Designed Monomers and Polymers ISSN: (Print) 1568-5551 (Online) Journal homepage: www.tandfonline.com/journals/tdmp20 Cashew nut shell liquid (CNSL) - a versatile monomer for polymer synthesis Mary C. Lubi & Eby Thomas Thachil To cite this article: Mary C. Lubi & Eby Thomas Thachil (2000) Cashew nut shell liquid (CNSL) a versatile monomer for polymer synthesis, Designed Monomers and Polymers, 3:2, 123-153, DOI: 10.1163/156855500300142834 To link to this article: https://doi.org/10.1163/156855500300142834 Published online: 02 Apr 2012. Submit your article to this journal Article views: 11771 View related articles Citing articles: 47 View citing articles Full Terms & Conditions of access and use can be found at https://www.tandfonline.com/action/journalInformation?journalCode=tdmp20 Designed Monomers and Polymers, Vol. 3, No. 2, pp. 123 – 153 (2000) VSP 2000. Review article Cashew nut shell liquid (CNSL) — a versatile monomer for polymer synthesis MARY C. LUBI and EBY THOMAS THACHIL ∗ Department of Polymer Science and Rubber Technology, Cochin University of Science and Technology, Kochi 682022, India Abstract—Cashew nut shell liquid (CNSL) is a by-product of the cashew industry. It is a naturally occurring substituted phenol which can take part in a variety of reactions. It is a cheap and renewable substance and can be employed for the manufacture of a multitude of useful products. It can replace phenol in many applications with equivalent or better results. CNSL by itself is useful for insecticidal, fungicidal, anti-termite, and medicinal applications, and as an additive, in many plastic formulations. Resins derived from CNSL are employed widely in the fields of friction materials, automobiles, surface coatings, adhesives, laminates, rubber compounding, and have several miscellaneous applications. Greater utilization of CNSL as a monomer for indusrial polymer products can be an attractive proposal in view of its low cost, abundant availability, and chemically reactive nature, amongst other attributes. This review gives an accounts of the composition, extraction, reactions, and applications of CNSL based on the available literature. Keywords: CNSL; cashew nut shell liquid; phenolics; monomer; polymer synthesis; renewable sources. 1. INTRODUCTION Cashew nut shell liquid (CNSL) occurs as a greenish-yellow viscous liquid in the soft honeycomb of the shell of the cashew nut. Cashew nut is a product of the cashew tree, Anacardium occidentale L. [1], which is native to Brazil. The plant may grow to 12 m in height. Cashew nuts are the cash crop yielded by the tree, but it also produces cashew apple, wood suitable for boats, charcoal, etc., and a gum similar to gum arabic. The cashew nut is greenish-gray in color and is attached to the cashew apple, which when ripe is either bright yellow or red. The cashew apple is used in beverages, jams, and jellies. The nut has two walls or shells, the outer one being smooth and somewhat elastic and olive green in color before maturity. When ∗ To whom correspondence should be addressed. 124 M. C. Lubi and E. T. Thachil the nut matures, the outside shell becomes grayish-brown in color. The inner shell is harder and must be cracked like the shells of other nuts. The honeycomb is housed between the inner and outer shells. The kernel is inside the shell and is covered with a brown skin known as testa. The nut has a kidney shape and may vary in size from 2.5 to 4 cm. The oil has a reddish-brown color, due to charring as well as chemical changes occurring during frying. Industrial grade CNSL is reddish-brown in color. CNSL constitutes about 20– 25% of the weight of the cashew nut. The main constituents of CNSL are phenolic compounds with long-chain substitution at the meta position. These compounds give most of the reactions of phenol and can be the basis for producing a number of polymeric substances of wide utility in industrial applications. CNSL, which enjoys a considerable cost benefit, can be a substitute for phenol in many applications. The use of CNSL in place of phenol is an excellent example of conservation of a synthetically derived substance and the utilization of a cheap agro by-product. In the modern context, CNSL occupies a position of great importance because of its renewable nature [2]. CNSL is abundantly available in many parts of the world, such as India, Brazil, Bangladesh, Tanzania, Kenya, Mozambique, tropical regions of Africa, and South-East and Far-East Asia. In some of these regions, cashew is a popular plantation product, while some others import cashew nuts for processing. 2. COMPOSITION The earliest work published concerning the composition of cashew nut oil was by Staedeler [3]. Since then, many researchers have investigated the constitution of the oil [4– 6]. Naturally occurring CNSL contains mainly four components: cardanol, cardol, anacardic acid, and 6-methyl cardol. Figure 1 shows the chemical structures of these compounds. Commercial-grade CNSL contains hardly any anacardic acid because of decarboxylation during the roasting process, which converts anacardic acid to cardanol or 2-pentadeca-diethyl phenol [7]. The roasting process also leads to polymerization, which accounts for 20– 25% of polymeric substances in the oil. Crude CNSL is corrosive but becomes less so by decarboxylation and removal of H2 S during the refining process. The effect of processing parameters on the refining of CNSL has been studied [8]. The components of CNSL are themselves mixtures of four constituents differing in side-chain unsaturation, namely saturated, monoene, diene, and triene. The structures of the side-chains of varying degrees of unsaturation occurring in the four major components of CNSL are identical. Figure 2 shows these linear structures. Paul and Yeddanapally [9] identified the components of anacardic acid as 1-hydroxy-2-carboxy-3-pentadecyl benzene, 1-hydroxy-2-carboxy-3-(80 -pentadecenyl)benzene, 1-hydroxy-2-carboxy-3-(80 ,110 -pentadecadienyl)benzene, and 1-hydroxy-2-carboxy-3-(80 ,110 ,140 -pentadecatrienyl)benzene. Table 1 lists the constituents of anacardic acid as determined by various techniques. Cashew nut shell liquid Figure 1. Components of CNSL. Figure 2. Components of the side-chain. 