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Kastamonu Uni., Orman Fakültesi Dergisi, 2020, 20(2): 158-174 Research Article Kastamonu Univ., Journal of Faculty Doi:10.17475/kastorman.801814

The Utilizing Rock Salt of Inorganic Filler in Medium Density Fibreboard (MDF) Production

Osman ÇAMLIBEL1* , Mehmet AKGÜL2

1Kırıkkale University, Kırıkkale Vocational School, Department of Materials and Materials Processing Technology, Yahsihan / Kırıkkale, TURKEY 2Karamanoglu Mehmetbey University, Yunus Emre Campus, 70100 Karaman, TURKEY *Corresponding author: [email protected]

Received Date: 25.07.2019 Accepted Date: 23.07.2020 Abstract Aim of study: To research the usage opportunities of the inorganic rock salt mineral in MDF production. Area of study: The materials were collected rock salt from Çankırı region, from the Western Black Sea region, respectively. The production was performed in a private company in Düzce. The tests were performed at Duzce Forest Faculty Laboratory and Gazi Industrial Engineering Laboratory. Material and methods: In the Asplund Defibrator, chips were baked wtihin 7-7.5 bar vapor pressure and 180 ° C temperature for 4-5 minutes. According to the weight of dry fiber, 1.5% paraffin was given before fibrillation, fibrillation later was given 1% solution. Inorganic fillers prepared in a separate tank in order to use rock salt instead of lignocellulosic fibers in the production of 1 m³ MDF. After that urea-formaldehyde glue is prepared as three different solutions which include the rock salt respectively with 3% (20 kg), 6% (40 kg), 9% (60 kg). This press applies 185-190 °C temperature and 32- 34 kg/cm² pressure to the mixture material in 270 second pressing time. MDF panels (2100x4900x18 mm) were produced in the process. Physical, mechanical and combustion tests experiments are performed over boards. Main results: MDF products which were added percent 3 with the rock salt have more performance than the other MDF panels in this study. Highlights: The usage of the rock salt with percent 3 is recommended in MDF products. Keywords: Rock salt, MDF, physical properties, mechanical properties, colour properties, fire retardants Orta Yoğunlukta Liflevha (MDF) Üretiminde İnorganik Dolgu Maddesi Kaya Tuzu Mineralinin Kullanılabilme Olanaklarının Araştırılması

Öz Çalışmanın amacı: İnorganik kaya tuzunun MDF üretiminde kullanılabilirliliğini araştırmaktır. Çalışma alanı: Malzemeler sırasıyla Çankırı yöresinden kaya tuzu, Batı Karadeniz bölgesinden odun toplanmıştır. Üretim Düzce'de özel bir firmada gerçekleştirildi. Testler Düzce Orman Fakültesi Laboratuvarı ve Gazi Ağaç İşleme Endüstri Mühendisliği Laboratuvarından yapılmıştır. Materyal ve yöntem: Asplund Defibrator'da cipsler 7-7.5 bar buhar basıncında, 180°C sıcaklıkta 4-5 dakika pişirilmiştir. Kuru lif ağırlığına göre liflendirmeden öncesi% 1.5 parafin, liflendirmeden sonra % 1 amonyum sülfat solüsyonu verildi. 1m³ MDF üretiminde lignoselülozik liflerin yerine; inorganik dolgu minerali kaya tuzu kullanmak için ayrı bir tankta hazırlanmıştır. Üre formaldehit tutkalı ile birlikte sırasıyla % 3 (20 kg), % 6 (40 kg), % 9 (60 kg) kaya tuzu solusyonu liflere blow line hattında verilmiştir. Lifler pasta haline getirildikten sonra sıcak preste 185-190°C sıcaklık, 32-34 kg/cm² basınç uygulanarak ve 270 saniyede levhalar üretilmiştir. Presleme sonrasında MDF paneller (2100x4900x18 mm) ölçülerinde üretilmiştir. Fiziksel, mekanik ve yanma testleri gerçekleştirilmiştir. Temel sonuçlar: Yüzde 3 kaya tuzu katkılı MDF ürünleri bu çalışmadaki diğer MDF panellerinden daha iyi performansa sahiptir. Araştırma vurguları: Kaya tuzunun yüzde 3 oran ile MDF üretiminde kullanımı önerilir. Anahtar kelimeler: Kaya tuzu, MDF, fiziksel özellikler, mekanik özellikler, renk özellikleri, yangın geciktiriciler

Citation (Atıf): Camlibel, O. & Akgul, M. (2020). The Utilizing Rock This work is licensed under a Creative Commons Salt of Inorganic Filler in Medium Density Fibreboard (MDF) 158 Attribution-NonCommercial 4.0 International Production. Kastamonu University Journal of Forestry Faculty, 20 (2), License. 158-174. Kastamonu Uni., Orman Fakültesi Dergisi, 2020, 20(2): 158-174 Çamlıbel and Akgül Kastamonu Univ., Journal of Forestry Faculty

