Fractionation of Kraft Lignin for Production of Alkyd Resins for Biobased Coatings with Oxidized Lignin Dispersants as a Co-Product

A new valorization pathway based on solvent fractionation was applied to kraft lignin, a major by-stream of the pulping industry, to extract a soluble lignin intermediate featuring an improved structural homogeneity, a low molecular weight, and a high content of phenolic hydroxyl and carboxylic acid groups to serve as a substitute of the nonrenewable polyacids in the formulation of alkyd resins, a dominant material used in the production of anticorrosion surface coatings. Herein, softwood kraft lignin was mixed in a low-cost green solvent, aqueous ethanol, prepared at different ratios, at room temperature to generate a soluble fraction of a low <i>M</i> _w of ≤2200 g mol^-1 and an insoluble fraction of a high <i>M</i> _w of ≥3950 g mol^-1 of lignin. The best combination of yields and molecular weights of soluble lignin (16-36% yield, 1740-1890 g mol^-1) was attained using 50-80 vol % ethanol in fractionation. Thus, these conditions were further employed at the pilot scale to demonstrate the scalability of this technology. Soluble lignin from pilot fractionation was used to produce an optimal alkyd resin formulation and thereafter an anticorrosion coating on the metal surface, both of which matched the target properties of industrial standards well (180 s Persoz hardness and 72 gloss units of coating, 100% adhesion of paint with no cracks or peeling in the cross-cut test, no corrosion after 120 h of the salt spray test). The insoluble solids from pilot fractionation could also be valorized by alkali-O₂ oxidation into lignin-based dispersants for special carbon black pigments. Overall, this study presents a new, simple strategy to develop an efficient, scalable, low-cost, and green process for upgrading kraft lignin into phenolic intermediates for biobased alkyd resins to facilitate sustainable production of high-performance anticorrosion coatings.