hydrolysis process can be recovered from paper-pulp or wood-chemical processes .
  • the lignin may originate from an organosolv process .
  • Organosolv is a pulping technique that uses an organic solvent to solubili ze lignin and hemicellulose .
  • the method comprises forming a binder composition having a pH value of 9 - 11 , or 9 . 3 - 10.5, or 9.5 - 10.
  • the binder composition has a pH value of 9 - 11, or 9.3 - 10.5, or 9.5 - 10.
  • the pH value may be adjusted by using e.g. an alkali such as sodium hydroxide or potassium oxide, or an acid, e.g. a weak acid. Glycolic acid and weak sulphuric acid may be mentioned as examples of acids that may be used.
  • the above pH values have the added utility of stabilizing the binder composition such that lignin may not be precipitated therefrom.
  • Polymerizing the crosslinking agent and the polymerizable substance in an aqueous composition may be conducted under heating at a temperature of 60 - 95 °C, or 75 - 90 °C, or 70 - 80 °C, or 70 - 90 °C. The heating in may be continued until a binder composition with a desired viscosity value is formed. In one embodiment, a pre-composition having a viscosity value of 30
  • - 500 mPa -s is formed.
  • 40 - 400 mPa -s is formed.
  • the polymerization may be continued for 0.15 - 6 hours, or 0.25 - 5 hours, or 0.5 - 3.5 hours.
  • the method comprises forming a binder composition having a viscosity of 5 - 300 mPa -s, or 10 - 250 mPa -s, or 50 - 200 mPa -s, or 75 - 150 mPa-s.
  • the binder composition has a viscosity of 5 - 300 mPa -s, or 10 - 250 mPa -s, or 50 - 200 mPa -s, or 75 - 150 mPa-s.
  • the viscosity can be measured at a temperature of 25 °C by using a rotary viscometer (Digital Brookfield viscometer LVDV-II+ Pro; cone spindle) .
  • the viscosity of the binder composition When the viscosity of the binder composition is 50 - 250 mPa -s, spraying of the binder composition over the fiber matrix may be enhanced.
  • the viscosity of the binder composition can be adjusted by the use of the urea and water.
  • the binder composition as disclosed in the current specification has the added utility of having an infinite water tolerance (water dilution capacity) , whereby a high amount of water may be used without phase separation of the binder composition.
  • the crosslinking agent may be an aldehyde, such as formaldehyde or paraformaldehyde.
  • the aldehyde is prepared from bio-methanol.
  • the aldehyde may thus be of biobased origin.
  • the aldehyde may alternatively be of fossil origin.
  • the aldehyde is prepared from methanol.
  • the total amount of crosslinking agent used for producing the binder composition may be 15 - 35 weight- % , or 17 - 30 weight-%, or 20 - 27 weight-%, based on the total dry weight of the binder composition.
  • the total amount of crosslinking agent used for producing the binder composition may be 20 - 35 weight-%, or 22 - 27 weight-%, or 23 - 25 weight-%, based on the total dry weight of the binder composition.
  • the total amount of crosslinking agent used for producing the binder composition may be 16 - 26 weight-%, or 18 - 24 weight-%, or 20 - 22 weight-%, based on the total dry weight of the binder composition.
  • the total amount of crosslinking agent used for producing the binder composition may be 15 - 25 weight-%, or 17 - 23 weight-%, or 19 - 21 weight- % , based on the total dry weight of the binder composition.
  • total dry weight should in this specification should in this specification be understood, unless otherwise stated, as the weight of the dry matter of the binder composition, i.e. excluding water.
  • the total amount of polymerizable substance used for producing the binder composition may be 40 - 70 weight-%, or 45 - 67 weight-%, or 47 - 65 weight-%, or 50 - 63 weight-%, based on the total dry weight of the binder composition.
  • the weight ratio of the crosslinking agent to the polymerizable substance may be 0.25 - 0.55, or 0.30 - 0.50.
  • a catalyst may also be used in the aqueous composition.
  • the catalyst may comprise a salt or a hydroxide of an alkali metal or alkali earth metal.
  • the catalyst is selected from a group consisting of sodium hydroxide, potassium hydroxide, barium hydroxide, and any combination or mixture thereof.
  • the catalyst is sodium hydroxide.
  • the polymerizing agent may in addition to lignin comprise a compound selected from the class of phenols.
  • the term "compound selected from the class of phenols” should be understood as meaning a fossil-based compound of phenols.
  • phenols are compounds consisting of a single aromatic ring where to one or more hydroxyls (— OH) are bonded.
  • a compound selected from the class of phenols may be e.g. phenol, cresol, or resorcinol.
  • phenols are toxic compounds.
  • the method comprises the proviso that no compound selected from the class of phenols is used for producing the binder composition.
  • the method as disclosed in the current specification has the added utility of providing a manner to produce a binder composition free of materials of fossil origin.
  • the binder composition produced may thus be free of fossil-based phenol compound (s) .
  • the binder composition as disclosed in the current specification may thus be prepared as a non-toxic binder composition. I.e. a binder composition with reduced share of toxic or hazardous compounds may be prepared.
  • the binder composition as disclosed in the current specification may be prepared as a binder composition having 100 % biological origin. Thus, all the components used for preparing the binder composition may be of biological origin and thus no fossil-based components may need to be used.
  • the method comprises forming a binder composition having a free formaldehyde content of at most 0.4 % , or at most 0.3 % , or at most 0.2 % , or at most 0.15 % , or at most 0.1 % . In one embodiment, the method comprises forming a binder composition having a free formaldehyde content of 0 - 0.4 %, or 0.01 - 0.3 %, or 0.03 - 0.2 %, or 0.05 - 0.15 %, or about 0.1 %.
  • the binder composition has a free formaldehyde content of at most 0.4 % , or at most 0.3 % , or at most 0.2 % , or at most 0.15 % , or at most 0.1 % . In one embodiment, the binder composition has a free formaldehyde content of 0 - 0.4 % , or 0.01 - 0.3 %, or 0.03 - 0.2 %, or 0.05 - 0.15 %, or about 0.1 %.
  • the free formaldehyde content may be determined in accordance with standard EN-ISO 11402.
  • the method comprises forming a binder composition having a free phenol content of at most 1 % , or at most 0.8 % , or at most 0.6 %, or at most 0.5 % , or at most 0.4 % . In one embodiment, the method comprises forming a binder composition having a free phenol content of 0 - 1 % , or 0.1 - 0.8 % , or 0.2 - 0.6 %, or 0.3 - 0.5 %, or about 0.4 %.
  • the binder composition has a free phenol content of at most 1 % , or at most 0.8 % , or at most 0.6 % , or at most 0.5 % , or at most 0.4 % . In one embodiment, the binder composition has a free phenol content of 0 - 1 % , or 0.1 - 0.8 % , or 0.2 - 0.6 %, or 0.3 - 0.5 %, or about 0.4.