Introduction various fire-retardant coatings. Kurt et al. Rapid population growth in the world, (2012) studied the effects of many rapidly increasing the demand for wood raw compounds (, borax, ammonium materials and the need for fiber raw materials etc.) used as fire retardants in wood. for developing countries could become a According to LeVan et al. (1990) the very important problem in the future. The inorganic salts such as di-ammonium growing population of the world and also phosphate, mono ammonium phosphate, zinc developing technology increased the demand chloride, ammonium sulphate, borax, and for wood-based materials in the last century. boric acid are the most common fire- Reduction of natural forest resources and retardant chemicals used for wood. Ozcıfcı et human-made forests, which were limited, al. (2007) studied the fire properties of caused by the growing importance of non- laminated veneer (LVL) prepared wood raw materials (Ganapathy, 1997). A lot from (Fagus orientalis L.) veneers of scientific and experimental studies are treated with some fire retardants. According made in our country and in other countries to their study, the lowest temperature and about this topic. The using of the agricultural mass loss were obtained for specimens wastes in the production of wood-based treated with di-ammonium phosphate and panels as raw materials has become boric acid–borax mixture. Tondi et al. (2014) significantly important in the industry. studied the comparison of disodium The study over the production of MDF octaborate tetrahydrate-based and - was performed by using Rhododendron boron-based formulations as fire retardant for Ponticum L. tree species (Akgul & Camlibel, wood structures. When the ratio of fire 2008). Akgul did the research on the MDF retardants in wood panels was increased, it production from corn stalks (Akgül, 2009). was found that their fire performances were In the forest products industry, the wood improved even more (Tsunoda, 2001). Such chips or lignocellulosic materials can be improvement is a significant outcome in produced smooth-surfaced panels by mixing wood industry. in suitable proportions with cement, water Usta et al. (2012) examined the effect of and chemicals. Wood composite products some boron compounds for the physical and with binding inorganic materials were the mechanical properties of medium density generated by using plaster, magnesium (MDF) panels in terms of the fire- cement and Portland cement. Guller retardant properties such as melamine urea- produced the inorganic material-binding formaldehyde (MUF) resins having different and particle boards (Guller, melamine contents (10%, 15%, and 20%). 2001). Kalaycıoğlu et. al. (2012) performed Valcheva et al. (2015) studied the effect of some studies on the cement composites and thickness of medium density fiberboard . Ashori & Nourbakhsh (2009) produced of tree species on their produced the board which had added selected physical and mechanical properties. nanoclays layered silicates as reinforced Xian-Qing et al. (2016) researchers have adhesive with 0%, 2%, 4%, 6%, 8% mixing investigated proper technical process ratios. parameters, proper sanding process Hafızoglu et al. (1994) researchers have paratemers at straw particleboard product investigated various fire retardants to be used line. Yang et al. (2019) researchers have with MDF panels. The effects of fire investigated the quality evaluation of retardants over the fire performance of MDF agricultural and forestry products based on and were determined and the results display processing technology is possible. showed that the fire performance of MDF Basta et al. (2006) researchers have and plywood increased nearly 6.4% and investigated assess some starch derivatives as 1.6% respectively. Istek et al. (2013) scavengers of free formaldehyde. Basta & investigated the effect of fire retardants on El-Saied (2008) studied carboxymethyl the combustion performance of medium- complexes [CMC–Cu (II)], density fiberboards that were coated with as additive in wood paper mixtures of water, binder, calcite, and product. Zuo et al. (2018) studied to

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reformed the water resistance, fire-retardant to realize the physical, colour, mechanical performances and mechanical strength of the and combustion properties of the produced straw-magnesium cement (SMC) composites. boards which have rock salt mineral Hosny et al. (1997) researchers have according to the reference board. investigated two kind of monologue and complexes of FeCl3, Fe(NO3)3 and Fe2(SO4)3 Material and Method with hydroxyethyl cellulose (HEC) and Used Wood Species in the Production of carboxymethyl cellulose (CMC). MDF Basta et al. (2013) studied high The wood species are beech (Fagus performance, agro-based composites from orientalis L.), (Quercus robur L) and rice straw, using eco- polyalcohol polymer- (Pinus sylvestris L). These species were based adhesive system. Basta & El-Saied brought from Düzce province forestry, West (2017) studied the role of activated carbons Black Sea region and Bolu province, (ACs), additives to enhance the application respectively. of a low-cost urea formaldehyde (UF) adhesive for production of rice straw boards. Rock Salt Basta et al. (2014) studied high-performance Rock salt has been used as a nutrient since rice-straw-based composites, the effect of ancient times. Rock salt is the most important deashing or dewaxing on the bonding product in our modern chemical industry. It behavior of rice straw fibers by eco-urea consists of Na and Cl ions. It is a mineral formaldehyde. with a specific weight of 2.1-2.55 gr/cm³. Özdemir (2019) produced three different The melting point of rock salt is 800 ºC and minerals (sepiolite, dolomite, and perlite) the boiling point is 1412 ºC. It is usually using five different ratios (3%, 6%, 9%, colourless. When rock salt is produced, the 12%, and 15%) according to the oven-dry colour may be grey, yellow, red, even blue wood fiber weight. Dönmez Çavdar et al. and green. The rock salt, which is used in (2019) investigated ammonium zeolite and this study, was brought from the Çankırı ammonium phosphate as fire retardants for region in Turkey. Turkey is very rich in microcrystalline cellulose thermoplastic terms of rock salt reserves (URL 2). composites. Dönmez Çavdar (2020) studied zeolite and natural zeolite, at contents of 4%, Chemicals 8%, and 12%, based on dry resin amount, as The used chemicals which are used in this filler fiberboard production with urea study are urea formaldehyde, liquid paraffin formaldehyde and melamine formaldehyde. and ammonium sulphate. These chemicals The production of MDF was about 4.910 were brought from Polisan Company in million m³/year in 2018 in Turkey. However, Gebze, Mercan Chemistry in Denizli and this figure was about 99.443 million cubic another company in Gebze, respectively. meters/year in the World (URL 1). Some researchers handled a lot of study in order to Establishment of the Production Process and reduce raw materials in MDF industry. These Determination of the Parameters Affecting researchers were about the usage possibilities the Process for the rock salt minerals instead of Provided that the other production lignocellulosic raw materials. conditions are the same, the test boards The inorganic rock salt mineral which has which are produced by changing the ratio of the mixing ratio respectively 0%, 3%, 6%, the rock salt mixture are the general-purpose 9% was produced for boards in MDF boards. These products were produced by production process. In this study, the Divapan Integrated Wood Company. The experimental investigations handled in order method is showed in Figure 1.

