Date Palm Medium Density Fiberboard: Process Modeling, Physical and Mechanical Characterization

An approach to produce medium density fiberboard (MDF) from date palm midrib fibers, an abundant agricultural byproduct generated during routine palm pruning, using urea-formaldehyde (UF) resin as a binder is studied. Systematically varied UF resin concentrations ranging from 0 to 12.5 wt.% were prepared and examined for tensile strength, elastic modulus, modulus of rupture water absorption and density swelling. The results indicate a consistent improvement in mechanical and physical performance with increasing UF resin content. Specifically, 12.5 wt.% board had about five times higher modulus of rupture and six times higher tensile strength compared with control sample. Water absorption reduced from about 185% in the control to about 90% at 12.5 wt.% board, while thickness swelling reduced from 177% to 22%. Moreover, a hot-press heat transfer simulation was conducted to validate the choice of curing time during the process. Using Fourier’s time-dependent heat conduction law, the time for the core temperature of a 10-mm-thick fiberboard was computed taking 5.5 min to reach 165°C, above usual thermal activation temperature (~160 °C) required for UF resin polycondensation with no acid catalyst. The resulting properties position the developed panels for non-structural interior MDF applications, such as furniture components and interior paneling.