Development of Cardanol-Bonded Cellulose Resin with Nonfood Plant Resources: Low Energy Heterogeneous Synthesis Process

Abstract

To synthesize a high-strength and heat-resistant novel cellulose-based bioplastic having a long side chain with low energy consumption, we developed a novel two-step heterogeneous process. The bioplastic is a cellulose ester synthesized by bonding a short side chain (acetic acid) and a long one (3-pentadecylphenoxy acetic acid, a derivative of cardanol, extracted from cashew nut shells). In conventional homogeneous processes, cellulose esters are recovered by precipitation with large quantities of poor solvents, which requires much energy consumption for their distillation. In the novel process, first, limited amounts of these chains are bonded in a heterogeneous system to achieve efficient product recovery by filtration without precipitation. Second, the short-chain acid is additionally bonded to attain good thermoplasticity of the final product, the cellulose resin, which is recovered by distilling the reaction solvent and the remaining short-chain component. The solvent usage was reduced by approximately 90% compared with a homogeneous process. The thermoplasticity of the resulting resin was comparable to that of a homogeneous one. Furthermore, the mechanical and thermal characteristics of the resin were greatly improved by adding a specific linear polyester, poly(butylene succinate adipate), and a glass fiber, achieving high target levels for durable products.

Green Polymer Chemistry: Some Recent Developments and Examples

“…Carbohydrate feedstock was engaged for the production of PLA (38)(39)(40)48), poly(2,5-dihydro-1,4-dioxane) (49), modified cellulose (50), and phosphorus -containing isosorbide esters (51).…”

“…The paper by Toyama et al (50) to synthesize a novel cellulosic derivative is a good example of process studies designed to decrease solvent and energy use without sacrificing product properties. The preparation of the dimer acid-epoxide adhesive by Li and Li (55) appears not to involve organic solvents or toxic chemicals and is more environmentally friendly.…”

Development of cardanol-bonded cellulose thermoplastics: high productivity achieved in two-step heterogeneous process

“…In this study, we developed a heterogeneous process called the ''two-step heterogeneous process'', to solve the above incompatibility (Toyama et al 2014a, 2014b. Conceptual and flow diagrams of the process are shown in Figs.…”