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Figure 1. Product process flow sheet

The resins and other chemicals are are mixed each other and this mixture is sent prepared in the glue unit. The rock salt blow line. This process and application is the inorganic mineral solution is prepared in the main topic of this study, and these solution preparing tank. After that these applications are shown in Figure 2. chemicals, which are prepared in the tank,

Figure 2. The preparation of the resin, inorganic rock salt solution and other chemicals

Product Processing Parameters rock salt solution and other chemicals to MDF board manufacturer provided these lignocellulosic . wood species very easily from the western The symbols in Table 1 respectively black sea region. Therefore, these tree correspond that R defines the consumed species were preferred. The acceptance of wood fibers for 1 m3 board, N defines the 70/30 ratio of hardwood/ fibers consumed rock salt minerals for 1 m3 board, used in the production of MDF provide the x and y subscripts define percentage (%) of properties of MDF boards in optimum the mixture. The percent 0% rocksalt in the quality. methodology is control board. Production parameters are given in Table 1. This table shows the addition of inorganic

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Table 1. Board content Board Product Inorganic Industrial Biomass Resin Hardener Paraffin Ratio Type Type filler fibers a b c d R100N0 MDF L UF AS - 100% 0 a b c d e R97N3 MDF L UF AS Wax RS 97% 3% a b c d e R94N6 MDF L UF AS Wax RS 94% 6% a b c d e R91N9 MDF L UF AS Wax RS 91% 9% aMedium density fibreboard. bLignocellulosic. cUrea formaldehyde. dAmmonium sulphate. eRock salt.

Fiber Analysis fibers are sieved with Imal Ultrasonic Wood fiber contains 70% and Analysis machine. The hot press diagram and 30% softwood fibers in this study. These analysis of the fiber is shown in Figure 3.

Figure 3. Analysis of the fiber and press diagrams

Chemicals Parameters minutes in Asplund defibrator with the The urea-formaldehyde glue has the vapour pressure of 7-7.5 bar, and 180 ºC following technical specs: temperature. The solid ratio of the urea-  Solid 65% formaldehyde is reduced to 50% solid level  Formaldehyde / urea molar ratio: 1.25 in the production process. The colour of  Density (at 20 0C g/cm3):1.227 ammonium sulphate crystal grains is off-  Viscosity (20 0C cps) 185 seconds white. It is prepared for hardener with 20% 0 solution, and then it is injected from a single  Gel time (100 C) (20% (NH4)2SO4): 25-40 sec point to blow line. The colour of liquid  pH: 7.5 to 8.5 paraffin is cream and the fat content is up to 2%. The penetration of liquid paraffin is 32,  Free formaldehyde content 0.5% max and then it is stored in reserve tank as liquid  Methylol groups 12-15% state. The liquid paraffin is mixed with the  Average shelf life is 45 days maximum ratio up to 1.5% to dry fiber.

The mixture whose definition is given Product and Hot Multiple Press Parameters above is made with fiber in Asplund Firstly, The hardwood and softwood defibrator. The hardener, rock salt solution species had brought from the Western Black and urea-formaldehyde are injected from Sea forests, and then these species were blow line to the biomass fiber. Fibers which chopped and stored one by one in silos are included the rock salt and the chemical according to the production parameters. are dried at the drier line up to 11-12%. Chips used in fiber products have been Dried fibers are made up to mat in the subjected to the process of cooking for 4-5

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mechanical station. The mat is produced by 270 is blue. L* is the lightness; 100 = white pressing in the multi hot press. The pressing and 0 = black. C* is the chroma or saturation; parameters are 180-190 0C, 32-34 kg/cm2, 0 represents only greyish colors and 60. 275 sec. The dimensions of the panel are The three measured co-ordinates, L*, a*, and 2100x4900x18 mm. After the panels are b*, were transformed to L*, C*, and h co- produced in the process, the panels are rested ordinates and ΔE values, according to the Eq in pre-storage on 5 days. The panels are (1) (Temiz et al., 2005). acclimatized here. The level of moisture is adjusted to 7.5%. After these processes, the top and bottom surfaces of panels are sanded with 40-80-120 degrees .

Physical Test Methods Physical properties are tested according to TS 642 ISO 554, (1997), TS EN 326-1 (1999) and the density of panels is tested TS EN 323 (2008). The water absorption test and thickness swelling test of the specimens are measured TS EN 317 (2008). The sheet surface toluene is tested TS EN 382-1 (1999). TS EN 325 (1999) standards, sample thickness and length of specimens are measured by using a digital micrometre and Figure 4. CIELAB the coordinate system with 0.01 mm gradients. shows the color changes in three coordinates which are represented as L*, a* and b* it Color Properties gives the total color difference equation as Color measurements are measured by using the tristimulus photoelectric ELab 222 colorimeter Elrepho Spectrophotometer, with  (1) a measuring head of 50 mm in diameter according to TS 642 ISO 554 (1997) and The L*a*b system has been chosen, since ASTM D 2244-07e1 (2007) standards. The only one color variable is needed to donate Elrepho spectrophotometer measures the hue, i.e. red, green, blue, or yellow and color of any material in a three-dimensional furthermore, this system is easy to refer to color area (Figure 4). This system which is our experience of colour characteristics such called CIE L*a*b* operates according to the as lightness, saturation, and hue. Each colour CIE Standard. The part of the coordinate parameter L*,a*,b and ΔE, was measured for system interested in this study is the first each material, time, and temperature. The quadrant which corresponds positive values average colour values, standard deviations, of a* and b*. The color parameters L*, a*, and 5% significance level based on and b* were determined by the CIE L*a*b* distribution were calculated assuming normal method on the surface fiberboards. Their distribution. The lower value of ΔE* variations concerning the treatment (ΔL*, indicates that the colour is either not changed Δa*, Δb*) was calculated. The color sphere or the change is negligible equation (Akgül, as the circle of the cross-section at L* = 50 2013). was defined. The color difference, ΔE total color difference is the distance between two Mechanical Test Methods color points in the color sphere. To the right: Mechanical properties were tested Cross section at L* = 50 showing the axis according to TS 642 ISO 554 (1997) and TS from green to red (a*) and from blue to EN 326-1 (1999). The specimens were also yellow (b*), the coordinates chroma (C*) and tested for bending strength TS EN 310 hue [h = arctan (b*/ a*)] is the hues of color: (1999), internal bond TS EN 319 (1999) and 0 or 360 is red, 90 is yellow, 180 is green and

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screw withdrawal perpendicular to the Samples 13x13x76 mm (radial x tangent x of the panel ASTM D 1037-78 (1994). length) dimensions were prepared for each A universal tester (Imal Mobiltemp shc22, type of experiment. Combustion test of rock model ib400) was used to assess mechanical salt MDF specimens was determined properties. The TS EN 326-1 (1999) standard according to TS 642 ISO 554 (1997) and was used to obtain panel samples. Following ASTM E 160–50 (1976). Specimens were TS EN 325 (1999) standards, sample conditioned at 27±2°C and 30–35 % relative thickness and length were measured using a humidity to the targeted equilibrium moisture digital micrometre and compass having 0.01 content of 7 % prior to the combustion test. mm gradients. Twenty four specimens were stored to make 12 layers which formed a prism Combustion Test Method (Figure 6).

