Leire
Lorenzo
a,
Walter
Pitacco
b,
Nour
Mattar
c,
Ibrahima
Faye
c,
Belén
Maestro
a and
Pablo
Ortiz
*a
aTECNALIA R&I, Basque Research and Technology Alliance (BRTA), Leonardo da Vinci 11, Parque Tecnológico de Alava, E-01510 Vitoria-Gasteiz, Spain. E-mail: pablo.ortiz@tecnalia.com
bAEP POLYMERS, AREA Science Park, SS 14, km 163, 5–34149 Basovizza, Trieste, Italy
cECOAT, Av. Louison Bobet 1, 06130 Grasse, France
First published on 14th January 2025
Lignin, a promising sustainable feedstock, has been utilized to produce polyols through a novel anionic ring opening polymerization of oxiranes. This approach overcomes the limitations of lignin's heterogeneity, enabling the synthesis of aliphatic polyols with tailored properties at room temperature and atmospheric pressure. By optimization of reaction conditions, polyols with specific characteristics suited for polyurethane dispersion coatings have been achieved. Notably, the process has been successfully scaled up by a factor of 330, from 15 mL to 5 L reactors, while the desired properties have been maintained. The resulting polyols have been used to partially substitute traditional polyols in polyurethane dispersions, demonstrating their potential in wood coating applications. This breakthrough has paved the way for the large-scale production of lignin-based polyols, offering a more sustainable alternative for the coatings industry.
One of the applications that is attracting greatest interest is the synthesis of biopolyols, thanks to the hydroxyl functionality of lignin.5,6 However, lignin is a heterogeneous biomacromolecule, and contains, among other functional groups, phenolic and aliphatic hydroxyl groups, whose different reactivity affects the polymerization, for example the polyurethane reaction.7 Therefore, making a homogeneous polyol from lignin has been pursued by researchers. The principal route for this conversion is the oxyalkylation reaction, in which lignin is reacted with alkylene oxides (e.g., propylene oxide).8–11 The oxyalkylation is typically done at harsh reaction conditions, leading to degradation and bad odor.
There is an alternative to the anionic ring opening polymerization, the cationic ROP, that has been recently developed by Tecnalia.12–15 This method allows room temperature and no pressure synthesis of lignin polyols (LPO) (Scheme 1).
The various reports for lignin polyol (LPO) synthesis target gram synthesis, and few reports go to multigram scale.8 Here we report to what is, to the best of our knowledge, the first report on the production of LPOs at industrially relevant environment, using 5 L batch reactors and obtaining 1–1.5 kg of product. Moreover, we show a proof of concept of the application of the synthesized polyols in polyurethane dispersion (PUD) coatings for wood in a sector with high interest in sustainable solutions.16
Polyurethane modification: The obtained alkyd resin (45.3%) was combined with the LPO (13.2%) and are stirred at 90 °C for an hour under vacuum in order to remove moisture that may react with isocyanate. The mixture was then cooled down to 50 °C and a cooling column is fixed to the reactor before adding dimethylolpropionic acid (DMPA). Acetone was then added to the mixture to dissolve the component all together and to control the viscosity of the mixture. The mixture was stirred for about 15 minutes before adding the neutralizing agent, the Triethylene amine (TEA). This latter is used to neutralize the carboxylic acid groups of DMPA, resulting in the formation of carboxylates salt. The carboxylates enhance the hydrophilicity of the PUD, improving its compatibility with water and facilitating the formation of a stable and finely dispersed product. The TEA was left to stir for approximatively 15 to 30 minutes. Isophorone diisocyanate (IPDI) was then added. At this stage, the reaction was allowed to proceed for 8 hours at 50 °C. The last step is the dispersion of polyurethane anionomers, in which deionized water was added slowly with a peristaltic pump under constant agitation. This process should be carried out for approximately one hour to ensure proper dispersion. An aqueous dispersion of 40 wt% solids was obtained after removal of the solvent and filtration of the dispersion.