125 126 M. C. Lubi and E. T. Thachil Table 1. Composition of the constituents of anacardic acid as determined by various techniques (values are in wt%) [5] Constituents of anacardic acid Technique employed Low temp. TLC–UV crystallization TLC– grav. TLC– GLC HPLC TLC–mass spectrometry Saturated Monoene Diene Triene 4.00 15.00 44.00 37.00 — 38.40 17.30 44.10 4.00 38.3 17.30 40.40 4.30 33.4 19.90 42.4 3.65 38.19 16.50 41.62 — 38.70 16.30 45.10 2.2–3.0 25.0– 33.3 17.8– 32.1 36.3– 50.4 Table 2. Composition of the constituents of cardanol as determined by various techniques (values are in wt%) [5] Constituents of cardanol Saturated Monoene Diene Triene Technique employed Molecular distillation Argentated column TLC–GLC — 60.00 10.00 30.60 5.40 48.50 16.80 29.30 2.68 29.50 16.60 51.2 TLC–mass spectrometry 3.11 36.10 20.10 40.60 1.98 31.31 15.23 51.47 3.94– 4.35 21.64– 32.2 15.36– 18.22 45.23– 58.99 Table 3. Composition of the constituents of cardol as determined by various techniques (values are in wt%) [5] Constituents of cardol Technique employed Saturated Monoene Diene Triene 0.30 8.10 21.90 69.70 TLC– GLC TLC–mass spectrometry — 9.60 25.20 62.20 0.24 10.74 20.64 68.39 0.19– 2.70 8.43– 15.15 24.2– 28.92 36.46– 67.18 Symes and Dawson [10] and Cornelius [11] identified the components of cardanol as 3-pentadeca-anisole, 3-(80 -pentadecenyl)anisole, 1-methoxy-3-(80 ,110 pentadecadienyl)benzene, and 1-methoxy-3-(80 ,110 ,140 -pentadecatrienyl)benzene. Table 2 gives the composition of the constituents of cardanol. The same group of workers also identified the components of cardol as 5-pentadecyl resorcinol, 5-(80 -pentadecyl)resorcinol, 5-(80 ,110 -pentadecadienyl)resorcinol, and 5-(80 ,110 ,140 pentadecatrienyl)resorcinol. The composition of the constituents of cardol is given in Table 3. Cashew nut shell liquid 127 Table 4. Composition of 2-methyl cardol as determined by various techniques [5] Constituents of 2-methyl cardol Technique employed TLC–GLC [34] Saturated Monoene Diene Triene 1.66 13.90 18.50 65.90 TLC–mass spectrometry [117] 2.43 15.30 20.40 61.50 3.92 18.43 20.15 57.50 0.96– 1.34 16.27– 25.28 20.56– 24.36 49.82– 62.20 Table 5. Phenolic composition of natural and technical CNSL (values are in wt%) [6] Component Natural CNSL Technical CNSL Cardanol Cardol 2-Methyl cardol Polymer Anacardic acid 1.2 11.31 2.04 20.3 64.93 62.86 11.25 2.08 23.8 — Tyman [6] established the components of 2-methyl cardol as 2-methyl-5-pentadecyl resorcinol, 2-methyl-5-(80 -pentadecenyl)resorcinol, 2-methyl-5-(80 ,110 -pentadecadienyl)resorcinol, and 2-methyl-5-(80 ,110 ,140 -pentadecatrienyl)resorcinol. The relative proportion of the saturated and unsaturated constituents of 2-methyl cardol is shown in Table 4. It has been shown that cardanol, the main constituent, consists of species of varying degrees of unsaturation in the side-chain. Table 5 gives typical compositions of natural and technical CNSL. The phenolic nature of the constituents of CNSL, along with varying degrees of unsaturation in the side-chain, makes it a highly polymerizable substance amenable to a variety of polymerization reactions. Of overriding importance, however, is the condensation reaction with active methylenes that formaldehyde exemplifies. This leads to a phenol– formaldehyde type condensation. 3. EXTRACTION Traditionally, a number of methods are employed to extract the oil from the nuts. Often a particular region follows a technique by convention rather than by deliberate choice. The following are the popular methods currently employed for the extraction of the oil [5]. 128 M. C. Lubi and E. T. Thachil 3.1. Hot oil bath method The raw nuts are passed through a bath of hot CNSL at 180– 200 ◦ C. The outer part of the shell bursts open and releases CNSL. About 50% of the oil is thus recovered. This process makes the decortication of nuts easy, without adversely affecting the quality of the kernels. Improvements over this basic technique include initial surface wetting and dipping in water at 20– 25 ◦ C and subsequent steam treatment prior to exposure to the hot CNSL bath. The excess moisture content of 7– 10% of the weight of the nuts causes the cells to burst, with the result that the oil oozes into the bath. Another 20% could be extracted by passing the spent shells through an expeller and the rest by a solvent extraction technique. The expeller oil can be upgraded by acid washing followed by centrifugation and heating. 3.2. Roasting method Sudden exposure to high temperature from ambient is the basis of this method. The shells are charred during this process, producing an explosive pressure in the cellular structure which forces the liquid out of the shell. One variation of this method is abrading at 100– 300 ◦ C for about 1 h and subsequent roasting at 400– 700 ◦ C in an inert atmosphere. In yet another patent, the nuts are first abraded and then treated with moisture and heated in an infrared oven. Finally they pass through a high-frequency electric field, where the liquid flows out. Often this technique is employed in conjunction with an expeller, where the oil is expelled from the shells to an extent of 90%. 3.3. Miscellaneous methods Heating by superheated steam to force out the oil and subsequent expulsion using an expeller form the basis of a recently reported method. Extraction of the oil by solvents such as benzene,toluene, petroleum hydrocarbon solvents or alcohols [12] or supercritical extraction using a mixture of CO2 and isopropyl alcohol are other reported techniques. Reports of a power-operated cashew nut sheller have also appeared [13]. 4. REFINING Sulfides, nitrogenous materials, and minerals contained in the crude CNSL directly affects the quality of the oil. Hence CNSL is often subjected to chemical treatment with materials such as hydrocarbon sulfates and sulfuric acid before industrial use. Several acid treatment processes have been found to reduce the poisoning or vesicant action [1]. Aqueous solutions of acids such as hydrochloric acid, sulfuric acid, acetic acid, chloroacetic acid or phosphoric acid, or acid sulfates such as sodium hydrogen sulfate are employed for this purpose.This performs two important functions: mineral salts of ammonium, calcium, and potassium are precipitated and Cashew nut shell liquid 129 Table 6. Physical constants of the oil before and after chemical treatment [1] Iodine No. Refractive index Specific gravity Saponification value Viscosity at 25 ◦ C Raw oil Treated oil 269 1.5158– 1.5162 958 19.6 400 254 1.5212– 1.5218 96 29.7 435 there is a reduction in the content of skin vesicant present in CNSL. The chemical treatment is accompanied by the evolution of hydrogen sulfide. The reduction in sulfur content has been found to correspond roughly to the removal of the agent responsible for the skin irritation. Treatment with amines or with hydroxides of the metals of Group IA or IIA has been found to reduce the cardol content. The refined CNSL can be readily distilled under reduced pressure or hydrogenated, both processes leading to products with good color stability. Steam treatment of H2 SO4 -treated CNSL followed by distillation has been found to deodorize this oil to a substantial extent. Physical constants of CNSL before and after chemical treatment are summarized in Table 6. 5. PHYSICAL PROPERTIES CNSL is a dark viscous oil with a characteristic smell, quite unlike other vegetable oils. It is opaque and when applied as a thin film, it is reddish-brown in color. It is immiscible with water but is miscible with most organic solvents. CNSL has germicidal and fungicidal properties. It is used traditionally as a cure for fungal attack of the feet in Kerala. 6. REACTIONS OF CNSL The chemical structure of CNSL is such that it can take part in a large number of reactions. Reactions of CNSL are of commercial importance because several useful industrial products can be produced starting from this substance. A few reviews have appeared summarizing the known reactions of CNSL [6, 14]. Many reactions of CNSL have been reported in the form of patents issued all over the world in the last three-quarters of this century. Often the mechanism underlying these reactions and the intermediate steps are left uninvestigated or unreported. The reaction schemes given in the following sections are based on cardanol, the major constituent of CNSL. 130 M. C. Lubi and E. T. Thachil Figure 3. Decarboxylation of CNSL. Figure 4. Hydrogenation of cardanol. 