Figure 6. Combustion test apparatus and samples

The fire of the heating flame was derived the weight (g) of a wood specimen after from an LPG tank controlled by a sensitive combustion test. bar gauged valve. The flame was balanced to The 936 pieces board which have additive the standard height before combustion test rock salt were burned according to standards samples’ frame. The combustion test method ASTM E 160–50 (1976). The applied tests was performed subsequently the flame stage are FIC (flame-induced combustion), FIC lux (FS), the without a flame stage (WFS), and (flame-induced combustion lux), SC (self the glowing stage (GS) according to ASTM combustion), SC lux (self combustion lux), E 160–50. (1976). Temperatures were SC time (self combustion time), ESC (ember recorded at the combustion column by using situation combustion), ESC lux (ember thermocouples at 15 and 30 s time intervals situation combustion lux), ESC time, mass for combustion with flame stage, without a loss, IST (initial starting temperature), IST flame stage, and glowing stage, respectively. time (initial starting temperature time), IST The mass loss of test specimens after lux, FC (full Combustion), FC time, (full combustion test was calculated from the Combustion time), FC lux (full combustion following equation: lux). The obtained data test results were WbfWaf evaluated by a computerized statistical Mass loss = 100 (2) Wbf program composed of an analysis of variance and following ANOVA Duncan tests at the 95 % confidence level by using SPSS 17 where Wbf is the weight (g) of a wood statistical software package. specimen before combustion test, and Waf is

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Results and Discussion analysis result. The results of MDF densities Physical Properties of Fiberboard stays in 0.65 g/cm³

Table 2. The results of ANOVA and Duncan mean separation test for density, the toluene surface, the thickness swelling (TS, 2-24 hours) and water absorption (WA, 2-24 hours) percent of the fiber boards are made from rock salt addictive fiber boards and control fibreboard Board Std. Board Std. Avg.x Avg.x Rock Salt Deviation Rock Salt Deviation

b a

) R100N0 0.72 0.00 R100N0 21.29 2.01 3 c c R97N3 0.72 0.01 R97N3 35.19 7.33 ab b R94N6 0.71 0.01 TS* R94N6 25.51 3.29 Density (gr/cm a b

R91N9 0.71 0.01 2 hours (%) R91N9 28.15 5.12 a a

R100N0 3.81 0.40 R100N0 41.68 2.86 (%)

b b R97N3 7.31 1.33 R97N3 60.47 8.92

c (%) b R94N6 8.20 1.31 TS* R94N6 64.37 7.92 WA**

d 24 hours c

2 hours R91N9 9.15 0.76 R91N9 72.177 4.75 a a 100 0 100 0 R N 10.55 0.28 R N 34.35 1.08

b b R97N3 14.48 1.04 R97N3 30.00 1.58

(%) b c R94N6 15.14 0.82 (cm) R94N6 29.00 1.29 WA** BST⁕⁕⁕ 24 hours c d R91N9 16.15 1.79 R91N9 22.00 1.48 X: The average value of the samples * 95% confidence interval for the average ANOVA. a, b, c, d values with the same letter are not significantly different (Duncan's test); *Thickness swelling; **Water absorption; ⁕⁕⁕Board surface toluene.

The ratio between the densities for the density of the fiberboard is the optimum lowest fiberboard with the average homogeneous density. fiberboard is always desired between 0.85 to 0.95 values. The efficiency of process The Result of the Swelling in Water for 2 parameters and applied hot press diagram in Hours Test of the Fibreboard (TS-2h) MDF production affect the optimum There is a significant difference between homogenous density of the fiberboard. If the (R100N0), (R97N3) and (R94N6, R91N9) ratio between the densities for the lowest according to the percentage of TS-2h. The fiberboard with the average fiberboard goes brief results of Table 2 could be explained as to one, then this ratio represents that the follows.