LPO composition: There are three components in the final LPOs: lignin, butylene oxide and copolymerized solvent (THF) (Scheme 1). To determine the composition of the LPO, excess solvent was removed until a constant weight of the LBP was obtained. The lignin wt% in the LPO was calculated by dividing the initial mass of lignin employed in the reaction by the total weight of the LPO obtained and multiplying the result by 100. The BO weight content in the LPO (BO wt%) was calculated by dividing the difference between the BO weight used in the reaction and the unreacted BO mass by the total weight of LBP obtained and multiplying the result by 100. Copolymerized THF contents (THF wt%) were calculated by subtracting the sum of the two above amounts from 100.
• Tack free time: Tack-free refers to the amount of time it takes for a coating to dry on the surface after its application. It is the moment when a coating is completely dry with little or no moisture left after application on the surface to be protected.
• Adhesion: ASTM D3359 standard is used. This test method covers procedures to assess the adhesion of coating films to metallic substrates. This is done by applying and removing pressure-sensitive tape over cuts made in the film.
• Flexibility: To determine the flexibility of the coatings films, a conical mandrel is used according to ASTM D522 standard. The cured coated films are bent over a conical mandrel and the resistance to cracking of the coating is determined.
• Impact resistance: This test consists of determining the resistance of coatings to the effects or rapid deformation and is based on ASTM D2794 standard. During the test, a flat-coated panel is placed under a weighted spherical ball assembly. Then the weighted ball is dropped onto the panel from different heights. The impact causes a dimple to form in the test panel, and it is examined visually or with a ten-power lens to determine the extent of cracking or other failures.
The optimization of the experiments was focused on obtaining a low Mw polyol, as the target OH range was relatively broad (Table 2). The experiments began with testing different lignin concentrations, which is linked with the abundance of OH groups in the reaction mixture (LPO 1–3). From these, the concentration of 165 g l−1 was chosen as the best as it gave the lowest Mw. An experiment to synthesize an LPO with lower amount of butylene oxide (BO) was carried out (LPO4) since it is known to decrease the Mw.15 It indeed resulted in a lower Mw, but due to an incomplete reaction. This could be visually seen (granular instead of liquid) and was also confirmed by both NMR and OH value, being the later higher than the original lignin. LPO5 was run with lower amount of catalyst, and this led to a liquid, lower Mw polymer with good Mw. However, these reaction conditions proved to be on the verge of the viability of the reaction, and the reproducibility was low, leading in some cases to a partial reaction like that witnessed with LPO4 (see ESI†). Therefore, a longer post addition time (2 hours instead of one) was implemented to allow longer time for the reaction to be completed, but it led to no improvement. Finally, a catalyst loading in between the standard and the reduced (LPO5) was tested in combination with two-hour post-addition time (LPO6). In the best result obtained, LPO2, a slightly higher than 30% of lignin was incorporated in the LPO. It has to be noted that if higher percentages are attempted, solid products are obtained, which cannot be further processed.
Parametersa | LPO1 | LPO2 | LPO3 | LPO4 | LPO5 | LPO6 |
---|---|---|---|---|---|---|
a FKL100 lignin. Addition rate (mL BO per mol OH-L per h) = 73. Scale of experiments: 1–2 g lignin, 100 mL reactor. b See section 2.2.3.1 for the formula used. c Determined by GPC. d Determined by titration. | ||||||
Lignin concentration (g L−1) | 110 | 165 | 220 | 165 | 165 | 165 |
BO/OH-L molar ratio | 1 | 1 | 1 | 0.5 | 1 | 1 |
% of mol of OH in lignin per mol THF | 6 | 9 | 12 | 9 | 9 | 9 |
Molar ratio BF3/OH-L | 0.125 | 0.125 | 0.125 | 0.125 | 0.03 | 0.06 |
Temperature (°C) | 25 | 25 | 25 | 25 | 25 | 25 |
Post addition time | 1 | 1 | 1 | 1 | 1 | 2 |
Lignin mass in polymerb (%) | 24 | 32 | 25 | 29 | 19 | 28 |
BO massb (%) | 12 | 16 | 12 | 7 | 9 | 14 |
THF massb (%) | 64 | 52 | 64 | 64 | 71 | 58 |
Polymer Mw![]() |
5148 | 3075 | 4514 | 2557 | 2007 | 4145 |
Polymer D | 3.9 | 3.2 | 4.0 | 3.8 | 2.6 | 3.5 |
OH valued | 66 | 103 | 99 | 427 | 146 | 108 |
AEP Polymers undertook the upscaling of the most promising result, LPO2, and the result, LPO7, showed less lignin incorporation, higher Mw, PD and lower OH value, which can be explained by the fact that the FKL65 had itself higher Mw, PD and OH value than FKL100 (Table 3). To try to reduce the Mw, the previous strategy of lowering the catalyst loading was investigated. LPO8, analogous to previously tested LPO5 resulted in a solid product due to only partial reaction. Then a catalyst loading between that of unsuccessful LPO8 and successful LPO7 was explored in LPO9 and LPO10. LPO10 with a catalyst loading of 0.08 (molar ratio BF3/OH groups in lignin) gave a good result and was scaled up at 1 L (LPO11).