6.1. Decarboxylation As mentioned earlier, anacardic acid decarboxylates on heating to cardanol. This reaction can occur during the extraction of CNSL or the refining process. Distillation of the crude CNSL also leads to decarboxylation as the distillate is found to contain mainly cardanol. Figure 3 shows the chemical changes involved during decarboxylation. 6.2. Hydrogenation [15] Hydrogenation is generally carried out using hydrogen and catalysts such as copper, nickel, palladium, and platinum (Fig. 4). Hydrogenated cardanol can be separated by distillation, as is done with crude CNSL. The saturation in the aliphatic sidechain can be carried out to completion, but evidence of hydrogenation of the aromatic ring has not been forthcoming. 6.3. Polymerization CNSL can be polymerized by a variety of techniques. The presence of the aliphatic side-chain gives these resins pronounced hydrophobicity, which is a valuable property for many applications. The unsaturation in the side-chain can be the basis for addition polymerization [15– 17] using free radicals or ionic initiators. Acids such as H2 SO4 , HCl, paratoluene sulfonic acid (PTSA), etc. can give polymeric products. The polymerization time in the presence of H2 SO4 is one of the Indian Standard specification for CNSL (Table 7). The acid polymer of CNSL is rubber-like and has a low susceptibility to oxidation. The kinetics and mechanism of the polymerization of cardanol using catalysts such as H2 SO4 and H3 PO4 and Lewis acids such as boron trifluoride etherate have been investigated. These studies show that cardanol undergoes Cashew nut shell liquid 131 Table 7. Indian standard specifications for CNSL Characteristic Requirement Specific gravity 0.95– 0.97 Viscosity at 30 ◦ C, cp (max) 550 Moisture, % by wt (max) 1.0 Matter insoluble in toluene, % by wt (max) 1.0 Loss in weight on heating, % by wt (max) 1.0 Ash, % by wt (max) 1.0 Iodine value (max) (a) Wijs method (b) Catalytic method 250 375 Polymerization (a) Time, min (max) (b) Viscosity at 30 ◦ C, cp (min) (c) Viscosity after acid washing at 30 ◦ C, cp (min) 4 30 200 oligomerization under acidic conditions through the side-chain unsaturation and that the oligomerization is initiated by protonation of the side-chain followed by cationic chain growth. CNSL can be polymerized using salts such as zinc chloride, stannic chloride, ferrous sulfate, aluminum sulfate, boron trifluoride, and salts of iron, cobalt, nickel, boron, chromium, lead, silver, mercury, manganese, etc. These salts are generally used to the extent of 1– 6%. The phenolic properties of CNSL are utilized to make condensation polymers by reaction with formaldehyde, furfural, HMTA, etc. [18– 20]. These polymers are similar to the product of phenol and formaldehyde condensation but show less reactivity during synthesis and later during cross-linking. Both resole and novolaktype resins can be made. In the presence of alkaline catalysts and with more formaldehyde, the methylol phenols condense either through methylene linkages or through ether linkages. In the latter case, subsequent loss of formaldehyde may occur with methylene link formation. In the case of the resole-type polymers, the structure of the final product has been studied by Tyman (Fig. 5). Working back from this structure and in analogy with similar reactions for phenol the reaction scheme leading to this final cross-linked network can be given as shown in Fig. 6. In the presence of acid catalyst and with less formaldehyde, the resin has no reactive methylol groups and therefore is incapable of condensing with other 132 M. C. Lubi and E. T. Thachil Figure 5. Resole resin made from cardanol [53]. molecules on heating in the absence of hardening agents. To complete resinification, more formaldehyde is added, resulting in cross-linking. The final structure of the novolac product has also been given by Tyman (Fig. 7). It is observed that condensation of CNSL takes place at one of the ortho positions and the para position of the phenolic ring. Condensation does not occur at the ortho position between the side-chain and the OH group. This can be attributed to a stoichiometric deficit of formaldehyde and steric hindrance caused by the lengthy side-chain. The expected reaction scheme for the novolac product is given in Fig. 8. This has been obtained by considering the final polymer structure and the reaction of phenol under similar conditions. The condensation reaction in this case is more difficult because of the immiscibility of CNSL and HCHO layers and the steric hindrance caused by the lengthy sidechain. Longer processing times are needed and the reaction product is a mushy, high viscosity substance, which tends to solidify at comparatively low degrees of polymerization. This reddish-brown substance is the most well-known product derived from CNSL. In certain applications, a preliminary step of polymerization through the side-chain is done before condensation polymerization. Similar reactions can be conducted with hydrogenated cardanol and the product converted to methyl ether and then oxidized with KMnO4 , giving methoxyterephthalic acid (Fig. 9). Mishra and Pandey investigated the kinetics of alkali-catalyzed formaldehyde condensation after thoroughly reviewing the results previously reported by various workers [21]. For the reaction catalyzed by NaOH, second-order kinetics has been reported when the concentration of the active position of the reactants is used instead of their molar concentration. The specific reaction rate constant for various reaction conditions and the energy of activation, E, have been calculated. A quick method for the determination of the composition of the resin at any stage of the reaction has also been suggested. O’Conner and Blum have studied the thermal stability of some formaldehyde condensate resins [22]. The structure and properties of CNSL novolac resin prepared using succinic acid as a catalyst have been investigated [23]. The synthesis and characterization of a large number of resins using different hydroxy aromatic compounds, fomaldehyde, furfural, and substituted aromatic compounds like CNSL in the presence of acid Cashew nut shell liquid 133 Figure 6. Polymerization of CNSL using alkali catalysts. and base as catalysts have been studied [24]. The synthesis and properties of resins from CNSL and different aldehydes have been the subject of a number of other investigations [25]. Oxidation polymerization using acid oxidizers such as HNO3 can also give polymers, which have proved to be excellent for surface coatings and paper and fabric impregnation [26]. CNSL on treatment with copper, lead, aluminum, etc. undergoes polymerization. The air-drying qualities of CNSL were found to improve 134 M. C. Lubi and E. T. Thachil Figure 7. Novolac resin made from cardanol. Figure 8. Polymerization of CNSL using acid catalysts. by this. Enzymatic polymerization of alkyl phenols derived from CNSL has been carried out in a dioxan– water mixture [27]. Heating is the simplest method of polymerizing CNSL. When CNSL is heated to 200 ◦ C or above, it undergoes polymerization. Cationic, anionic or oxidizing agents can accelerate the process. When the polymerization is proceeding with heat alone, salts present in CNSL catalyze it. Alkalis can also be used as catalysts for the polymerization of CNSL by heat. The first step is usually the reaction of phenolic hydroxyl with the alkali, and the compound thus obtained acts as a catalyst for the polymerization. Cashew nut shell liquid 135 Figure 9. Condensation of hydrogenated cardanol followed by etherification and oxidation. Figure 10. Sulfonation of cardanol. 