  • the free phenol content of the binder composition may be determined by gas chromatography-flame ionization detector (GC-FID) method in accordance with standard SFS-EN ISO 8974:2002 with the exception that the alkaline sample solution is diluted before neutralization .
  • GC-FID gas chromatography-flame ionization detector
  • the method comprises forming a binder composition exhibiting formaldehyde emission of 0 - 0.3 mg/m 2 h, or 0 - 0.25 mg/m 2 h, or 0 - 0.2 mg/m 2 h, or 0 - 0.15 mg/m 2 h, or 0 - 0.1 mg/m 2 h, or 0 - 0.05 mg/m 2 h, or 0 - 0.03 mg/m 2 h, or 0 - 0.01 mg/m 2 h.
  • the binder composition exhibits a formaldehyde emission of 0 - 0.3 mg/m 2 h, or 0 - 0.25 mg/m 2 h, or 0 - 0.2 mg/m 2 h, or 0 - 0.15 mg/m 2 h, or 0 - 0.1 mg/m 2 h, or 0 - 0.05 mg/m 2 h, or 0 - 0.03 mg/m 2 h, or 0 - 0.01 mg/m 2 h.
  • the method comprises forming a binder composition exhibiting phenol emission of at most 1.5 mg/m 2 h, or at most 1.3 mg/m 2 h, or at most 1 mg/m 2 h, or at most 0.8 mg/m 2 h, or at most 0.5 mg/m 2 h.
  • the binder composition exhibits a phenol emission of at most 1.5 mg/m 2 h, or at most 1.3 mg/m 2 h, or at most 1 mg/m 2 h, or at most 0.8 mg/m 2 h, or at most 0.5 mg/m 2 h .
  • the formaldehyde emission and the phenol emission exhibited by the binder composition may be measured according to standard ISO 12460-3:2015 with modified sample size (using a mold with dimensions of 173 mm in length, 22 mm in width and 22 mm in height) .
  • modified sample size using a mold with dimensions of 173 mm in length, 22 mm in width and 22 mm in height.
  • the measured emissions are applicable for the binder composition.
  • 30 - 100 weight-%, or 40 - 99 weight-%, or 50 - 95 weight-%, or 60 - 90 weight-%, or 70 - 85 weight-%, of the polymerizable substance originates from lignin.
  • the binder composition as disclosed in the current specification may be used for producing an insulating wool product.
  • the insulating wool product may be a mineral wool product, such as glass wool product, stone wool product, or slag wool product.
  • the insulating wool product may thus comprise a fiber matrix and a binder composition as disclosed in the current specification.
  • the insulating wool product comprises a fiber matrix selected from glass fiber, stone fiber, or cellulose fiber.
  • the total amount of binder composition in the insulating wool product is 1 - 10 weight-%, or 2 - 9 weight-%, or 3 - 8 weight-%, or 4 - 7 weight-%, or 5 - 6 weight-%, based on the total weight of the insulating wool product .
  • Further additive ( s ) may be combined with the binder composition when producing the insulating wool product .
  • De-dusting oils , emulsifiers , dyes , extenders , and scavengers may be mentioned as examples of such additives .
  • the insulating wool product may be produced by spraying the binder composition over melted fiber matrix, which is pre-formed in high temperatures , e . g . at over 1000 °C .
  • the fiber matrix of the insulating wool product may be in the form of a sheet , slabs , batts , rolls , a panel , or blown .
  • the method disclosed in the current specification has the added utility of enabling one to produce a binder composition having properties being beneficial for producing an insulating wool product .
  • the produced binder composition may exhibit a content of free formaldehyde and content of free phenols that make it especially suitable to be used for producing an insulating wool product .
  • Using the binder composition as disclosed in the current specification for the production of an insulating wool product has the added utility of providing the wool product with low emissions while simultaneously exhibiting a high strength .
  • the above components were mixed and heated at a temperature of about 70 °C in order to polymerize the lignin, phenol, and formaldehyde, to form the pre- composition .
  • silane was mixed with this formed precomposition .
  • sandbars were prepared by mixing the binder composition samples with silica sand (grain size of 0.1 - 0.6 mm) in a mold with dimensions of 173 mm in length, 22 mm in width and 22 mm in height, and then by pressing the formed mixture with a suitable hydraulic press capable of producing 1.6 N/mm 2 of specific pressure. The pressed sandbar mixture was then cured in an oven at a temperature of 180°C for
  • the formed sandbars where then analyzed for their formaldehyde and phenol emissions. As the sand as such does not affect the measured results, the measured emissions are applicable for the binder composition.
  • the analyses were made by unwrapping the sandbars and then putting the same into a sample rack inside a gas analysis chamber (e.g. GreCon GA 6000) with constant temperature of 60°C, airflow of 60 1/h and pressure of 1100 Pa. The samples were held within the chamber for four hours, during which the released emissions were directed into wash bottles, and then analyzed with Hach' s cuvette test method within 24 hours with Spectrophotometer (e.g. DR3900) . The results are presented in the below tables. Table 3 . Emissions from cured sandbars
  • the sample contained 0 . 2 weight-% of silane based on the total dry weight of the binder composition, but no urea or ammonium sulphate .
  • Sandbar samples prepared with differing amounts of s ilane were prepared as above presented and tested for the strength of the formed sandbars .
  • "LPF500" pre-composition was used as a basi s for all the samples .
  • the dry strength of the sandbar samples was tested according to standard EN 310 : 1993 Modulus of rupture (which is equal to the dry strength of the sample ) .
  • the results are presented in Fig . 1 . From the results one can see that samples with as low amount as 0 . 2 weight- % or 0 . 5 weight-% of silane in the binder composition exhibited suitable dry strength values .
  • Sandbar samples were prepared as above presented by using the different binder composition samples .
  • the dry strength of the sandbar samples was tested according to standard EN 310 : 1993 Modulus of rupture (which is equal to the dry strength of the sample ) .
  • the results are presented in Fig . 3 .
  • a method, a binder composition, the use , or the insulating wool product , disclosed herein, may comprise at least one of the embodiments described hereinbefore .
  • the benefits and advantages described above may relate to one embodiment or may relate to several embodiments .
  • the embodiments are not l imited to those that solve any or all of the stated problems or those that have any or al l of the stated benefits and advantages. It will further be understood that reference to 'an' item refers to one or more of those items.
  • the term "comprising" is used in this specification to mean including the feature (s) or act(s) followed thereafter, without excluding the presence of one or more additional features or acts.