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The ratio for this test is 91.62% for R97N3 softwood fiber according to hardwood fiber. according to R100N0. Therefore, the Thus, the entering of the water and moisture percentage of TS-2h increases for R97N3. between fibers are more difficult softwood Similarly, the ratio is 114.65% for R94N6 fiber according to hardwood fiber. As the according to R100N0. Therefore, the amount of hydrophobic material in percentage of TS-2h increases for R94N6. The fiberboard product increases, the swelling in ratio is 140.15% for R91N9 according to thickness decreases. But there is a negative R100N0. Therefore, the percentage of TS-2h effect on the adhesion of fibers. increases for R91N9. Since the anisotropic swelling of the The Results of the Water Absorption for 2 secondary wall fibers in the cell wall and Hours Test of the Fibreboard (WA-2h) these fibers in board lie with different There is a significantly difference directions and angels, the swelling of the between (R100N0), (R97N3), (R94N6, R91N9) board is the smallest. Hydrophobic materials according to the percentage of WA-2h. The and water-resistant resin could be used in brief results of Table 2 could be explained as order to increase the resistance of the board follows. against to swelling effect. The percentage of The ratio for this test is 8.31% for R97N3 swelling of MDF depends on the density of according to R100N0. Therefore, the the board, the chemical structure of inorganic percentage of WA-2h increases for R97N3. rock salt, the geometrical shape of the rock Similarly, the ratio is 19.76% for R94N6 salt and the amount of the rock salt. The according to R100T0. Therefore, the quantity of the surface of the board, the percentage of WA-2h increases for R94N6. density profile of the board, the adhesion The ratio is 32.22% for R91N9 according to strength between the fibers, the length of R100N0. Therefore, the percentage of WA-2h fibers, the shortness of the fibers depend on increases for R91N9. the type and the amount of the paraffin which is added to MDF. The Results of the Water Absorption for 24 Hours Test of the Fibreboard (WA-24h) The Result of the Swelling in Water for 24 There is a significant difference between Hours Test of the Fiberboard (TS-24h) (R100N0), (R97N3, R94N6) and (R91N9) There is a significant difference between according to the percentage of WA-24h. The (R100N0), (R97N3, R94N6) and (R91N9) brief results of Table 2 could be explained as according to the percentage of TS-24h. The follows. brief results of Table 2 could be explained as The ratio for this test is 45.10% for R97N3 follows. according to R100N0. Therefore, the The ratio for this test is 37.21% for R97N3 percentage of WA-24h increases for R97N3. according to R100N0. Therefore, the Similarly, the ratio is 54.43% for R94N6 percentage of TS-24h increases for R97N3. according to R100N0. Therefore, the Similarly, the ratio is 43,46% for R94N6 percentage of WA-24h increases for R94N6. according to R100N0. Therefore, the The ratio is 73.17% for R91N9 according to percentage of TS-24h increases for R94N6. R100N0. Therefore, the percentage of WA-24h The ratio is 53.04% for R91N9 according to increases for R91N9. As the amount of R100N0. Therefore, the percentage of TS-24h inorganic rock salt increases in MDF increases for R91T9. production, the absorption of the water in Softwood fibers are longer than the fiberboards increases. hardwood fibers. For softwood fibers the felting ratio, the elasticity ratio and F factor The Results of Toluene on the Surface of the are higher than the hardwood fibers. On the Board Test of the Fibreboard (BST) contrary, for hardwood fibers the rigid There is a significant difference between coefficient, the muhlsteph ratio, the runkel (R100N0), (R97N3), (R94N6) and (R91N9) and ratio and the bulk density value are higher according to the percentage of toluene on the than softwood fibers. As the contact angle surface of the board test. The brief results of increases, the adhesion ability increases for Table 2 could be explained as follows.

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The ratio for this test decreases 14.50% mat, pre-press pressure, hot-pressing for R97N3 according to R100N0. Therefore, the parameters and hot press. The applied percentage of BST decreases for R97N3. temperature press and time diagrams during Similarly, the ratio decreases by 18.45% for the hot press of the board are very important. R94N6 according to R100N0. Therefore, the Sanding of MDF, the sanding paper percentage of BST decreases for R94N6. The properties, sanding method and sandpaper ratio is 56.14% for R91N9 according to affect the smoothness of the board surface. R100N0. Therefore, the percentage of BST decreases for R91N9. Colour Properties of Fiberboard The factors which are affected the surface Standards are applied in this test ASTM quality of MDF board before production are D2244-07e1 (2007). The surface colour the amount of the inorganic rock salt filler, analysis of fiberboards is calculated by using the geometry of the inorganic rock salt filler, Eq.(1). The results are tabulated in Table 3. the chemical structure, amount of type The results of ANOVA and Duncan mean of cellulosic raw material, density, fiber separation test for ΔL black-white colour structure, fiber dimensions, the ratio of fiber change, Δa red-green colour change, Δb moisture, the kind of the resin, the amount of yellow-blue colour change, ΔE total colour the resin and the other included chemicals. difference percent of the fiberboards made The factors which are affected the surface from rock salt addictive fiber and control quality during the production of MDF board fiberboards are shown in Table 3. Each test is are mat fiber moisture, pulverized sprayed measured with 20 different samples in this water amount of the top and bottom of the study.

Table 3. The results of ANOVA and Duncan mean separation test for ΔL black-white colour change, Δa red-green colour change, Δb yellow-blue colour change, ΔE total colour difference percent of the fiberboards made from rock salt addictive fiber and control fiberboards. Board Type Std. Board Type Std. Avg.x Avg.x Rock Salt Deviation Rock Salt Deviation a a R100N0 60.13 0.93 R100N0 17.46 0.56 b b y R97N3 58.15 0.39 t R97N3 17.15 0.24 ΔL c Δb c R94N6 55.15 1.04 R94N6 15.81 0.43 c c R91N9 54.93 1.24 R91N9 15.89 0.44 a a R100N0 5.62 0.06 R100N0 62.87 0.97 b b z R97N3 5.41 0.03 x R97N3 60.86 0.43 Δa c ΔE c R94N6 5.34 0.09 R94N6 57.62 1.12 b c R91N9 5.43 0.14 R91N9 57.44 1.31 X: The average value of the samples * 95% confidence interval for the average ANOVA. a, b, c, d values with the same letter are not significantly different (Duncan's test); ΔEx total colour difference; ΔLy black-white colour change; Δaz red-green colour change; Δbt yellow-blue colour change.

The Variation of L The Variation of a There is a significant difference between There is a significant difference between (R100N0), (R97N3) and (R94N6, R91N9) in the (R100N0), (R97N3, R91N9), (R94N6) and in the variation of . The brief results of Table 3 variation of a . The brief results of Table 3 could be explained as follows. could be explained as follows. This variation decreases by 3.40% for This variation decreases by 3.88% for 97 3 100 0 R N according to R N . Similarly, the R97N3 according to R100N0. Similarly, the variation decreases by 7.08% for R94N6 variation decreases by 5.29% for R94N6 according to R100N0. Therefore, the variation according to R100N0. Therefore, the variation decreases for R94N6. The variation decreases decreases for R94N6. The variation decreases 9.46% for R91N9 according to R100N0. Therefore, the variation decreases for R91N9.

