124 722 __THS 2222222 22%.: 42.2; 222' 222.3222 2422244222222 24:22 2:42-24 1: 4 222.22. :22; 2242324 2024 2222 42:222—222. 222 4 a. 24 22:24 222422 $2422 220222442 04422‘.434402524 1941. C “In-1 LII-313A R Y r I u f‘ . ‘( ‘ A '1‘ '\ ,/‘ ‘ P ..1LII{53?1 5) $1.; 3 I "'2‘ 2,...“ University j .45.: hammfiunsx-nJhm I. SOME STUDIES OF RESIN FORMATION FROM CASHEW NUT SHELL OIL by CARL WALTER 3022220312223 I A THESIS Submitted to the Graduate School of lichigan State College of Agriculture and Applied Science in partial fulfilment of the requirements for the degree of MASTER OF SCIENCE Department of Chemistry September, 1941 (Na. \. \$>K‘ SOME STUDIES OF RESIN FORMATION FROM CASHEW NUT SHELL OIL 331-6633 ACKHOWLEDGMENT To Dr. R. C. Huston, the writer wishes to acknowledge his appreciation for the guid- ance and helpful suggestions which have made possible the completion of this work. The writer also wishes to thank General FDods, Inc.. for furnishing the cashew nut shell oil. and for the method used in the separating and decarboxylating of anacardic acid found in eectione V-B - l and 3, and V-B - 4 respectively. I. II. III. IV. VI. TABLE OF CONTENTS Introduction . . . . . . . . . . Historical . . . . . . . . . . . Theoretical o o o e e e e o o 0 Technique of Handling the Oil . Experimental 0 o e e e o o e o o A. B. D. E. materials 0 o o e I o e o e 0 Separation of Component Parts 1. Preparation of Calcium Anacardate 2. Preparation of Cardanol . Separation of Components by Steam DIStillation o e o o o o o o o Polymerization Reactions . . Stabilization Of COlor o o 0 Special Treatment of the Cashew Nut Shell Oil Use of Inhibitors Dry Hydrogen Chloride Hydrogeneration Preparation of the Platinum Catalyst Procedure for Use of Apparatus Used 5. Regeneration of Anacardic Acid . 4. Preparation of Anacardol . . . Physical Properties of Resins Obtained . A. B. Observations . . . . . . . . 10 TIMO 2. Color 5. Color Stability Testings . . . . . . . . . . l. Softening Point 2. Melting Point Page 15 16 16 18 18 2O 21 24 28 52 52 52 Table of Contents (cont'd) 5. Flow under Pressure 4. Specific Gravity VII. COHClUSionSeooeoo-ooooe I VIIIQSWaI‘yooocoooe-oso... IX. Bibliography c o o o e o o o o o o I. INTRODUCTION Since the discovery of Bakelite a great deal of research has been done on the polymerization of syn- thetic and naturally occurring substituted phenols with formaldehyde to obtain.modified phenol-formaldehyde resins. Coming under the latter category is the oil of the cashew shell. formerly a waste by product, which is made up essentially of cardanol (see page 10) and ana- cardic acid (see page 10). This paper will deal with further studies of cashew nut shell oil and formaldehyde especially in the presence of certain modifiers. II. HISTORICAL The cashew nut made its first appearance in the lit- erature in 1911 when Schenk (1) reported it as a new confection. From.then until 1922 the kernel of the nut was studied and the husk was given no attention at all. In 1923 however J.J. Sudborough (2) found that the husk contained 39.8% oil with d261.0151. acid value 107. saponification equivalent 119, iodine number 296 n.fi%§ 1.5158. and was made up essentially of anacardic acid (022H3205) and cardol ' (032H5204), both being substi~ tuted phenols with unsaturated side chains. These facts point to resins of both "A“ and "C" type. but the problem remained untouched until 1927 when Harvey (3) obtained a patent for the treatment of the oil with nitric acid. etc., or formaldehyde which yieldei a product suitable for molding or lacquers. From then