6.4. Sulfonation Sulphonation CNSL derivatives can be sulphonated to yield alkyl aryl sulphonic acid or their metal salts. The reaction is carried out using concentrated H2 SO4 at 108 ◦ C. The reaction scheme is shown in Fig. 10. To prevent polymerization during sulfonation, an aryl or alkali group is substituted for hydrogen and the double bonds of the aliphatic side-chain are saturated by hydrogenation before treatment with the acid. 6.5. Nitration Direct nitration of cardanol or CNSL leads to simultaneous oxidation and polymerization. But nitration of hydrogenated cardanol gives the trinitro-derivative, which 136 M. C. Lubi and E. T. Thachil Figure 11. Nitration of cardanol. Figure 12. Etherification of cardanol. is a very useful product. The yields are better when sulfonated compounds are used as the starting material (Fig. 11). 6.6. Halogenation Halogenation of CNSL can be accomplished with comparative ease. For example, chlorine gas can be passed through CNSL dissolved in kerosene to obtain 15% (w/w) chlorination. Chlorinated CNSL reacts with active methylenes at a faster rate and are more flame-resistant. The halogenation is accomplished by polymerization and thickening and a large exotherm. 6.7. Etherification [28] Cardanol can be reacted with dialkyl sulfates in presence of alkalis to give dialkyl cardanols. Similar reactions can be carried out on hydrogenated cardanol. Another route to cardanol ethers is by the reaction of halogen compounds with CNSL in the presence of alkalis. Acid ethers of cardanol can be obtained by reaction with 1-chloropropionic acid. Allyl ethers can be obtained by treating CNSL with allyl chloride, bromide, iodide or sulfates. Glyceryl ethers of hydrogenated cardanol have been prepared by the reaction of hydrogenated cardanol with glycerin monochlorohydrin or glycol monochlorohydrin. Glyceryl ethers of cardanol have also been obtained by the reaction of epichlorohydrin. Figure 12 shows the chemical changes involved during etherification. 6.8. Esterification Cardanol can be reacted with acid chlorides in the presence of alkalis to give cardanol esters. Thus, benzoyl chloride gives benzoyl cardanol (Fig. 13). The same reaction can be carried out on anacardic acid, present in raw CNSL, to give mixed ether ester. By treating an epoxy compound derived from CNSL with unsaturated Cashew nut shell liquid 137 Figure 13. Esterification of CNSL. Figure 14. Epoxidation of cardanol. dicarboxylic acids or their anhydrides polyester can be obtained. This, in turn, can be mixed with a vinyl monomer to obtain an unsaturated resin composition [29]. Various other esters of industrial importance have also been reported. 6.9. Epoxidation Epoxidation of the side-chain can be accomplished by the reaction of CNSL with epichlorohydrin [30]. This is the basis for numerous international patents. The chemical changes during this reaction are shown in Fig. 14. CNSL polymers were reacted with glycerin monochlorohydrin or glycol monochlorohydrin in the presence of alkali to obtain polyhydroxy-alkyl halides. Epoxy resin can also be prepared from glycidyl ethers by reaction with CNSL. 6.10. Miscellaneous reactions Pillai and co-workers have investigated the phosphorylation of cardanol and its condensate with phosphoric acid and the prospective applications of the products [31]. Urethanes have been synthesized from CNSL, as in the case of other hydroxy compounds, by the reaction with isocyanates. Acetals of CNSL have been prepared by the reaction of dimethyl acetal or polymeric acetals such as poly-vinyl acetal or poly-vinyl butyral. Acetals of CNSL resin have advantages such as better electrical properties due to the total absence of water, ease of processing because of the non-volatile nature of the reactants, less dermatic effect on the skin, and faster reactions compared with phenolic resins. Isocyanates have been prepared from hydrogenated cardanol by reaction with SO2 Cl2 followed by nitration, methylation, and reduction [32]. Azo dyes are made by the reaction of phenols with primary aromatic amines after diazotization of hydrogenated cardanol [33]. By reacting CNSL with triethylene-tetramine, phenolic 138 M. C. Lubi and E. T. Thachil polyamines can be prepared [34]. Benzotriazole derivatives are prepared from hydrogenated cardanol by diazotizing with aromatic amines followed by reduction. Styrenation of CNSL resin can be done by reacting styrene with CNSL hexamine condensate [35]. Acrylic resin and a variety of other polymers derived from CNSL have also been reported. 7. APPLICATIONS Polymers derived from CNSL have certain outstanding properties which make them unique for many applications. The most attractive aspect of CNSL as a starting material is its low cost. The polymer shows flexibility, due to internal plasticization resulting from the presence of a long side-chain. This long aliphatic side-chain also gives water resistance. It has low fade characteristics, which make it a desirable component of brake lining formulations. CNSL has inherent anti-microbial and anti-termite properties. It is compatible with a wide variety of polymers such as alkyds, melamines, polyesters, etc. Its ready solubility in a number of common solvents makes it a natural choice for a large number of surface-coating applications. A serious problem of CNSL-based polymers is the color imparted by the oil. Although there are several suggested methods [1] for obtaining a transparent, lightly colored substance, it is doubtful whether economical methods exist for making brilliantly colored products from CNSL. There have been a number of reviews on the applications of CNSL-based materials [36– 45]. Most of these draw upon information available from the patent literature. In the present context, we have attempted to include all available reports of scientific and academic research in the area, in addition to information collected from several patents. 