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3.49% for R91N9 according to R100N0. This variation decreases by 3.30% for Therefore, the variation decreases for R91N9. R97N3 according to R100N0. Similarly, the The Variation of b variation decreases by 9.11% for R94N6 There is a significant difference between according to R100N0. Therefore, the variation (R100N0), (R97N3) and (R94N6, R91N9) in the decreases for R94N6. The variation increases variation of b . The brief results of Table 3 by 9.45% for R91N9 according to R100N0. could be explained as follows. Therefore, the variation decreases for R91N9. This variation increases by 1.80% for As the amount of inorganic rock salt increases in MDF production, the value R97T3 according to R100T0. Similarly, the decreases. variation decreases 10.43% for R94T6 according to R100T0. Therefore, the variation Mechanical Properties of Fiberboard decreases for R94T6. The variation decreases 9.88% for R91T9 according to R100T0. The results of ANOVA and Duncan mean separation test for bending strength, modulus Therefore, the variation decreases for R91T9. elasticity, internal bond, surface screw The Variation of E holding ability, Jank hardness measured There is a significant difference between vertically to the plate surface of the (R100N0), (R97N3) and (R94N6, R91N9) in the fiberboards made from rock salt addictive variation of E . The brief results of Table 3 fiber and control fiberboards are shown in could be explained as follows. Table 4.

Table 4. The results of ANOVA and Duncan mean separation test for density and mechanical properties of the rock salt addictive fiberboards and control fibreboard Rock salt Std. Rock salt Std. Type Avg.x Type Avg.x Board Deviation Board Deviation

d a

) R100N0 36.89 2.44 R100N0 3,482.91 218.22 2 c b R97N3 32.87 2.23 R97N3 3,164.58 153.36 b c R94N6 26.93 2.75 R94N6 2,637.68 178.04 (MOE) (MOR) strength Bending (N/mm Modulus elasticity a (N/mm2) d R91N9 23.87 1.23 R91N9 2,474.19 148.02

a a R100N0 0.58 0.03 R100N0 10.07 0.30

b b R97N3 0.48 0.03 R97N3 8.77 0.65

(IB) c c

R94N6 0.38 0.05 screw R94N6 7.34 1.22 Surface holding (N/mm2) d ability (N) d

Internal bond R91N9 0.32 0.02 R91N9 6.40 0.33 a R100N0 81.05 1.23

b R97N3 79.64 1.85

(N) c R94N6 77.64 1.14 d R91N9 75.53 2.07 Jank hardness X: The average value of the samples. *95% confidence interval for the average ANOVA. a, b, c, d values with the same letter are not significantly different (Duncan's test).

Mat moisture of the draft of the laying parameters and applied hot press diagram in unit, density, fiber distribution and press MDF production affect the optimum parameters affect the density during homogenous density of the fiberboard. If the production. The difference between the ratio between the densities for the lowest density of the fiberboard influences the fiberboard with the average fiberboard goes physical and technological properties to one, then this ratio represents that the (Ayrılmış, 2000). density of the fiberboard is the optimum The ratio between the densities for the homogeneous density. lowest fiberboard with the average The Results of the Bending Strength (MOR) fiberboard are always desired between 0.85 (N/mm2) Test to 0.95 values. The efficiency of process

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There is a significant difference between top and bottom surface of the boards are (R100N0), (R97N3), (R94N6, R91N9) according to plasticized during the hot press. The press the percentage of bending strength test. heat is transferred to the centre of the board. The brief results of Table 4 could be The resin becomes a cure. The sheet becomes explained as follows. The ratio for this test is stable. The most important factor in wood is 12.22% for R97N3 according to R100N0. the cellulose chain. Therefore, the percentage of bending strength decreases for R97N3. Similarly, the ratio is The Results of the Internal Bond (IB) 2 36.98% for R94N according to R100N0. (N/mm ) Test Therefore, the percentage of bending strength There is a significant difference between decreases for R94N6. The ratio is 54.54% for (R100N0), (R97N3), (R94N6) and (R91N9) R91N9 according to R100N0. Therefore, the according to the percentage of internal bond percentage of bending strength decreases for (IB) test. The brief results of Table 4 could R91N9. be explained as follows. The mechanical properties of the MDF The ratio for this test is 20.82% for R97N3 are significant to the bending strength. MDF according to R100N0. Therefore, the is required to be resistant to places of use. percentage of the internal bond decreases for The bending strength is made according to R97N3. Similarly, the ratio is 52.20% for the relevant standard. All measurement R94N6 according to R100N0. Therefore, the results of the test boards which are measured percentage of the internal bond decreases for above TS EN 622-5 (2008) standard value. R94N6. The ratio is 82.25% for R91N9 Fiber length is the most important factor according to R100N0. Therefore, the affecting bending strength. As the fiber percentage of the internal bond decreases for length and the fibers contact degree increases R91N9. with each other's fibers. Thus, a more The IB strength of the board decreases as effective adhesion area is formed. Thus, it the amount of inorganic minerals increases. boosts the bending strength of the board. The The mechanical properties for the 9% softwood fiber length is between 6-7 mm. inorganic mineral added to board is the The hardwood fiber length is between 0.5 lowest because rock salt inorganic filler and 2 mm. The hardwood fiber wall minerals reduce the between fibers contact thickness is thick and the lumen is narrow. and adhesion strength. This negatively affects fiber-to-fiber bonding The increase in the density of MDF and compression. The softwood fiber wall positively affects the internal bond of the thin, lumen wide and elipse close. Therefore, board. Optimum efficiency is achieved in the it affects the fiber-fiber bonding and press diagram. The press diagram in Fig. 3 compression factor positively. The bond ratio was applied. During pressing; temperature, of MDF to fiber-fiber increases the tensile pressure and time diagrams are applied. strength. Factors affecting surface quality and The Results of the Modulus Elasticity (MOE) bending strength (MOR) of MDF are type of (N/mm2) Test lignocellulosic raw material, density of raw There is a significant difference between material, fiber structures, fiber sizes, fiber (R100N0), (R97N3), (R94N6, R91N9) according to moisture content, type of glue, amount of the percentage of modulus elasticity test. The glue, other chemical material, mat moisture brief results of Table 4 could be explained as content, refineer fibrillation degree, amount follows: of pulverize water spray of up and down of The ratio for this test is 10.05% for R97N3 mat, pre-press pressure, hot press type, hot according to R100N0. Therefore, the press factors, hot press specific values, hot percentage of modulus elasticity decreases press temperature, hot press pressure and hot for R97N3. Similarly, the ratio is 32.04% for press time are effective. R94N6 according to R100N0. Therefore, the During hot pressing, draft (mat) moisture percentage of modulus elasticity decreases is an important factor. Mat humidity is 9- for R94N6. The ratio is 40.76% for R91N9 11% preferred. At this humidity value, the according to R100N0. Therefore, the