Parametera | LPO2c | LPO7 | LPO8 | LPO9 | LPO10 | LPO11 |
---|---|---|---|---|---|---|
a BO/OH-L molar ratio 1, % of mol of OH in lignin per mol THF = 9, reaction temperature: r.t., addition rate (mL BO per mol OH-L per h) = 73. b Scale of the reactor. c The slight difference between the OH values, Mw and D reported for LPO2 from those shown in Table 2 is due to being measured by different equipment. | ||||||
Lignin | FKL100 | FKL65 | FKL65 | FKL65 | FKL65 | FKL65 |
Scaleb (mL) | 100 | 500 | 500 | 250 | 250 | 1000 |
Molar ratio BF3/OH-L | 0.125 | 0.125 | 0.06 | 0.1 | 0.08 | 0.08 |
Post addition time | 1 | 1 | 2 | 1 | 1 | 1 |
Lignin mass in polymer (%) | 32 | 26 | 47 | 28 | 30 | 28 |
Polymer Mw (g mol−1) | 2961 | 4347 | N.D. | 3243 | 3023 | 3325 |
Polymer D | 4.2 | 5.2 | N.D. | 4.5 | 4.5 | 4.7 |
OH value | 96 | 88 | 164 | 98 | 108 | 94 |
LPO11 exhibited for the first time a minor – although measurable – exothermal effect reaching 40 °C due to the higher scale of the experiment. This catalysed the reaction further with respect to smaller scale experiments, leading to a slight increase in the molecular weight and a lower lignin content. Whereas on the small-scale the exothermal heat of reaction was not observed, the progressive increase of batch size made it appreciable. As enthalpy of reaction speeds up kinetic of this polymerization, this can be the root cause of significantly higher molecular weight than expected. Therefore, for further upscaling the temperature of the reaction was controlled thanks to the cooling jacket. In the reaction temperature profile for experiment LPO13 a maximum temperature of 30 °C can be seen after the end of the addition of the epoxide (Fig. 1). The peak at the end of the reaction (around 2 hours) correspond to the neutralisation of the catalyst.
The upscaling of the was carried out performing the synthesis on 2 L and 5 L reactors (Table 4), reaching a scale larger than 330 times the initial lab-scale experiments (15 mL).
LPO | Lignin fraction | Reaction scale | Lignin mass in polymer (%) | OH value (mg KOH per g) | M w (g mol−1) | Polymer D |
---|---|---|---|---|---|---|
Reaction conditions: BO/OH-L molar ratio 1, % of mol of OH in lignin per mol THF = 9, molar ratio BF3/OH-L 0.08, reaction temperature: r.t., addition rate (mL BO per mol OH-L per h) = 73. | ||||||
LPO12 | FKL65 | 2 L reactor | 30% | 106 | 2881 | 4.3 |
LPO13 | FKL65 | 5 L reactor | 32% | 109 | 2609 | 3.9 |
In terms of shape, geometry and configuration, the 5 L reactor system used is representative of bigger stirred batch reactors used in pre-industrial and industrial applications (Chart 1). Moreover, an optimisation was also performed in the solvent removal step, and instead of using the rotary evaporator (as in the lab-scale protocol), the solvent was distilled directly from the reactor in a more efficient way, avoiding crude reaction transfer that could prevent quantitative recovery of the product.