7.1. Brake linings and clutch facings [46, 47] This industry is the largest consumer of CNSL. CNSL polymers are a natural choice for this application because of an excellent blend of properties such as absorption of heat generated due to friction, longer retention of braking efficiency, high impact strength and modulus, low fade characteristics, and low cold wear. These resins gave good miscibility with rubber and other natural and synthetic materials. CNSL friction materials are ideal for low-speed automobiles where the temperature reached does not exceed 250 ◦ C . CNSL furfural reaction products have very even frictional characteristics over wide temperature ranges. Numerous patents exist on the technique of producing friction materials starting from CNSL. The preparation of resins for brake linings reportedly involves an acid catalyst side-chain polymerization followed by conventional formaldehyde condensation. CNSL aldehyde or CNSL, phenol and aldehyde friction composition can be obtained with desired properties when synthesized in the presence of aryl borates. Drying oil can be used to modify CNSL aldehyde products to be used Cashew nut shell liquid 139 as friction elements. CNSL-modified phenolic resin with carbon fiber, powdered cast iron, and BaSO4 was found to have excellent fade and wear characteristics. CNSL-based resins and cashew dust have been used for preparing corrosion and skid-resistant friction materials. A friction material having low brake noise was obtained from blends of CNSL-modified phenolic resins with rubber and certain additives. Friction materials with enhanced thermal stability were obtained from formulations having CNSL-based particles along with other ingredients. Anacardic acid can be reacted with tris(2-hydroxyl ethyl)isocyanurate to obtain products which can be used as improved binders for friction materials. Several methods to modify the CNSL resin chemically for increased thermal stability and the effect of these modifications on the fade property have been reported. Fatty acids from oils can be reacted with CNSL and then converted to hard infusible particles useful as friction dust. Potassium acetate, pyridine, etc. are used as catalysts for the fatty acid– CNSL reactions at 200– 300 ◦ C and the products are found to be suitable for friction dust formulations. A number of CNSL-based friction materials with specific performance properties have been reported. Clutch facings with low hygroscopy have been developed from CNSL. Friction compositions without any volatile products, and possessing improved fading resistance, good resistance to noise, wear resistance, improved reliability, heat resistance, high resistance to hygroscopy, corrosion resistance, and rust resistance have also been reported. PCNSL could be an excellent matrix resin for brake linings. Phenol-cardanolaldehyde resins have been used as binders for extrudable brake linings. Molding compositions have also been made from CNSL resins to obtain filled compositions useful for brake and clutch linings as well as floor coverings. 7.2. Surface coatings 7.2.1. Paints and primers. The chemically stable nature of CNSL, the solubility of the resin in various solvents, the inherent hydrophobicity and chemical resistance, the film-forming nature, and a high degree of unsaturation make CNSL polymers highly suitable for surface coating applications. Cured CNSL formaldehyde films soften at elevated temperatures and remain in a rubbery condition. The formulation and manufacture of various classes of paints based on CNSL have been described by Ramanujam [48]. CNSL condensates can be reacted with alkyl ortho ester to give films of high heat resistance and excellent elecrical properties. Phenolic resin using 5% cardanol is used for making coatings for cans used in food packaging. Lac– CNSL combinations have also been found useful for surface coatings which are weatherresistant and as metal primers which are anti-corrosive and water and solventresistant [49, 50]. The condensation product of CNSL, phenol, and HCHO with an acid was treated with chloroacetic or bromoacetic acid under alkaline conditions and neutralized with ammonium hydroxide or an amine to give a water-based coating material. Water-based CNSL –HCHO paint was also prepared by treating CNSL with HCHO 140 M. C. Lubi and E. T. Thachil and cross-linking with maleic anhydride and neutralization with ammonia [51]. Possibilities of developing a water-thinnable coating composition from CNSL have been indicated. Paints can be formulated as water-based stable emulsions of oil-in-water type using CNSL –HCHO resins. Water-based coatings with good hot water and chemical resistance have been prepared by reacting CNSL –HCHO condensation products in the presence of an acid with bromoacetic or chloroacetic acid. Anti-corrosive paint formulations designed for ship bottoms have been widely reported [52, 53]. Coatings of various colors can be made from CNSL oxidized with HNO3. CNSL oxidized with HNO3 was found to give coatings that air-dry very quickly. The products are suitable for making paints, varnishes, electrical insulation, impregnating paper, woven fabrics, etc. Coated papers for bottle caps have been developed from CNSL [54]. The most satisfactory coating appears to be CNSL cured at 150 ◦ C for 10 min. Primers based on PCNSL dry within 2 h. The addition of lead and cobalt naphthenates or barium and potassium chromates and lead and silico-chromates is found to give improved corrosion resistance [55]. Materials such as kaolin, bauxite residue, barium and zinc chromates, lead silico-chromates, manganese, and mica have been added to CNSL formulations as fillers. Some of these formulations showed enhanced corrosion resistance [56]. CNSL –HCHO reaction products can be reacted with waste walnut kernel oil to obtain stoving enamels. Co-ordinatively bound anti-corrosion paint useful for clean metal surfaces has been prepared from CNSL –salicylic acid formaldehyde resin. Black slate enamels were prepared from CNSL or CNSL distillate residue using silica and emery powder as pigments. Baking enamels were prepared by condensing CNSL with HCHO in the presence of linseed oil or turpentine. CNSL polymerizes with metal or metal oxides and forms a good medium for paints for further cooking with drying oils. The addition of unsaturated oils to CNSL improves their flexibility and drying characteristics. The simplest method of incorporating a drying oil is by adding CNSL and heating the mixture [57]. CNSL distillation residue can be heated with castor oil to obtain surface coatings. Coating compositions have also been made from CNSL –aldehyde products in the presence of rosin, furfural, drying oils, fatty acids or their combinations. CNSL –HCHO bound emulsion paint can be employed on freshly plastered walls [58]. CNSL primers containing barium potassium chromate, linseed oil, zirconium chromate or red oxide have been studied [59]. CNSL –aldehyde anti-fouling paints have been prepared by incorporating copper aceto-arsenite or linseed oil rosin condensate [60]. Coating made from castor oil by reaction with maleic anhydride can be improved by incorporating a small amount of CNSL. Styrenation of CNSL-based phenolic resin improved the paint performance. Factors which affect the copolymerization of CNSL resin with styrene have been studied. Polymerized CNSL can be mixed with oils and resins such as linseed, china-wood, and coumaron to give coatings for cloth, fabrics, papers, and metal sheets, and wires dipped in these liquids carry a film of the liquid which, on drying, Cashew nut shell liquid 141 is flexible but hard and tough. The products are suitable for preparing electrical insulating materials