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percentage of modulus elasticity decrease for There is a significant difference between R91N9. (R100N0), (R97N3), (R94N6) and (R91N9) In MDF production the fiber length according to the percentage of Jank hardness increases the modulus of elasticity of the test. The brief results of Table 4 could be board. The important factors affecting the explained as follows. modulus of elasticity are the chemical, The ratio for this test decreases 1.82% for anatomical structure, density, amount of R97N3 according to R100N0. Therefore, the extractive substance, extractive content, pH, percentage of Jank hardness decreases for the humidity of the mat fiber, press R97N3. Similarly, the ratio decreases by temperature, press pressure and timing 4.45% for R94N6 according to R100N0. diagram, respectively. The more contact and Therefore, the percentage of Jank hardness sticking surface between the fibers, the decrease for R94N6. The ratio is 7.35% for greater the elasticity modulus. As the contact R91N9 according to R100N0. Therefore, the surface between the fibers and the area of percentage of Jank hardness decreases for adhesion decreases, the elastic modulus of R91N9. Akgul et al., (2013) measured the the sheet decreases. Ayrılmış (2000) elasticity modulus of the board produced measured between 2857-3494 N/mm² the burned pine between 2567-2733 elasticity modulus of the board produced N/mm². from black pine, beech, oak fiber The Combustion Properties of Fiberboard The Results of the Surface Screw Holding Table 5 shows FIC, FIC lux, SC, SC lux, Ability (N) Test ESC, ESC lux ESC time and mass loss There is a significant difference between experiments results according to ANOVA (R100N0), (R97N3), (R94N6) and (R91N9) Duncan for MDF board which have additive according to the percentage of the surface rock salt. screw holding ability test. The brief results of The temperature has been measured as Table 4 could be explained as follows. R100N0 (560,21ºC), R97N3 (553.29ºC), R94N6 The ratio for this test is 14.82% for R97N3 (550.16ºC), R91N9 (547.54) in the FIC according to R100N0. Therefore, the experiment for the produced in the process percentage of the surface screw holding line. When the FIC temperature of the panels ability decreases for R97N3. Similarly, the with addictive inorganic mineral is ratio is 37.20% for R94N6 according to compared, the panel resists to the FIC R100N0. Therefore, the percentage of the temperature as the amount of the addictive surface screw holding ability decreases for inorganic mineral is increased. The highest R94N6. The ratio is 57.17% for R91N9 FIC temperature in the control panel is according to R100N0. Therefore, the measured as 560,21°C in %100R. The FIC percentage of the surface screw holding temperature decrease as the amount of the ability decreases for R91N9. addictive inorganic mineral in MDF. The screw holding resistance is the most Therefore, the heat is absorbed in MDF important for mechanical properties. The which is produced with rock salt mineral, and surface screw holding strength of the board is the MDF has resistive properties against the related to the strength of the between fibers combustion. adhesive. The screw holding test results are SC temperatures are measured as standardized in TS EN 622-5 (2008). Akgül 662.58ºC for R100N0, 570.68ºC for R97N3, & Çamlıbel (2008) tested the surface screw 566.11ºC for R94N6, 556.56ºC for R91N9 in holding strength of MDF produced from the SC temperature experiment. The value of Rhododendron ponticum L wood fibers temperature decreases. This reduction is between 121.07-125.42 kp. As the amount of responsible for the chemical properties of the inorganic rock salt increases in MDF, the rock salt mineral. ESC temperatures are surface screw holding ability decreases. measure 652.57ºC for R100N0, 251.83ºC for R97N3, 235.76ºC for R94N6, 203.07ºC for 2 The Results of Jank Hardness (N/mm ) Test R91N9 in the ESC temperature experiment.

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ESC temperature decreases as the ratio of SC lux experiment. The results of the ESC inorganic mineral usage increases. lux experiment are 302.57 lux for R100N0, The light density is measured as 309.00 154.36 lux R97N3, 228.21 lux R94N6, 201.26 lux for R100N0, 284.91 lux for R97N3, 281.91 lux R91N9. As the amount of the inorganic lux for R94N6, 281.33 lux for R91N9 in FIC filling material increases the density of ESC lux experiment. FIC light density decreases decreases. The results of the mass loss and releases light fog as the number of experiment are 96.35% for R100N0, 95.35% inorganic material increases in the addictive for R97N3, 94.85% for R94N6, 93.30% for MDF. The light density is measured as R91N9. After MDF which has inorganic 302.42 lux for R100N0, 264.04 lux for R97N3, mineral is burned, the ash amount is more 270.98 lux for R94N6, 272.77 lux for R91N9 in surplus according to the test panel.