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Abstract

A method for producing a binder composition is disclosed. The method comprises: i) polymerizing crosslinking agent and polymerizable substance in an aqueous composition by mixing and heating at a temperature of 60 – 95 °C for preparing a pre-composition, wherein at least 30 weight-% of the polymerizable substance originates from lignin, and ii) mixing the pre-composition with silane, wherein silane is used in an amount of 0.1 – 0.9 weight-% based on the total dry weight of the binder composition, to form a binder composition having a free formaldehyde content of at most 0.5 %.

Description

A BINDER COMPOSITION, A METHOD FOR PRODUCING A BINDER COMPOSITION, ITS USE , AND AN INSULATING WOOL PRODUCT
TECHNICAL FIELD
The present disclosure relates to a method for producing a binder composition . The present disclosure further relates to a binder composition and to its use . The present disclosure further relates to an insulating wool product .
BACKGROUND
An insulating wool product such as mineral wool can be produced by spaying a binder on a melted fiber matrix . Traditionally used binders for insulating wool production are sodium silicates , polyesters , melamine urea formaldehyde , polyamides , furane-based resins , and others , phenolic resin ( PF) -based binders . PF-resin has a high free formaldehyde ( FA) content affecting the emissions of the final product unless a relevant amount of urea is used . The inventors have therefore recogni zed the need to produce a binder composition to be used for producing an insulating wool product in a more sustainable manner .
SUMMARY
A method for producing a binder composition is disclosed . The method comprises : i ) polymeri zing crosslinking agent and polymeri zable substance in an aqueous composition by mixing and heating at a temperature of 60 - 95 °C for preparing a pre-composition, wherein at least 30 weight- % of the polymeri zable substance originates from lignin, and ii ) mixing the pre-composition with silane , wherein silane is used in an amount of 0 . 1 - 0 . 9 weight- % based on the total dry weight of the binder composition, to form a binder composition having a free formaldehyde content of at most 0 . 5 % .
Further is disclosed a binder composition comprising crosslinking agent polymeri zed with polymeri zable substance , and silane , wherein :
- at least 30 weight-% of the polymeri zable substance originates from lignin,
- the binder composition comprises silane in an amount of 0 . 1 - 0 . 9 weight-% based on the total dry weight of the binder composition, and
- the binder composition has a free formaldehyde content of at most 0 . 5 % .
Further is disclosed the use of the binder composition as disclosed in the current specification for producing an insulating wool product .
Further is disclosed an insulating wool product comprising a fiber matrix and a binder composition, wherein the binder composition comprises crosslinking agent polymeri zed with polymeri zable substance , and silane , wherein :
- at least 30 weight-% of the polymeri zable substance originates from lignin,
- the binder composition comprises silane in an amount of 0 . 1 - 0 . 9 weight-% based on the total dry weight of the binder composition, and
- the binder composition has a free formaldehyde content of at most 0 . 5 %.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings , which are included to provide a further understanding of the embodiments and constitute a part of this specification, illustrate embodiments and together with the description help to explain the principles of the above . In the drawings :
Fig . 1 illustrates the results of example 4 ; Fig . 2 illustrates the results of example 5 ; and
Fig . 3 illustrates the results of example 6 .
DETAILED DESCRIPTION
The present disclosure relates to a method for producing a binder composition . The method comprises : i ) polymeri zing crosslinking agent and polymeri zable substance in an aqueous composition by mixing and heating at a temperature of 60 - 95 °C for preparing a pre-composition, wherein at least 30 weight- % of the polymeri zable substance originates from lignin, and ii ) mixing the pre-composition with silane , wherein silane is used in an amount of 0 . 1 - 0 . 9 weight- % based on the total dry weight of the binder composition, to form a binder composition having a free formaldehyde content of at most 0 . 5 % .
The present disclosure further relates to a binder composition comprising crosslinking agent polymeri zed with polymeri zable substance , and silane , wherein :
- at least 30 weight-% of the polymeri zable substance originates from lignin,
- the binder composition comprises silane in an amount of 0 . 1 - 0 . 9 weight-% based on the total dry weight of the binder composition, and
- the binder composition has a free formaldehyde content of at most 0 . 5 % .
The binder composition may be an aqueous binder composition .
The present disclosure further relates to the use of the binder composition as disclosed in the current specification for producing an insulating wool product . The method may thus be used for producing a binder composition for producing an insulating wool product .
Further is disclosed an insulating wool product comprising a fiber matrix and a binder composition, wherein the binder composition comprises crosslinking agent polymerized with polymerizable substance, and silane, wherein:
- at least 30 weight-% of the polymerizable substance originates from lignin,
- the binder composition comprises silane in an amount of 0.1 - 0.9 weight-% based on the total dry weight of the binder composition, and
- the binder composition has a free formaldehyde content of at most 0.5 weight-%.
The inventors surprisingly found out that by using the binder composition as disclosed in the current specification, one is able to produce an insulating wool product that exhibits a low amount of formaldehyde emissions as well as a low amount of phenol emissions, while simultaneously having a high water-tolerance and strength. Thus, the binder composition as disclosed in the current specification has the added utility of being a more environmentally friendly solution to be used for producing an insulating wool product.
In one embodiment, silane is used in an amount of 0.2 - 0.7 weight-%, or 0.3 - 0.5 weight-%, based on the total dry weight of the binder composition. In one embodiment, the binder composition comprises silane in an amount of 0.2 - 0.7 weight-%, or 0.3 - 0.5 weight-%, based on the total dry weight of the binder composition. Silane has the added utility of promoting adhesion to achieve high strength and good moisture resistance in an insulating wool product.
In one embodiment, the method comprises mixing in ii) the pre-composition also with a scavenger and/or a hardener. In one embodiment, the binder composition comprises also a scavenger and/or a hardener. In one embodiment, the scavenger is selected from urea, ammonia, dicyandiamide, melamine, tannin such as tannin extracts, gallic acid, sodium hydrogen sulfite (NaHSOs) , sodium sulfite (Na2SOs) , sodium metabisulphite (Na2S20s) , ammonium hydrogen sulfite, polyamides, dextrose, amine, ammonia sulfite, ammonium salts, ammonium hydroxide, ammonium carbonate, ammonium bicarbonate, oxygenated sulfur salts, sodium sulfite, sodium bisuifate, sodium metabisulfite, melamine, cyanoguanidine, guanamine, caprinoguanamine, melamine, dicyandiamine, ethyl acetoacetate, green tea catechin, lignocellulosic, tannic acid, wood bark flours, chestnut flour, fir trees flour, wheat flour, rice hus flour, hemp four, molasses, and/or charcoal. In one embodiment, the scavenger is urea. Also, a mixture of at least two scavengers may be used.