such as impregnated cloth fabrics or paper for coating conductor bars, sheets or wires and also for producing water-proof cloth fabrics, lining for food containers,bottle caps, etc. CNSL is made non-vesicant by reaction with vegetable oils, terpentine, etc. in the presence of nitric acid. The products give an air-drying film for wood, paper, and metals. The CNSL distillation residue can also be reacted with phosphoric acid to give baking primers with improved adhesion and corrosion protection ability [61]. A modified solvent process for the manufacture of CNSLbased resin for coating formulations has been described [62]. The process solves the problem of pollution and reduces the processing time. The condensate of CNSL and aldehyde, polyols and polybasic acids, and modifiers are polycondensed and mixed with cross-linking agents to obtain coatings with good hardness and a fast drying rate. Anacardic acid is reacted with unsaturated fatty acids to reduce the hydroxyl content to 80– 90% of the original to obtain products that can be dried in air [63]. Epoxy resins based on CNSL are used as protective coating materials; autoprimers; linings for cans, drums, and pipes; potting and encapsulation of electrical and electronic components; and in electrical laminates. Being soluble in common solvents such as naphtha and benzene, the coatings are air-drying and do not require any expensive hardener, as in the case of conventional epoxy resins. Polyester resin based on CNSL and its derivatives are reported to be good coating materials [64]. 7.2.2. Specialty coatings. Vinyl resin based on cardanol gives films with excellent adhesion and flexibility and resistance to oils and greases, water, and chemicals. The products can be used in paints and varnishes and the modified composition has high chemical resistance. Phosphated CNSL –HCHO reaction products give coatings with improved heat resistance, flexibility, and adhesion. CNSL oil modified alkyd resin finds use in the surface coatings industry and printing inks. Chlorinated resinous coating compositions suitable for fire-retardant and insecticidal coatings have been prepared from CNSL. Fire-resisting and heat-insulating paints based on sodium silicates, CNSL, chlorinated CNSL or their condensation products have been developed. A molten mixture of CNSL, asphalt, rubber, and petroleum resin could be used as a rust-proof tacky composition. CNSL modified by heating at 160– 300 ◦ C in the presence of certain accelerators gives stoving enamels resistant to alkali and acid solution, mineral and fatty oils, and various organic solvents. CNSL distillate residue is also used as a coating for increasing the durability of light roofing corrugated sheets [65]. A coating based on CNSL distillate residue was used for the interior of ferroconcrete domes used for the collection of gobar gas. Coating compositions possessing insecticidal properties were obtained by adding DDT, gamexane, etc. to CNSL or chlorinated CNSL after treatment with HCHO. A coating of CNSL containing copper sulfate extends the life of coconut leaf thatch from 1 to 4 years [66]. Specialty coatings based on CNSL for wooden surfaces of fishing boats and modified with polybutadiene and epoxy- 142 M. C. Lubi and E. T. Thachil modified CNSL have been reported. CNSL –HCHO condensation product in an alkaline medium on styrenation gives a resin which can be used as a varnish or pigmented to yield an enamel or paint. The film has good resistance to saline and alkaline waters. Rapid-drying coatings containing epoxides were prepared by reacting cardanol with ethylene oxide, hexamine, and toluene diisocyanate. The copolymer so obtained is mixed with dibutyl tin dilaurate, lead, and cobalt naphthenate before use. Surface coatings with epoxy groups have been prepared by the reaction of epichlorohydrin with CNSL –phenol– formaldehyde resins [67]. A coating based on CNSL resins modified with p-butyl phenol has improved weatherability. Heating CNSL with copper at 200 ◦ C or by heating with 10% nitric acid and dissolving it in a solvent, a coating material for containers can be made. Containers made from paperboard, wood, gelatin, cellulose acetate, and metals can be coated and made waterproof by its application. The products are useful for food containers as the coatings are not affected by fruit juices, alkalis, acetic acid, brine, pickling solution, or hydrocarbons. Mixing of CNSL –HCHO resin dissolved in solvents with Portland cement gives a cement that sets in 6 h at room temperature and has good resistance to water, oil, and heat. This can also be used as paint. CNSL reacts with alkaline materials such as cement, alumina, barium hydroxide, sodium carbonate, etc. to give coatings for walls of cement, wood, fabric, etc. which are impervious to water. Electropainting compositions [68] have also been prepared from CNSL. CNSL was treated with HCHO using alkali catalysts to give a water-soluble resin for use in electrodeposition on mild steel [69]. For improving adhesion and flexibility, drying oils, bisphenols, and epoxy resins were incorporated into CNSL –aldehyde reaction products. CNSL, in combination with linseed oil resin as a matrix, is used in anti-fouling marine paint formulations. Polymerized CNSL can be mixed with oils and resin such as linseed, china wood, and coumaron to give coatings for fabrics, paper, and metal sheets. CNSL –epoxy systems are useful as coatings on rusted surfaces. Resins prepared by the reaction of bisphenol epoxy resins with CNSL and unsaturated fatty acids are used for the preparation of air-drying corrosion-resistant coatings [70]. Surface coatings for the protection of concrete against attack by chemical fertilizers have been developed from CNSL. CNSL –hexamine resins are used with lead and cobalt naphthenates after mixing with calcined mud, dehydrated castor oil, and solvents to give corrosion-resistant primers. Coatings giving tough elastic films were prepared from CNSL –glycerin reaction products [71]. 7.2.3. Varnishes. Esters of acrylic acid with cardanol give products useful for the manufacture of varnishes which are resistant to water and dilute Na2 CO3 solutions [72]. Copolymers of CNSL and bhilawan nut shell liquid (BNSL) have been used in the manufacture of varnishes and stoving enamels. CNSL –aldehyde products can be mixed with raw or cooked oils and the mixture can be used to prepare varnishes. Varnishes resistant to water and gasoline were prepared by incorporating Cashew nut shell liquid 143 sulfur in CNSL. Corrosion-resistant varnishes were prepared by heating CNSL in the presence of litharge, dryers, and thinners [73]. Electrical insulating varnishes were prepared by treating CNSL with HCHO and compounding the resulting material with pure phenolic resin or alkyd resin in suitable proportions [74]. Films of these materials are water- and chemicalresistant and can be used as insulating varnishes with high electrical resistance and as bobbin enamels and laboratory table tops. Pale-colored lacquers and varnishes were obtained by copolymerizing cardanol formaldehyde condensate with drying oil, alkyd resin, styrene, other resins, and monomers. These are highly resistant to