on much work has been done on the problem.with H.T. Har- vey doing the major portion. In the same year he (4) patented the polymerization of cashew nut shell oil and glycerol induced by heat and catalyst. In 1928 another patent was issued to Harvey (5) covering the drying of cashew nut shell oil with a metal such as Cu. Al. or Pb. In 1928 he (6) also received a patent for the treatment of cashew nut shell oil with ammonia. smmonium.hydroxide. etc. to produce compounds that varied in color from red to violet useful as coloring agents. A product useful for paints and varnishes was made by headhg the oil with nitric acid and patented by Harvey (7) in 1929. In the same year he (8) patented an insulator made from cashew nut shell oil and formaldehyde with hmirochleric acid as the catalyst. A process for extracting the oil from the shell was devised and patented by Hughes (9) in 1951. The nuts are subjected to a sudden change in temperature from nor- mal to charring, bursting the cellular structure of the shell and allowing the liquid to run out. A compound suitable for insulation was prepared in 1931 by Harvey (10) by vulcanizing cashew nut shell oil with rubber. Also in 1951 Harvey (11) patented a product prepared from cashew nut shell oil and fonmaldehyde. A.J. Haagen Smit (12) in 1931 proved the structure of snacardic acid to be 2-03. l-COOH 5-n015327 benzene. Harvey again in 1932 patented a great deal of work including, (13) cashew nut shell oil used as a plasti- cizer with cellulose esters such.as cellulose acetate. (14) an insulator from.cashew nut shell oil and a drier such as manganese. (15) a water-proofing material from the oil for waterproofing of concrete surfaces, etc.. (16) a red to violet coloring material from the oil and ‘ ammonia and formaldehyde. (17) a resin obtained by treat- ing cashew nut shell oil with an acid and oxidising with nitric acid. (18) a varnish containing a modifier of China wood oil. (19) a varnish for inside of iron food containers. Ryan in 1932 also patented a varnish (20) made from cashew nut shell oil. a congealed vegetable oxidation product such as copal gum. and a suitable catalyst. In 1933 Harvey (21) prepared a compound consisting of the oil. stearin pitch and hexamethalene tetramine. In 1934 a product from.cashew nut shell oil and casein with an alkaline catalyst was prepared by Harvey (22). The first mention of distillation was noted in 1934 when Harvey (23) reported and patented a method for the distillation of cashew nut shell oil at a temperature of 300° to 400° C. at atmospheric pressure which yielded a product of germicidal phenolic character. Damitz (24) in 1935 reported a brittle fusible resin from cashew nut shell oil and ester gum heated together at a temperature of 315° C. ‘ Dickey (25) also in 1935 polymerized cashew nut shell oil with rubber to give a material suitable for typewriter platens, etc. Harvey (26) obtained a product suitable for water~ proofing walls by reacting the oil with barium hydroxide and then a glyerride. Pillay (27) in 1935 found the formula of anacardic acid to be 022H5203 M.P.22.5° C. It contained two active hydrogens one of which was phenolic. Pyrolysis of the acid yielded anacardol 0213520 B.R.215.2°. a§8.9399 n§9.1.5107. Two double bonds were shown in both com- pounds, but were not located. The side chain however was straight. The formula. CODE OH OH 015327 15H27 Anacardic acid Anacardol Rector (28) developed a new process for*extracting the oil from the shell in 1936. The nuts were immersed in a bath of cashew nut shell oil at a temperature and for a time adjusted to effect the discharge of a major portion of the oil without scorching the kernels. Patel (29) in 1937 studied the effects of decarbaxyr lation. The saponification number (117) and acid value (109) of the oil decreased on heating until they became almost zero. The rate of decrease was higher at higher temperatures. This decrease was due mainly to decarboxy- lation. 