In one embodiment, the hardener is selected from sulphates and/or phosphates. In one embodiment, the hardener is selected from ammonium sulphate and/or ammonium hydroxide. In one embodiment, the hardener is ammonium sulphate. In one embodiment, the hardener is selected from alkaline metal sulphate, alkaline metal phosphate, alkaline earth metal sulfates and/or alkaline earth metal phosphates. Also, a mixture of at least two hardeners may be used.
In one embodiment, the method comprises mixing in ii) the pre-composition also with urea and/or ammonium sulphate. In one embodiment, the binder composition comprises also urea and/or ammonium sulphate.
The urea may be used for producing a binder composition with a suitably low viscosity value. The urea may further be used for increasing the dry solids content of the binder composition. In one embodiment, urea is used in an amount of 0 - 9 weight-%, or 0.1 - 9 weight-%, or 0.5 - 8 weight-%, or 1 - 7 weight-%, or 2 - 6 weight-%, or 3 - 5 weight-%, based on the total wet weight of the binder composition. In one embodiment, the binder composition comprises urea in an amount of 0 - 9 weight-%, 0.1 - 9 weight-%, or 0.5 - 8 weight-%, or 1 - 7 weight-%, or 2 - 6 weight-%, or 3 - 5 weight-%, based on the total wet weight of the binder composition. Urea may be used to decrease the viscosity of the binder composition so that it may be sprayed on the fiber matrix when used for producing insulating wool. The inventors surprisingly found out that, if used, only a low amount of urea may be needed to further drop the free formaldehyde content of the binder composition and thus the formaldehyde emissions of the produced insulating wool product. In one embodiment, no urea is used for producing the binder composition. In one embodiment, the binder composition comprises no urea.
The "total wet weight" should in this specification be understood, unless otherwise stated, as the weight of both the dry matter and the liquid part, e.g. water, of the binder composition.
Ammonium sulphate, when used in the binder composition for producing an insulating wool product, has the added utility of providing the insulating wool product a satisfactory tensile strength formed during the curing process.
In one embodiment, ammonium sulphate is used in an amount of 0 - 15 weight-%, or 0.5 - 15 weight-%, or 1 - 14 weight-%, or 2 - 13 weight-%, or 3 - 12 weight- % , or 4 - 11 weight-%, or 5 - 10 weight-%, or 6 - 9 weight-%, based on the total dry weight of the binder composition. In one embodiment, ammonium sulphate is used in an amount of 0 - 7 weight-%, or 0.5 - 7 weight- % , or 1 - 6 weight-%, or 2 - 5 weight-%, or 3 - 4 weight- % , based on the total dry weight of the binder composition. In one embodiment, ammonium sulphate is used in an amount of 5 - 15 weight-%, or 6 - 14 weight-%, or 7 - 13 weight-%, or 8 - 12 weight-%, or 9 - 11 weight-%, based on the total dry weight of the binder composition. In one embodiment, the binder composition comprises ammonium sulphate in an amount of 0 - 15 weight- % , or 0.5 - 15 weight-%, or 1 - 14 weight-%, or 2 - 13 weight-%, or 3 - 12 weight-%, or 4 - 11 weight-%, or 5 - 10 weight-%, or 6 - 9 weight-%, based on the total dry weight of the binder composition. In one embodiment, the binder composition comprises ammonium sulphate in an amount of 0 - 7 weight-%, or 0.5 - 7 weight-%, or 1 - 6 weight-%, or 2 - 5 weight-%, or 3 - 4 weight-%, based on the total dry weight of the binder composition. In one embodiment, the binder composition comprises ammonium sulphate in an amount of 5 - 15 weight-%, or 6 - 14 weight-%, or 7 - 13 weight-%, or 8 - 12 weight-%, or 9 - 11 weight-%, based on the total dry weight of the binder composition.
In one embodiment, no ammonium sulphate is used for producing the binder composition. In one embodiment, the binder composition comprises no ammonium sulphate.
The lignin used for preparing the binder composition may be selected from a group consisting of kraft lignin, steam explosion lignin, biorefinery lignin, supercritical separation lignin, hydrolysis lignin, flash precipitated lignin, biomass originating lignin, lignin from alkaline pulping process, lignin from soda process, lignin from organosolv pulping, lignin from alkali process, lignin from enzymatic hydrolysis process, and any combination thereof. In one embodiment, the lignin is wood based lignin. The lignin can originate from softwood, hardwood, annual plants or from any combination thereof.
By "kraft lignin" is to be understood in this specification, unless otherwise stated, lignin that originates from kraft black liquor. Black liquor is an alkaline aqueous solution of lignin residues, hemi cellulose, and inorganic chemicals used in a kraft pulping process. The black liquor from the pulping process comprises components originating from different softwood and hardwood species in various proportions . Lignin can be separated from the black liquor by different , techniques including e . g. precipitation and filtration .
Lignin usually begins precipitating at pH values below 11 - 12 . Different pH values can be used in order to precipitate lignin fractions with different properties . These lignin fractions differ from each other by molecular weight distribution, e . g. Mw and Mn, polydispersity, hemicellulose and extractive contents . The molar mass of lignin precipitated at a higher pH value is higher than the molar mas s of lignin precipitated at a lower pH value . Further, the molecular weight distribution of lignin fraction precipitated at a lower pH value i s wider than of lignin fraction precipitated at a higher pH value . The precipitated lignin can be purified from inorganic impurities , hemicellulose and wood extractives using acidic washing steps . Further purification can be achieved by filtration .
The term "flash precipitated lignin" should be understood in this specification as lignin that has been precipitated from black liquor in a continuous process by decreasing the pH of a black liquor f low, under the influence of an over pressure of 200 - 1000 kPa, down to the precipitation level of lignin using a carbon dioxide based acidifying agent , preferably carbon dioxide , and by suddenly releasing the pressure for precipitating lignin . The method for producing flash precipitated lignin is disclosed in patent application FI 20106073 . The residence time in the above method is under 300 s . The flash precipitated lignin particles , having a particle diameter of less than 2 pm, form agglomerates , which can be separated from black liquor using e . g. filtration . The advantage of the flash precipitated lignin is its higher reactivity compared to normal kraft lignin . The flash precipitated lignin can be purified and/or activated if needed for the further processing . The l ignin may be derived from an alkali process . The alkali process can begin with liquidi zing biomass with strong alkali followed by a neutrali zation proces s . After the alkali treatment , the lignin can be precipitated in a similar manner as presented above .
The lignin may be derived from steam explosion . Steam explosion is a pulping and extraction technique that can be applied to wood and other fibrous organic material .
By "biorefinery lignin" is to be understood in this specification, unless otherwise stated, lignin that can be recovered from a refining facility or process where biomass is converted into fuel , chemicals and other materials .