water and have a superior electrical insulating property. These resins can be used as insulation varnish, food can lacquers, and wood finishes. Electrical windings impregnated with CNSL have improved mechanical properties. The rate of heat dissipation is also high. Films of CNSL are insoluble in petroleum spirit and oils and impervious to water and can be repeatedly heated to 250 ◦ C and above and cooked without impairing their electrical properties. Water and gasoline-resistant varnishes can be prepared from sulfur-containing CNSL having 13% sulfur [75]. The addition of drying oils to CNSL –aldehyde or CNSL –phenol– aldehyde resins also results in improved varnishes. Polymerized CNSL can be mixed with linseed, china wood or fish oils to obtain varnishes. Mixtures of polymerized CNSL and bodied linseed oil have been used to make quick-drying varnishes [76]. Varnishes prepared from cadnanol, styrene, and dehydrated castor oil have reduced water vapor permeability and improved mechanical properties [77]. Condensation of CNSL with diphenyl oxide and subsequent treatment with formaldehyde can give heat-curable varnishes. For making varnishes from natural gums, it is necessary to heat gums with solvents for long times to render them miscible with each other. When CNSL is used together with solvents, the gums become soluble in a shorter time and the products are completely soluble in conventional solvents. Reaction products from CNSL and natural resins or gums prepared by reacting them together at 300 ◦ C until brittle and then diluting them with solvents are used as varnishes. CNSL can be used to modify shellac and the products are used to insulate electrical coils. Varnish from cardanol– HCHO–epoxy resin can be baked at a low temperature. Water-thinnable varnishes have also been prepared from CNSL. 7.2.4. Lacquers. Lacquers made from CNSL could be used for insulation and protective or decorative purposes for furniture, buildings, automobiles, etc. [78]. Their films have optimum toughness and elasticity, excellent gloss, and superfine adhesive qualities. The dried films are superior to those of ordinary oil paints with respect to resistance to oils, greases, moisture, and chemicals. Cashew lacquers can be easily applied to the substrates by brushing, spraying, and dipping. In terms of total cost per unit area, they are cheaper than ordinary varnishes. Lacquers for special applications such as screen lacquering are prepared by condensing CNSL and formaline in the presence of alkalis, and for gold lacquering CNSL –HCHO 144 M. C. Lubi and E. T. Thachil condensate is treated with Ti(OBu)4 . Water-thinnable thermosetting lacquers have also been made. Lacquers suitable for painting porcelain or glassware have been developed by thermal polymerization of rosin ester with a drying or non-drying oil and CNSL. Lacquers for inlaying were prepared from CNSL –HCHO condensate under alkaline conditions in ketones or cellulose-containing Ti(OBu)4 catalyst. 7.3. Adhesives The high polarity, inherent tackiness of phenolic materials, and the ease with which liquid to solid conversion can be accomplished make CNSL a desirable starting material for adhesive formulations. The rheology of CNSL adhesives has been studied [79]. Relaxation in a Couette viscometer and penetrometry of CNSL –HCHO resin adhesives revealed shear thickening, yet the system possessed a yield value. Heat-sensitive adhesives used on the back of reflectors have been synthesized from CNSL. The preparation of adhesives by condensation of xylol, HCHO, and CNSL using various catalysts and hardeners has been reported [80]. Pressure-sensitive adhesives and adhesives for bonding rubbers to fibers have also been developed from CNSL. PCNSL shows a five-fold increase in adhesive properties from those of conventional CNSL –HCHO resin [81]. CNSL adhesives with superior water resistance and shear strength have been prepared. The hardening rate of CNSL-based adhesives was noticeably accelerated by a small amount of colloidal polymers with a considerable amount of hydroxyl groups. CNSL –aldehyde resins mixed with tannin aldehyde resin have been used with tamarind seed powder as a filler to control the flow properties [82]. Cold setting wood adhesives are made from CNSL –PF resin prepared with NaOH as a catalyst by adding 10– 12% PTSA as a hardener. CNSL-based resins have been used as adhesives for plywood [83]. Polymerized CNSL can also be used with aldehydes to make plywood adhesives by treating with phenol and formaldehyde in the presence of acids. Plywood adhesives prepared from CNSL –HCHO can be made fireproof by incorporation of ammonium phosphate, and ammonium dihydrogen phosphate or diammonium hydrogen phosphate [84]. CNSL oxidized with KMnO4 or MnO2 at 100 ◦ C and reacted with HCHO and compounded with CuCl2 gives adhesives suitable for plywood. CNSL modified with furfural, aniline, xylol, etc. also gives good plywood adhesives [85]. An aqueous emulsion of cardanol is used for coating plywood for laminating purposes. Low-grade wood species impregnated with the resin show upgrading of quality. CNSL polymerized with H2 SO4 and mixed with low condensate PhOH–HCHO resin and 5% CuCl2 can be used as an adhesive for plywood [86]. Exterior-grade plywood adhesives have also been developed from CNSL. Two to 3% KMnO4 as an accelerator decreases the pressing time [87]. Red onion skin extract and HCHO resins modified with CNSL have been used in the formulation of wood adhesives with better water resistance and shear strength [88]. A CNSL –xylene– HCHO-based composition has been prepared as a binder resin for particle boards [89]. Borax can be added to increase the fire retardancy of Cashew nut shell liquid 145 particle boards [90]. CNSL can be used as a binder for making wood substitute from agricultural waste. A medium-density fiberboard comprising CNSL and coconut fibers as the major constituents has been developed for use in place of wood [91]. CNSL adhesive formulations based on CNSL and HCHO are suitable for replacing PhOH–HCHO adhesives in the manufacture of moisture-proof adhesives. Adhesives based on CNSL with improved bonding to other materials, such as metals, have been reported. Polymerized CNSL –furfural– furfural alcohol mixtures have been used as binders for heat exchangers made from carbon plates. Adhesives can also be prepared by using CNSL with gelatinous materials such as animal glue, blood and egg, albumin, etc. Adhesives are also prepared from casein and CNSL [92]. Epoxy resins have been modified to obtain solventless adhesives which could cure at room temperature and give greater impact strength and shear resistance by preparing liquid resin from bisphenol A, epichlorohydrin, and a diglycidyl ether of CNSL as plasticizer [93]. 