0n heating the iodine value (266) increased initially owing to the splitting off of carbon dioxide and the decomposition of the oil into unsaturated sub. stituents. A subsequent decrease was thought to be due to polymerization of the unsaturates. The specific grav- ity (.996) of the oil decreased and then increased slightly on further heating. The mean molecular weight decreased to a minimum and then gradually increased. Hughes (30) modified his previous method for the exe traction of the oil by first causing the nut to absorb water and then immersing it in a hot bath of the shell oil. Harvey and Benita (31) in.1937 patented a procesl for effecting the polymerization of the oil by using sale furie acid. In 1938 Harvey and Damitz (32) devised a method of driving off the sulfur existing in the oil and then effecting polymerization. In 1938 we found the first mention of cardanol (33) being used with formaldehyde. It was obtained by either steam distillation or distillation at atmospheric prose sure. Gardner (34) in 1938 reported the use of cashew nut shell oil as a drying agent in points. Jeffries (35) also in 1938 reported another method for the extraction of the oil. A column of nuts and broken shells was subjected to a downward stream of super- heated steam, the water and oil being collected at the bottom. In the same year Jeffries and Pierce (36) de~ vised a special pretreatment of the nuts before extrac‘ tion of the oil. A patent issued to the Harvol Corporation (37) in 1938 described a process for the polymerization of cashew nut shell oil by using 1 - 6% by volume of concentrated sulfuric acid or with zinc chloride or tein tetrachloride. The product obtained was used in paints. varnishes and impregnsnts. Wats and Bherscha (38) used the oil as a mosquito larvicide in 1958. Five parts of cashew nut shell oil and 95 parts of kerosene were used. In 1958 Pierce and Jeffries (39) added another revision to their apparatus for the extraction of the oil. This consisted in appe‘ retus for effecting rapid cooling and draining of the shells that had been extracted. Harvey (40) in 1959 showed the formula of cardsnol H H (CH2)5- c . 0(CH2)5 - CH3 K ~\ and used it with formaldehyde to make costings. molded products. etc. Hughes (41) in the same year polymerized cashew nut shell oil with glycerol phtholic unhydride condensation products to obtain materials suitable for shooting and molding, Kiezmick (42) polymerized the oil with sul- furic acid to a flowable state and then completed poly- merization to a rubbery state with hexamethalene tetra~ mine. Patel and Patel (43) reported that the roasted shells contained 18 - 20% oil with a saponificetion number of 4.5. iodine number of 294, dgg .9578 and mean molecular weight of 540. ‘ Caplsn (44) in 1940 used diethyl sulphate dissolved in the oil and heat to effect reaction of the solution with the metals naturally present in the 011. These precipitated metals sere then removed and the product polymerized to yield resins suitable for paints. var— nishes, etc. Downing (45) showed that dermatitis from cashew nut shell oil is not caused by ingestion of the cooked nuts, but only by contact with the oil of