By "supercritical separation lignin" is to be understood in this specification, unless otherwise stated, lignin that can be recovered from biomass using supercritical fluid separation or extraction technique . Supercritical conditions correspond to the temperature and pressure above the critical point for a given substance . In supercritical conditions , distinct liquid and gas phases do not exist . Supercritical water or liquid extraction is a method of decomposing and converting biomass into cellulosic sugar by employing water or liquid under supercritical conditions . The water or liquid, acting as a solvent , extracts sugars from cellulose plant matter and lignin remains as a solid particle .
The lignin may be derived from a hydrolysis process . The lignin derived from the hydrolysis process can be recovered from paper-pulp or wood-chemical processes .
The lignin may originate from an organosolv process . Organosolv is a pulping technique that uses an organic solvent to solubili ze lignin and hemicellulose .
In one embodiment , the method comprises forming a binder composition having a pH value of 9 - 11 , or 9 . 3 - 10.5, or 9.5 - 10. In one embodiment, the binder composition has a pH value of 9 - 11, or 9.3 - 10.5, or 9.5 - 10. The pH value may be adjusted by using e.g. an alkali such as sodium hydroxide or potassium oxide, or an acid, e.g. a weak acid. Glycolic acid and weak sulphuric acid may be mentioned as examples of acids that may be used. The above pH values have the added utility of stabilizing the binder composition such that lignin may not be precipitated therefrom.
Polymerizing the crosslinking agent and the polymerizable substance in an aqueous composition may be conducted under heating at a temperature of 60 - 95 °C, or 75 - 90 °C, or 70 - 80 °C, or 70 - 90 °C. The heating in may be continued until a binder composition with a desired viscosity value is formed. In one embodiment, a pre-composition having a viscosity value of 30
- 500 mPa -s, or 40 - 400 mPa -s, or 50 - 250 mPa -s, or 75 - 200 mPa -s, or 100 - 150 mPa -s, is formed. The polymerization may be continued for 0.15 - 6 hours, or 0.25 - 5 hours, or 0.5 - 3.5 hours.
In one embodiment, the method comprises forming a binder composition having a viscosity of 5 - 300 mPa -s, or 10 - 250 mPa -s, or 50 - 200 mPa -s, or 75 - 150 mPa-s. In one embodiment, the binder composition has a viscosity of 5 - 300 mPa -s, or 10 - 250 mPa -s, or 50 - 200 mPa -s, or 75 - 150 mPa-s. The viscosity can be measured at a temperature of 25 °C by using a rotary viscometer (Digital Brookfield viscometer LVDV-II+ Pro; cone spindle) . When the viscosity of the binder composition is 50 - 250 mPa -s, spraying of the binder composition over the fiber matrix may be enhanced. The viscosity of the binder composition can be adjusted by the use of the urea and water. The binder composition as disclosed in the current specification, has the added utility of having an infinite water tolerance (water dilution capacity) , whereby a high amount of water may be used without phase separation of the binder composition. The crosslinking agent may be an aldehyde, such as formaldehyde or paraformaldehyde. In one embodiment, the aldehyde is prepared from bio-methanol. The aldehyde may thus be of biobased origin. The aldehyde may alternatively be of fossil origin. In one embodiment, the aldehyde is prepared from methanol.
The total amount of crosslinking agent used for producing the binder composition may be 15 - 35 weight- % , or 17 - 30 weight-%, or 20 - 27 weight-%, based on the total dry weight of the binder composition. The total amount of crosslinking agent used for producing the binder composition may be 20 - 35 weight-%, or 22 - 27 weight-%, or 23 - 25 weight-%, based on the total dry weight of the binder composition. The total amount of crosslinking agent used for producing the binder composition may be 16 - 26 weight-%, or 18 - 24 weight-%, or 20 - 22 weight-%, based on the total dry weight of the binder composition. The total amount of crosslinking agent used for producing the binder composition may be 15 - 25 weight-%, or 17 - 23 weight-%, or 19 - 21 weight- % , based on the total dry weight of the binder composition.
The "total dry weight" should in this specification should in this specification be understood, unless otherwise stated, as the weight of the dry matter of the binder composition, i.e. excluding water.
The total amount of polymerizable substance used for producing the binder composition may be 40 - 70 weight-%, or 45 - 67 weight-%, or 47 - 65 weight-%, or 50 - 63 weight-%, based on the total dry weight of the binder composition.
The weight ratio of the crosslinking agent to the polymerizable substance may be 0.25 - 0.55, or 0.30 - 0.50.
A catalyst may also be used in the aqueous composition. The catalyst may comprise a salt or a hydroxide of an alkali metal or alkali earth metal. In one embodiment, the catalyst is selected from a group consisting of sodium hydroxide, potassium hydroxide, barium hydroxide, and any combination or mixture thereof. In one embodiment, the catalyst is sodium hydroxide.
The polymerizing agent may in addition to lignin comprise a compound selected from the class of phenols. In this specification, unless otherwise stated, the term "compound selected from the class of phenols" should be understood as meaning a fossil-based compound of phenols. I.e. phenols are compounds consisting of a single aromatic ring where to one or more hydroxyls (— OH) are bonded. Such a compound selected from the class of phenols may be e.g. phenol, cresol, or resorcinol. Such phenols are toxic compounds. In one embodiment, the method comprises the proviso that no compound selected from the class of phenols is used for producing the binder composition. The method as disclosed in the current specification has the added utility of providing a manner to produce a binder composition free of materials of fossil origin. The binder composition produced may thus be free of fossil-based phenol compound (s) . The binder composition as disclosed in the current specification may thus be prepared as a non-toxic binder composition. I.e. a binder composition with reduced share of toxic or hazardous compounds may be prepared. The binder composition as disclosed in the current specification may be prepared as a binder composition having 100 % biological origin. Thus, all the components used for preparing the binder composition may be of biological origin and thus no fossil-based components may need to be used.
In one embodiment, the method comprises forming a binder composition having a free formaldehyde content of at most 0.4 % , or at most 0.3 % , or at most 0.2 % , or at most 0.15 % , or at most 0.1 % . In one embodiment, the method comprises forming a binder composition having a free formaldehyde content of 0 - 0.4 %, or 0.01 - 0.3 %, or 0.03 - 0.2 %, or 0.05 - 0.15 %, or about 0.1 %.
In one embodiment, the binder composition has a free formaldehyde content of at most 0.4 % , or at most 0.3 % , or at most 0.2 % , or at most 0.15 % , or at most 0.1 % . In one embodiment, the binder composition has a free formaldehyde content of 0 - 0.4 % , or 0.01 - 0.3 %, or 0.03 - 0.2 %, or 0.05 - 0.15 %, or about 0.1 %.
The free formaldehyde content may be determined in accordance with standard EN-ISO 11402.