Table 5. The statistical results for FIC, FIC lux, SC, SC lux, ESC, ESC lux ESC time and mass loss experiments of MDF board. Board Std. Board Std. Avg.x Avg.x Rock Salt Deviation Rock Salt Deviation a a

R100N0 560.21 17.98 R100N0 309.00 2.83

a b R97N3 553.29 9.13 R97N3 284.91 2.70 a b FIC FIC

e (ºC) R94N6 550.16 7.19 R94N6 281.91 1.64 (LUX) a b

Temperatur R91N9 547.54 11.37 R91N9 281.33 1.06 a a

100 0 100 0 R N 662.57 6.64 R N 302.42 24.86

b a R97N3 570.68 3.53 R97N3 264.04 8.04

SC bc SC a (ºC) R94N6 566.11 4.60 R94N6 270.98 14.31 c (LUX) a R91N9 556.56 2.03 R91N9 272.77 0.03 Temperature Temperature a a

R100N0 652.57 18.99 R100N0 302.57 19.19

b b R97N3 251.83 9.28 R97N3 153.36 15.79 bc c ESC ESC

e (ºC) R94N6 235.56 20.13 R94N6 228.21 23.73 (LUX) c bc Temperatur

R91N9 203.07 9.29 R91N9 201.26 9.10

a a

R100N0 64.33 0.95 R100N0 96.35 0.07 b b R97N3 68.50 1.41 R97N3 95.35 0.07

a % c ESC Time Time R94N6 64.00 0.70 R94N6 94.85 0.07 Mass loss loss Mass (minute) c d R91N9 59.00 0.70 R91N9 93.30 0.28 N: Number of samples, x: average value of samples, * 95% confidence interval for average ANOVA. a,b,c,d values with the same letter are significantly different (Duncan’s test).

Table 6 shows FIC temperature, FIC lux, MDF board which have additive rock salt. SC temperature, SC lux, IST temperature, The mass loss analysis of fiberboards is IST time, IST lux, FC temperature, FC time, calculated by using Eq.(2). The results are FC lux, IST time and mass loss experiments tabulated in Table 5. results according to ANOVA Duncan for

Tablo 6. Combustion experiment of MDF produced in the production process

FIC Average. SC Average. ESC Average. IST Average FC Average IST Mass loss Tempx (Lux) Tempx (Lux) Tempx (Lux) Tempx Time (Lux) Tempx Time (Lux) Minute (%)

Board (ºC) (ºC) (ºC) (ºC) (minute) (ºC) (Minute) (dk)

%100R 560.21 309 662.58 302.42 652.57 302.57 654 150 321 614 540 301 64.33 96.35

R97N3 553.29 284.92 570.68 264.04 251.83 154.36 560 210 251 133.5 780 180 68.5 95.35

R94N6 550.17 281.92 566.11 270.98 235.76 228.21 394 465 240.5 194.5 720 234.5 64 94.85

R91N9 547.54 281.33 556.56 272.77 203.07 201.26 201.5 495 175.5 155 720 218 59 93.30 x: average value of temperature.

Conclusions

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As the amount of inorganic rock salt MDF which has rock salt mineral addictive. increases in MDF production both the As the amount of the inorganic filling mechanical tests and the physical test mineral increases, the resistive against consequences decrease. pH of the rock salt, combustion increases. The rock salt additive the chemical structure of the rock salt which has 9 percent ratio has raised against mineral is affected by the mechanical and the to combustion both 23.76% at FIC physical tests quality of the board. The rock temperature and 19.06% in SC temperature. salt inorganic filler minerals reduce the It is concluded that rock salt mineral can be between fibers contact and adhesion strength. used against the fire as a resistive in the As the amount of inorganic rock salt production of MDF. increases in MDF production, both the percentage of TS-2h and the percentage of Acknowledgements TS-24h increase. As the amount of inorganic This study was supported by T.C. rock salt increases in MDF production, the Ministry of Science Industry and percentage of the WA-2h and WA-24h Technology, Duzce University, and Divapan increases. WA values of fiberboard increase Integrated Wood Company and Wood according to standards. This reason is the Chemistry and Technology Department in usage amount of rock salt mineral and its Faculty of Forestry at Duzce University. geometrical structure. As the amount of inorganic rock salt increases in MDF, the References quality of BST decreases. Therefore, the Akgul, M. (2009). Medium density fiberboards amount of rock salt mineral must be within manufactured from corn stalks. Duzce acceptable limits. University Journal of Forestry, 5(2) 95-103. As the amount of inorganic rock salt Akgul, M., Ayrılmış, N., Camlıbel, O. & Korkut, increases in MDF, the surface total colour S. (2013). Potential utilization of burned wood in manufacture of medium density fibreboard. difference of the board increases in terms of The Journal of Material Cycles and Waste the result of colour parameters ( E , L , Management, 15(2), 195-201. a and b ) according to the control board. Akgul, M. & Çamlıbel, O. (2008). The As the amount of inorganic rock salt Manufacture of medium density fiberboards increases in MDF, the total colour difference using rhododendron (R. Ponticum L.) and whiteness (black-white colour change) biomass. Building and Environment, 43, 438- over the surface board increase. The rock salt 443. inorganic mineral is suitable for the ASTM D 2244-07e1 (2007). Standard practice for calculation of color tolerances and color production of MDF board. It is suggested differences from instrumentally measured that rock salt inorganic mineral could be used color coordinates. American Society for within acceptable limits according to the Testing and Materials, West Conshohocken, alternative biomass. PA. Rock salt inorganic minerals reduce the ASTM D 1037-78 (1994). Standards methods of ability to bond fiber-fiber bonds on the evaluating the properties of wood-based-fiber board. The mechanical properties of the and particle panel materials The American board decrease as the amount of inorganic Society for Testing and Materials USA. minerals increases. The mechanical ASTM E 160–50 (1976) Standard test method for properties for the 6- 9% inorganic mineral combustible properties of treated wood by the crib test. added to the board is the lowest because rock Ayrılmış, N. (2000). Impact of tree varieties on salt inorganic filler minerals reduce the the technological features of MDF, Master between fibers contact and adhesion strength. Thesis. İstanbul University Institute of It is suggested that rock salt inorganic Science and Technology, İstanbul. mineral could be used within acceptable Basta, A. H., El-Saıed, H., Gobran, R.H. & limits according to the alternative biomass. Sultan, M.Z. (2006). Enhancing The experiments give positive results environmental performance of formaldehyde- according to FIC, SC, ESC, FIC lux, SC lux, based adhesives in lignocellulosic composites, ESC lux, IST, ESCS, mass loss tests for part III: evaluation of some starch derivatives.

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