the shells and reported that ointments and pastes should be avoided but hot wet dressing applied. Cayo (46) decreased the poison ivy effect by treat- ing the oil with protein such as egg or blood albumin or heating with acetamide, benzamido, etc. Harvey and Caplan (47) published a paper on cashew nut shell oil describing the manufacturing processes, polymerization utilizing both the unsaturated nature of the oil and the phenolic group. Upon distillation the distillate consisting largely of anacardic acid polymer- ized slowly. The residue showed both phenolic and an- saturated preperties and also reacted slowly with alde- hydes. III. THEORETICAL From the graphic formula on the following page it is evident that the components or cashew nut shell oil (cardanol and anacardic acid) and their synthetic deriv- atives (dihydrocardanol, anacardol and tetrahydroana- cardic acid) are all substituted phenols and should therefore react as such in the presence of formaldehyde. According to Baekeland one mole of formaldehyde reacts with one mole of phenol or its derivatives to yield benzyl alcohols as follows:- H H HO cos t s so tugs 4-— ‘ —' as car" He " (:1 HO c-c-OH I a H H The benzyl alcohols formed will then. by the elimination of water. combine to give a straight chained, thermoset- ting resin H H as 6-03 HG 6-01! B 4' H so c-G—OH so 0-0-0}! 3 H . c H a If however more formaldehyde is used, a thermosetting resin will be obtained due to the formation of cross linkages. 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Harvey, Harvey, Harvey, Ayan. Harvey, Harvey, Harvey, Damitz, Dickey, Harvey, Pillay, Rector, M.T. M.T. E.T. 2.1. M.T. Fred M. Charla s 2.5.”! i; J. P.P. T.M. T. Patel, Mg... 86 HOMO {13.5218 8 , EOR. Harvey & Damitz, F.fi. Harvey & Damitz, F.M. Harvey, M.T. 0.1. 26; P 25544 Ger. P 558, 748 Oct. 15, 1926 C.A. §§= P 14598'9 U.S. 1, 838, 076 Dec. 22, 1952 0.2.‘28: P 14598,9 U.S. 1, 858, 075 Dec. 22, 1952 0.1. 22: P 14598:9 U.S. 1, 858, 072 Lee. 22, 1952 0.1. 21; P 52055 U08. 1. 921, 292 Aug. 8, 1955 C.A. 28; P 55416 U.S. 1, 952, 515 Mar. 27, 1954 0.1. 225 P 51887 U.S. 1, 950, 085 Mar. 6, 1954 0.2. 29; P 75293 U.S. 2, 014, 570 Sept. 17, 1954 C.A. 29: P 81024 0.5. 2, 008, 458 July 18, 1954 C.A. 29: 2585 0.5. 1, 977, 826 Oct. 23; 1955 0.4. 29: 68886 J. Ind. Chem. 500. $2} 226-51 (1955) 0.1. 53: P 5185 0.8. 2, 018, 091 Oct. 22, 1956 C.A. 51: P 55139 J. Univ. Bombay g; Pt. 27.114-51 (1936) 0.1. 51; P 9845 U.S. 2, 058, 456 Oct. 27, 1957 0.1. 51: P 1522’5 U... 2, 067, 919 Jan. ., 1957 0.1. 51: P 88125 U.S. 2, 128, 247 Aug. 30, 1937 0.1. 52. P 2741 U.S. 2, 098, 824 Nov. 9:"1958 34. 35. 56. 37. 38. 40. 41. 42. 47. Gardner, H o A 0 Oil, Paint & Drug Jeffries, Wm. Brit. P 486, 169 Jeffries, Wm. & Pierce brit. P 480, 981 Harvey, 1LT. Brit. P 481, 960 Wats, B.C. & Bharaeha, K.H. J. Malaria Inst. Jeffries, Wm. & Pierce Brit. P 480, 468 Harvey, M.T. U.S. 2, 157, 126 H‘uléfile 3 , 13:31. A o U.S. 2, 145, 880 Kuzmick, J.N. U.S. 2, 156, 451 Patel, Mus. & H.111. .In . & News Ed. of J. o 1: 83-90 (1938) Caplan, S. U08. 2, 176, 059 Dawning, J.G. C.A. 32: P march $, 19 C.A. 32: P 6500 March”21, 1958 0.1. 52: 6248 India 1, 21’ 0.1. 52: P . Feb. 25, 1958 5 P C.A. 5- 0.1. 55: 50274 Jan. 17, 1959 0.1. 55: P 68548 May 2, 1959 0.1. 55: 8887 m 0.1. 54: P 12027 Oct. 17, 1940 0.1. 54: 42954 J. Ind. Hygene Toxical.”§g: 169 (1940) Cave, Martha B. U03. 2, 183' 957 Harvey, M.T. & Caplan, S. 0.1. 54: 25021 Dec. 1 1940 9: 0.1. 54: 76571 u..- Ind. Eng. Chem. 52:1506-10 (1940) Ind. Chem.Soc. 3 1293 02808 0673 > ||”WWII“1||H||W|l|l|lliIlHllUIHIHIWIHIIIHW\I