In one embodiment, the method comprises forming a binder composition having a free phenol content of at most 1 % , or at most 0.8 % , or at most 0.6 %, or at most 0.5 % , or at most 0.4 % . In one embodiment, the method comprises forming a binder composition having a free phenol content of 0 - 1 % , or 0.1 - 0.8 % , or 0.2 - 0.6 %, or 0.3 - 0.5 %, or about 0.4 %.
In one embodiment, the binder composition has a free phenol content of at most 1 % , or at most 0.8 % , or at most 0.6 % , or at most 0.5 % , or at most 0.4 % . In one embodiment, the binder composition has a free phenol content of 0 - 1 % , or 0.1 - 0.8 % , or 0.2 - 0.6 %, or 0.3 - 0.5 %, or about 0.4.
The free phenol content of the binder composition may be determined by gas chromatography-flame ionization detector (GC-FID) method in accordance with standard SFS-EN ISO 8974:2002 with the exception that the alkaline sample solution is diluted before neutralization .
In one embodiment, the method comprises forming a binder composition exhibiting formaldehyde emission of 0 - 0.3 mg/m2h, or 0 - 0.25 mg/m2h, or 0 - 0.2 mg/m2h, or 0 - 0.15 mg/m2h, or 0 - 0.1 mg/m2h, or 0 - 0.05 mg/m2h, or 0 - 0.03 mg/m2h, or 0 - 0.01 mg/m2h. In one embodiment, the binder composition exhibits a formaldehyde emission of 0 - 0.3 mg/m2h, or 0 - 0.25 mg/m2h, or 0 - 0.2 mg/m2h, or 0 - 0.15 mg/m2h, or 0 - 0.1 mg/m2h, or 0 - 0.05 mg/m2h, or 0 - 0.03 mg/m2h, or 0 - 0.01 mg/m2h.
In one embodiment, the method comprises forming a binder composition exhibiting phenol emission of at most 1.5 mg/m2h, or at most 1.3 mg/m2h, or at most 1 mg/m2h, or at most 0.8 mg/m2h, or at most 0.5 mg/m2h. In one embodiment, the binder composition exhibits a phenol emission of at most 1.5 mg/m2h, or at most 1.3 mg/m2h, or at most 1 mg/m2h, or at most 0.8 mg/m2h, or at most 0.5 mg/m2h .
The formaldehyde emission and the phenol emission exhibited by the binder composition may be measured according to standard ISO 12460-3:2015 with modified sample size (using a mold with dimensions of 173 mm in length, 22 mm in width and 22 mm in height) . As the sand as such, that used for the measurements according to the standard, does not affect the measured results, the measured emissions are applicable for the binder composition.
In one embodiment, 30 - 100 weight-%, or 40 - 99 weight-%, or 50 - 95 weight-%, or 60 - 90 weight-%, or 70 - 85 weight-%, of the polymerizable substance originates from lignin.
The binder composition as disclosed in the current specification may be used for producing an insulating wool product. The insulating wool product may be a mineral wool product, such as glass wool product, stone wool product, or slag wool product.
The insulating wool product may thus comprise a fiber matrix and a binder composition as disclosed in the current specification.
In one embodiment, the insulating wool product comprises a fiber matrix selected from glass fiber, stone fiber, or cellulose fiber. In one embodiment, the total amount of binder composition in the insulating wool product is 1 - 10 weight-%, or 2 - 9 weight-%, or 3 - 8 weight-%, or 4 - 7 weight-%, or 5 - 6 weight-%, based on the total weight of the insulating wool product .
Further additive ( s ) may be combined with the binder composition when producing the insulating wool product . De-dusting oils , emulsifiers , dyes , extenders , and scavengers may be mentioned as examples of such additives .
The insulating wool product may be produced by spraying the binder composition over melted fiber matrix, which is pre-formed in high temperatures , e . g . at over 1000 °C . The fiber matrix of the insulating wool product may be in the form of a sheet , slabs , batts , rolls , a panel , or blown .
The method disclosed in the current specification has the added utility of enabling one to produce a binder composition having properties being beneficial for producing an insulating wool product . The produced binder composition may exhibit a content of free formaldehyde and content of free phenols that make it especially suitable to be used for producing an insulating wool product . Using the binder composition as disclosed in the current specification for the production of an insulating wool product has the added utility of providing the wool product with low emissions while simultaneously exhibiting a high strength .
EXAMPLES
Reference will now be made in detail to various embodiments , examples of which are illustrated in the accompanying drawings .
The description below discloses some embodiments in such a detail that a person skilled in the art is able to utili ze the embodiments based on the disclosure . Not all steps or features of the embodiments are discussed in detail , as many of the steps or features will be obvious for the person skilled in the art based on this specification . Example 1 - Preparing binder compositions
In this example different binder compositions were prepared.
The following components and their percentages were used in this example for producing the precompositions :
Samples with 30 weight-% of the polymerizable substance being lignin (LPF300)
Kraft lignin 8.7 weight-%
Phenol 20.3 weight-%
Formaldehyde 13.9 weight-%
NaOH 4 weight-%
The rest being water
Samples with 50 weight-% of the polymerizable substance being lignin (LPF500)
Kraft lignin 15.8 weight-%
Phenol 15.8 weight-%
Formaldehyde 11.5 weight-%
NaOH 4 weight-%
The rest being water
Samples with 70 weight-% of the polymerizable substance being lignin (LPF700)
Kraft lignin 20.7 weight-%
Phenol 8.9 weight-%
Formaldehyde 9.4 weight-%
NaOH 4 weight-%
The rest being water
The above components were mixed and heated at a temperature of about 70 °C in order to polymerize the lignin, phenol, and formaldehyde, to form the pre- composition . Then silane was mixed with this formed precomposition .
Further samples were prepared by adding varying amounts of urea and/or ammonium sulphate . I f urea was used, then it was added before silane . The amounts of silane , urea, and ammonium sulphate used in the different samples are indicated in the blow tables . A commercial phenol-f ormaldehyde resin ( PF) was used as a comparative example . The prepared binder compositions were tested as presented in the below examples .
Example 2 - Measuring free formaldehyde content and free phenol content
The free formaldehyde content and the free phenol content of prepared samples were measured as described in the current specification . The composition of the tested samples and their results are presented in the below table 1 .
Table 1 . Amount of urea, ammonium sulphate , and silane in the samples and the measured results
*The free phenol content: Determined by gas chromatography-flame ionization detector (GC-FID) method in accordance with standard SFS-EN ISO 8974:2002 with the exception that the alkaline sample solution is diluted before neutralization
**The free formaldehyde content: Determined in accordance with standard EN-ISO 11402
Table 2. Amount of urea, ammonium sulphate, and silane in the samples and the measured results
*The free phenol content: Determined by gas chromatography-flame ionization detector (GC-FID) method in accordance with standard SFS-EN ISO 8974:2002 with the exception that the alkaline sample solution is diluted before neutralization
**The free formaldehyde content: Determined in accordance with standard EN-ISO 11402
From the results presented in table 1 and table 2 one can see that with the binder compositions prepared have a low content of free formaldehyde and free phenol.
