The effect of reaction parameters in phenol formaldehyde resin synthesis and the evaluation of product properties

Research subject: 

In this research, the synthesis method of phenol-formaldehyde resin has been investigated, which can be used in the wood and chipboard industry. This resin is prepared in two forms, Novolac and Resole, which different products are formed by changing the reaction conditions. Resole is used as a liquid adhesive in the wood and chipboard industry.

Research approach: 

 Various parameters are effective in the synthesis of the resin and the properties of the final product such as the molar ratio of formaldehyde to phenol, the pH of the reaction medium, the temperature and time of the reaction, and the amount of water released from the reaction. The synthesis of this material was carried out under reaction conditions with the molar ratio of formaldehyde to phenol from 1.84 to 2.50, the reaction medium pH from 4.0 to 10.85, the reaction temperature from 80 to 100 ◦C, the reaction time from 0.5 to 4 h, and the water output amount in the term of dehydration dimensionless number from 0.18 to 1.02.

The results showed that the maximum product stability time was obtained for 18 days at the molar ratio of 2, the alkaline medium at pH 9 to 10, the reaction temperature at 90 to 95 ◦C, and reaction time at 2 h. Moreover, viscosity, density, gelation time, and percentage of solids were obtained 180 cP, 1.224 g/cm3, 30 S, and 51.20%, respectively. Product properties were optimized by adding diethylene glycol and urea. The stability time increased to 105 days by adding 8% diethylene glycol and the free formaldehyde amount in the product decreased to 1.29% by adding 4% urea. According to the properties of the created product, the obtained reaction conditions can be used for the mass production of the resin.