Application of Lignin as Partial Binder Replacement in Magnesium Phosphate Bonded Paper Sludge Composite Products; Board Properties and Economic Analysis

The study investigated the feasibility for partial phosphate binder replacement with lignin in phosphate bonded paper sludge composites. A central composite experimental design (CCD) was used to optimise the board manufacturing process, wherein the effect of process temperature, as well as lignin content were investigated with respect to board properties based on the ASTM D1037 standard. Moduli of rupture and elasticity of up to 7.2 MPa and 2.8 GPa respectively in the boards with lignin content of 36–43 wt% and formulation temperatures of 118–133 °C were observed. The phosphate binder input, which bears a huge cost in the process was reduced by up to 49% with lignin incorporation. The effect of pine veneer lamination on the strength properties of the composite boards was investigated. Pine veneer lamination improved mechanical properties, with the moduli of rupture and elasticity increasing from 7.2 to 22.1 MPa (67% increase) and 2.8 to 3.6 GPa (22% increase) respectively. The economic viability of the boards produced was also assessed and the results showed that the required selling price for the composite boards is competitive in the local market for inexpensive construction materials, sold at wholesale prices for between R 158/m² and R 295/m², depending on product finishing.