Example 3 - Measuring formaldehyde and phenol emissions
Prepared binder composition samples were used to prepare sandbars and the sandbar samples were tested as described in the current specification. The sandbars were prepared by mixing the binder composition samples with silica sand (grain size of 0.1 - 0.6 mm) in a mold with dimensions of 173 mm in length, 22 mm in width and 22 mm in height, and then by pressing the formed mixture with a suitable hydraulic press capable of producing 1.6 N/mm2 of specific pressure. The pressed sandbar mixture was then cured in an oven at a temperature of 180°C for
2 hour and 45 minutes. After the curing, the samples were tightly wrapped with a plastic wrap to prevent the loss of emissions from the material.
The formed sandbars where then analyzed for their formaldehyde and phenol emissions. As the sand as such does not affect the measured results, the measured emissions are applicable for the binder composition. The analyses were made by unwrapping the sandbars and then putting the same into a sample rack inside a gas analysis chamber (e.g. GreCon GA 6000) with constant temperature of 60°C, airflow of 60 1/h and pressure of 1100 Pa. The samples were held within the chamber for four hours, during which the released emissions were directed into wash bottles, and then analyzed with Hach' s cuvette test method within 24 hours with Spectrophotometer (e.g. DR3900) . The results are presented in the below tables. Table 3 . Emissions from cured sandbars
* The sample contained 0 . 2 weight-% of silane based on the total dry weight of the binder composition, but no urea or ammonium sulphate .
From table 3 one can see that the formaldehyde emissions as well as the phenol emissions for the prepared binder composition are very low .
Table 4 . Emissions from cured sandbars
* all the samples contained 0 . 2 weight-% of silane and 4 weight-% of ammonium sulphate based on the total dry weight of the binder composition .
From table 4 one can see that with the binder compositions prepared with as low amount of urea as 7 . 5 weight-% one is able to prepare a binder composition having the formaldehyde emission of as low as at most 0 . 01 mg/m2h, whereas a urea amount of 18 weight-% is needed to reduce the formaldehyde emissions to 0 . 075 mg/m2h in the comparative PF sample . Also , the phenol emissions for the prepared samples were on a low level . Example 4 - Strength of the binder compositions
In this example the effect of varying the amount of s ilane in the binder compositions on the dry strength of the prepared sandbars was tested .
Sandbar samples prepared with differing amounts of s ilane were prepared as above presented and tested for the strength of the formed sandbars . "LPF500" pre-composition was used as a basi s for all the samples . The dry strength of the sandbar samples was tested according to standard EN 310 : 1993 Modulus of rupture (which is equal to the dry strength of the sample ) . The results are presented in Fig . 1 . From the results one can see that samples with as low amount as 0 . 2 weight- % or 0 . 5 weight-% of silane in the binder composition exhibited suitable dry strength values .
Example 5 - Strength of the binder compositions
In this example the dry strength of sandbars prepared with the binder composition samples prepared in example 2 was tested . Sandbar samples were prepared as above presented . The dry strength of the sandbar samples was tested according to standard EN 310 : 1993 Modulus of rupture (which is equal to the dry strength of the sample ) . The results are presented in Fig . 2 .
From the results one can see that the dry strength of sandbars prepared with the binder composition samples as disclosed in the current specification one may achieve equally good values as with the comparative commercial PF resin .
Example 6 - Strength of the binder compositions
In this example the dry strength of sandbars prepared with the binder composition samples based on pre-compositions LPF500 and LPF300 was tested . The following samples were prepared :
Table 5 . Amount of urea, ammonium sulphate , and silane in the samples
Sandbar samples were prepared as above presented by using the different binder composition samples . The dry strength of the sandbar samples was tested according to standard EN 310 : 1993 Modulus of rupture (which is equal to the dry strength of the sample ) . The results are presented in Fig . 3 .
From the results one can see that the dry strength of sandbars prepared with the binder composition samples as disclosed in the current specification is high .
It is obvious to a person skilled in the art that with the advancement of technology, the basic idea may be implemented in various ways . The embodiments are thus not limited to the examples described above ; instead, they may vary within the scope of the claims .
The embodiments described hereinbefore may be used in any combination with each other . Several of the embodiments may be combined together to form a further embodiment . A method, a binder composition, the use , or the insulating wool product , disclosed herein, may comprise at least one of the embodiments described hereinbefore . It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments . The embodiments are not l imited to those that solve any or all of the stated problems or those that have any or al l of the stated benefits and advantages. It will further be understood that reference to 'an' item refers to one or more of those items. The term "comprising" is used in this specification to mean including the feature (s) or act(s) followed thereafter, without excluding the presence of one or more additional features or acts.

Claims

1. A method for producing a binder composition, wherein the method comprises: i) polymerizing crosslinking agent and polymerizable substance in an aqueous composition by mixing and heating at a temperature of 60 - 95 °C for preparing a pre-composition, wherein at least 30 weight- % of the polymerizable substance originates from lignin, and ii) mixing the pre-composition with silane, wherein silane is used in an amount of 0.1 - 0.9 weight- % based on the total dry weight of the binder composition, to form a binder composition having a free formaldehyde content of at most 0.5 % .
2. The method of claim 1, wherein silane is used in an amount of 0.2 - 0.7 weight-%, or 0.3 - 0.5 weight-%, based on the total dry weight of the binder composition .
3. The method of any one of the preceding claims, wherein the method comprises mixing in ii) the pre-composition also with a scavenger and/or a hardener.
4. The method of any one of the preceding claims, wherein the method comprises mixing in ii) the pre-composition also with urea and/or ammonium sulphate.
5. The method of claim 4, wherein urea is used in an amount of 0.1 - 9 weight-%, or 0.5 - 8 weight-%, or 1 - 7 weight-%, or 2 - 6 weight-%, or 3 - 5 weight- % , based on the total wet weight of the binder composition.
6. The method of any one of claims 4 - 5, wherein ammonium sulphate is used in an amount of 0.5 - 15 weight-%, or 1 - 14 weight-%, or 2 - 13 weight-%, or 3 - 12 weight-%, or 4 - 11 weight-%, or 5 - 10 weight- % , or 6 - 9 weight-%, based on the total dry weight of the binder composition.
7. The method of any one of the preceding claims, wherein the method comprises forming a binder composition having a pH value of 9 - 11, or 9.3 - 10.5, or 9.5 - 10.
8. The method of any one of the preceding claims, wherein the method comprises forming a binder composition having a viscosity of 5 - 300 mPa -s, or 10
- 250 mPa -s, or 50 - 200 mPa -s, or 75 - 150 mPa-s.