In order to have another quality control parameter in addition to OH value and lignin content, viscosity was selected due to its simple execution and widespread use in the chemical industry. On the other hand, viscosity is clearly affected by the presence of residual solvent (THF). In the polyol synthesis, THF acts both as reagent and as solvent, and therefore the unreacted THF at the end of the reaction needs to be removed to obtain the pure polyol and to recover and recycle the solvent.
The residual THF is difficult to remove completely, but nevertheless, the comparison with the graph obtained for various repetitions of the definitive protocol with different THF residual content, can be useful for qualitative determination of the product obtained knowing the volatile content (Fig. 2).
The content of unreacted THF after the end of butylene oxide addition, was also used to qualitatively monitor the reaction. As discussed THF acts both as reagent and as solvent, therefore the reaction can be followed by measuring the reduction of the THF content. At the beginning of the reaction, THF is 80 wt% of the reaction mixture and then it is gradually incorporated in the product. When the volatile content is above 70 wt% the reaction is incomplete, and the product is a solid (as observed in LPO8). If the residual THF content is around 40 wt% a higher Mw than desired is obtained. A THF content of 52 ± 1%, corresponding to around 40% conversion of the initial THF, was identified as the value that gave the required final properties in terms of OH value and Mw. This can be therefore considered as a simple method to follow the reaction even if the results are susceptible to minor errors due to the volatile nature of THF and should be used only as an indication to be confirmed through the other analytical methods previously described.
As a summary of this section, the protocol for the synthesis of LPOs was successfully adapted from lab-scale (15–500 mL reactors) to 2–5 L reactors. The challenges encountered in this transfer and the approach followed to overcome them are summarized in Table 5.
Challenges | Impact | Improvement in scaled-up process |
---|---|---|
Heat generated by the exothermic reaction | Increase in temperature catalyzes the reaction further than desired producing higher molecular weights | Controlling the temperature through a cooling jacket fed by a refrigerated bath circulator allowed to maintain the properties within the requirements |
Monitoring the reaction using a method simpler than P-NMR and GPC | Missing an in-process control method, fixed reaction times were used without considering minor inter-batch variations and leading to replicability issues | THF content was identified as a possible parameter to monitor the reaction based on comparison with collected data |
Avoid losses of material caused by the high viscosity of the LPO | Multiple steps involving raw materials and LPO transfer resulted in loss of yield | Integration of the process, combining all the steps sequentially in the same reactor, led to higher efficiency |
The PUD were applied on wood (Chart 3) and their properties measured. The addition of LPO did not lead to significant differences in certain key performance parameters. Specifically, the comparison showed similarity in terms of tack-free time, adhesion on metal, flexibility, and impact resistance (see ESI†). It is noteworthy that both the reference PUD and the PUD with LPO exhibited similar drying characteristics, with both formulations becoming tack-free after 30 minutes in the presence of a drier. Also, the results showed that both formulations achieved the same adhesion class (Class 0), indicating excellent adhesion to metal surfaces. Flexibility is a crucial property in coatings, especially in wood applications for instance. In this case, the results suggest that both the reference PUD and the PUD with LPO exhibit a similar level of flexibility, indicating that the addition of LPO did not compromise this aspect. Surprisingly, the impact resistance of both formulations was reported to be less than 5 cm, suggesting that the addition of LPO did not lead to an improvement in impact resistance.
Lignin polyols could partially replace standard polyols used in alkyd-PUD systems. However, there was an important limitation on the percentage that could be used due to the gelation effect caused by the LPO. In the future, depolymerized lignin might be available in large quantities and with its lower molecular weight is likely to reduce the viscosity of the resulting LPO.
Current efforts are ongoing in further exploring the application of the LPOs for PUD coatings.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4lp00328d |
This journal is © The Royal Society of Chemistry 2025 |