Synthesis and characterization of biodegradable Kraft lignin-based hydrophilic phenol formaldehyde foams

Phenol formaldehyde foams, extensively utilized in wide range of applications face challenges due to depleting petroleum resources and adverse environmental concerns. This study explores a promising shift to biobased alternatives, specifically investigating the use of Kraft lignin (KL) by replacing about 10 to 50% phenol content to synthesize open-cell hydrophilic phenolic foams. The produced foams undergo comprehensive testing to evaluate wetting properties, porosity, mechanical strength, and biodegradation potential. Remarkably, foams with a high percentage of Kraft lignin exhibit outstanding physical and wetting characteristics. Notably, substituting 50% of phenol with KL gave rise to a foam with a density of 40 kg/m³, open cell porosity of about 100%, water absorption capacity of 2100%, and an average water uptake rate of 0.9 cm³/s. Furthermore, these lignin-substituted foams display enhanced biodegradability compared with their petroleum-based counterparts. The foam with the 40% phenol substitution exhibits the highest weight loss of approximately 68% in 15 days during the biodegradation test. The biodegradation was further confirmed using scanning electron microscopy and FT-IR analysis of the degraded samples.