9. The method of any one of the preceding claims, wherein the method comprises forming a binder composition having a free formaldehyde content of at most 0.4 % , or at most 0.3 % , or at most 0.2 % , or at most 0.15 % , or at most 0.1 % .
10. The method of any one of the preceding claims, wherein the method comprises forming a binder composition having a free phenol content of at most 1 % , or at most 0.8 % , or at most 0.6 % , or at most 0.5 % , or at most 0.4 % .
11. The method of any one of the preceding claims, wherein 30 - 100 weight-%, or 40 - 99 weight-%, or 50 - 95 weight-%, or 60 - 90 weight-%, or 70 - 85 weight-%, of the polymerizable substance originates from lignin .
12. The method of any one of the preceding claims, wherein the method comprises forming a binder composition exhibiting formaldehyde emission of 0 - 0.3 mg/m2h, or 0 - 0.25 mg/m2h, or 0 - 0.2 mg/m2h, or 0 - 0.15 mg/m2h, or 0 - 0.1 mg/m2h, or 0 - 0.05 mg/m2h, or 0
- 0.03 mg/m2h, or 0 - 0.01 mg/m2h.
13. The method of any one of the preceding claims, wherein the method comprises forming a binder composition exhibiting phenol emission of at most 1.5 mg/m2h, or at most 1.3 mg/m2h, or at most 1 mg/m2h, or at most 0.8 mg/m2h, or at most 0.5 mg/m2h.
14. A binder composition, wherein the binder composition comprises crosslinking agent polymerized with polymerizable substance, and silane, wherein: - at least 30 weight-% of the polymerizable substance originates from lignin,
- the binder composition comprises silane in an amount of 0.1 - 0.9 weight-% based on the total dry weight of the binder composition, and
- the binder composition has a free formaldehyde content of at most 0.5 % .
15. The binder composition of claim 14, wherein the binder composition comprises silane in an amount of 0.2 - 0.7 weight-%, or 0.3 - 0.5 weight-%, based on the total dry weight of the binder composition.
16. The binder composition of any one of claims 14 - 15, wherein the binder composition comprises also a scavenger and/or a hardener.
17. The binder composition of any one of claims 14 - 16, wherein the binder composition comprises also urea and/or ammonium sulphate.
18. The binder composition of claim 17, wherein binder composition comprises urea in an amount of 0.1 - 9 weight-%, or 0.5 - 8 weight-%, or 1 - 7 weight-%, or 2 - 6 weight-%, or 3 - 5 weight-%, based on the total wet weight of the binder composition.
19. The binder composition of any one of claims 17 - 18, wherein the binder composition comprises ammonium sulphate in an amount of 0.5 - 15 weight-%, or 1 - 14 weight-%, or 2 - 13 weight-%, or 3 - 12 weight-%, or 4 - 11 weight-%, or 5 - 10 weight-%, or 6 - 9 weight-%, based on the total dry weight of the binder composition.
20. The binder composition of any one of claims 14 - 19, wherein the binder composition has a pH value of 9 - 11, or 9.3 - 10.5, or 9.5 - 10.
21. The binder composition of any one of claims 14 - 20, wherein the binder composition has a viscosity of 5 - 300 mPa -s, or 10 - 250 mPa-s, or 50 - 200 mPa -s, or 75 - 150 mPa -s .
22. The binder composition of any one of claims 14 - 21, wherein the binder composition has a free formaldehyde content of at most 0.4 %, or at most 0.3 % , or at most 0.2 % , or at most 0.15 % , or at most 0.1
23. The binder composition of any one of claims 14 - 22, wherein the binder composition has a free phenol content of at most 1 % , or at most 0.8 % , or at most 0.6 % , or at most 0.5 % , or at most 0.4 % .
24. The binder composition of any one of claims 14 - 23, wherein 30 - 100 weight-%, or 40 - 99 weight- %, or 50 - 95 weight-%, 60 - 90 weight-%, or 70 - 85 weight-%, of the polymerizable substance originates from lignin .
25. The binder composition of any one of claims 14 - 24, wherein the binder composition exhibits a formaldehyde emission of 0 - 0.3 mg/m2h, or 0 - 0.25 mg/m2h, or 0 - 0.2 mg/m2h, or 0 - 0.15 mg/m2h, or 0 - 0.1 mg/m2h, or 0 - 0.05 mg/m2h, or 0 - 0.03 mg/m2h, or 0 - 0.01 mg/m2h .
26. The binder composition of any one of claims 14 - 25, wherein the binder composition exhibits a phenol emission of at most 1.5 mg/m2h, or at most 1.3 mg/m2h, or at most 1 mg/m2h, or at most 0.8 mg/m2h, or at most 0.5 mg/m2h.
27. Use of the binder composition of any one of claims 14 - 26 for producing an insulating wool product .
28. The use of claim 27, wherein the insulating wool product comprises a fiber matrix selected from glass fiber, stone fiber, or cellulose fiber.
29. The use of any one of claims 27 - 28, wherein the total amount of binder composition in the insulating wool product is 1 - 10 weight-%, or 2 - 9 weight-%, or 3 - 8 weight-%, or 4 - 7 weight-%, or 5 - 6 weight-%, , based on the total weight of the insulating wool product.
30. An insulating wool product comprising a fiber matrix and a binder composition, wherein the binder composition comprises crosslinking agent polymerized with polymerizable substance, and silane, wherein :
- at least 30 weight-% of the polymerizable substance originates from lignin,
- the binder composition comprises silane in an amount of 0.1 - 0.9 weight-% based on the total dry weight of the binder composition, and
- the binder composition has a free formalde- hyde content of at most 0.5 %.
EP24715847.0A 2023-05-04 2024-03-26 A binder composition, a method for producing a binder composition, its use, and an insulating wool product Pending EP4705252A1 (en)

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FI20235494A FI20235494A1 (en) 2023-05-04 2023-05-04 A binder composition, a method for producing a binder composition, its use, and an insulating wool product
PCT/FI2024/050144 WO2024227968A1 (en) 2023-05-04 2024-03-26 A binder composition, a method for producing a binder composition, its use, and an insulating wool product

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FI125991B (en) 2010-10-15 2016-05-13 Upm Kymmene Corp Method and apparatus for continuous precipitation of lignin from black liquor
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EP3632866A1 (en) * 2018-10-05 2020-04-08 Rockwool International A/S Aqueous binder composition
SE546842C2 (en) * 2020-11-04 2025-02-25 Stora Enso Oyj Use of a lignin-based bonding resin
CN112625627B (en) * 2020-12-11 2022-06-24 中南林业科技大学 Preparation method of lignin modified environment-friendly urea-formaldehyde resin adhesive
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