7.4. Foundry The phenolic nature of CNSL facilitates the use of resins derived from it in place of conventional phenolic materials used in the foundry industry. The fire-retardant and ablative properties associated with the phenolic structure are responsible for this. CNSL is being used as a substitute for linseed oil in the manufacture of foundry core oil, which is used as a binder in the foundry [94]. CNSL-modified phenolic resins are mixed with amines and ammonium salts of inorganic acids and water-soluble surfactants to give low-viscosity caking agents for sand molding. CNSL, phenol, and cyclohexanone condensate prepared in the presence of formalin and acids has also been used as binders for sand cores, along with hexamine and potassium stearate. Resin prepared from phenol and CNSL ethers by reaction with aldehydes has also been used in molding powders or as a binder. CNSL paraform condensates are reacted with diacetoacrylamine and polyamines to obtain adhesives for sand castings. Polymerized CNSL –formaldehyde resin can be modified with phthalic anhydride and glycerin and cured at 125 ◦ C with 3% litharge to obtain binders for the foundry industry [95]. No-bake core binders, used by the metal casting industry, have been prepared by reacting isocyanates with cardanol– paraformaldehyde and cardanol– alkyd resins [96]. 7.5. Laminates CNSL-based resins improve the resistance to heat, the bonding of the reinforcement materials, and the flexibility of laminates, while reducing brittleness and age hardening. Resins for laminated products are made from CNSL and phenol by reaction with aldehydes. Cardanol can also be used in place of CNSL. CNSLmodified phenolic resins are used for making laminates with good dimensional stability and warp resistance. Punchable heat-resistant laminates of paper with 146 M. C. Lubi and E. T. Thachil copper foil can be made using CNSL –HCHO resin. Coated paper for bottling chemicals, pharmaceuticals, and other preparations has been made from CNSL after curing at 150 ◦ C for 10 min [97]. Epoxidized CNSL increases the tensile strength and flexural strength of laminates. Thermally stable and fire-resistant laminates based on CNSL have been reported. Metal– polymer laminates requiring high separation forces have been developed from CNSL [98]. 7.6. Rubber compounding The incorporation of CNSL has been found to improve the properties of rubber products. It aids processing and enhances the vulcanizate properties [99]. It also helps the incorporation of ingredients into rubber and increases its resistance to moisture. The effect of cardanol on the processing, mechanical, and aging properties of elastomers has been studied [100]. CNSL can be added to rubber compounds to improve the processability and resistance to crack and cut and thermal stability [101]. CNSL acts as a plasticizer for sulfur and helps the incorporation of sulfur in rubber and other products. Methyl, ethyl, propyl, and butyl ethers of anacardic materials and thickened CNSL products act as excellent plasticizers for synthetic rubber and also lower the Shore hardness and improve the aging and elongation characteristics of cured rubber. Styrene– CNSL reaction products have been used as plasticizers for rubbers to improve the intake of fillers. Vibration-absorbing rubber compositions have been developed starting from CNSL. Tyre rubber composition having good processability and hardness have been developed using CNSL. CNSL enhances the insolubility of NR vulcanizates in petroleum solvents and acts as an antioxidant in NR vulcanizates [102]. The effectiveness of various antioxidants prepared from cardanol have been studied. 1,4-Hydroxy-2-pentadecylphenyl-3-phenyl thiourea synthesized from CNSL improves the heat stability of NR vulcanizates [103]. If NR is treated with CNSL either by milling or by heating with organic solvents, no decrease in unsaturation is observed [104]. Compounding of less than 10% cardanol with NR reduces viscosity, increases tackiness, and improves tensile strength, abrasion resistance, and aging properties [105]. If less than 10% cardanol is added to filled NR products, the modulus and abrasion resistance are improved [106]. Cutting pads for leather are made from NR and CNSL –HCHO resin. Products from acid polymerized CNSL and hexamine are millable materials which serve as a plasticizer for NR. The processability characteristics of the NR –halogenated CNSL polymer system have been studied. The rheology of blends of NR and PCNSL has been studied [107]. The increase in pseudoplasticity index and the decrease in consistency index, viscosity, shear modulus, and activation energy of the melt flow with increasing concentration of PCNSL, temperature, and shear rate indicate the plasticizing effect of PCNSL. PCNSL can be used to increase the tensile properties of NR and helps to give a lower degree of stress relaxation at higher strain rates and strain levels [108]. The selfadhesion strength of NR compounds can be modified by PCNSL. PCNSL-modified Cashew nut shell liquid 147 NR vulcanizates show improved thermal stability and resistance to fatigue failure. Bromo-derivatives of PCNSL improve the flame retardancy of NR vulcanizates [109]. Polymerized CNSL acts as a biological plasticizer for nitrile rubber and its blends [110]. Cellular rubber compositions have been developed from CNSL –phenol– aldehyde– nitrile rubber mixes. Cardanol can be used for the vulcanization of butyl rubber [111]. Pentadecylbenzoquinone-dioxime synthesized from CNSL gave heat-resistant vulcanizates for SBR and IIR [112]. Resoles based on CNSL were modified with butanol, phenyl isocyanate, and rosin, and used for the vulcanization of butyl rubber. CNSL resin blends with SBR have been used to produce railroad brake shoes. The low-temperature properties of SBR plasticized with Cardolite625, the ethyl ester of the monophenolic component of CNSL, are superior to those of similar compounds containing naphthene-based plasticizers. CNSL –amine condensation products are used as an effective antioxidant for SBR [113]. Cardanolbased resoles used for the vulcanization of SBR were found to impart superior physical properties to the vulcanizates. Latexes of SBR or NBR can be mixed with CNSL-modified phenolic resins and hexamine and then mixed with fillers to obtain compositions suitable for molding or extrusion. Chloroprene can be reacted with CNSL to obtain products ranging from resilient rubber-like materials to hard rigid ones. Hydrocarbon ethers of anacardic materials are useful for plasticizing polychloroprene. Difficulties observed in processing cis-1,4-polybutadiene can be overcome by blending it with liquid ethers obtained by the reaction of CNSL with polyhydric phenols such as resorcinol. 7.7. Plastic materials and additives A study by Pillai et al. has shown that high-performance and specialty polymers can be produced from cardanol by a variety of methods [114]. Flame-retardant prepolymers were obtained from cardanol by simultaneous phosphorylation and oligomerization. About 10– 15% CNSL increases the thermal stability of substituted phenolic resin. The effect of replacement of phenol by CNSL on the properties of novolac and resole resins has been experimentally investigated [115]. Lightweight, sandwich-type plastic, composite panels suitable for partitions, cladding, flush door, etc. [116]. can be made using CNSL –HCHO resins. Foam plastics developed from CNSL are found to become lighter upon aging for 12 days at 100 ◦ C [117]. The effect of the addition of cardanol on peroxide curing of polyester resin has also been studied [118]. PCNSL enhances the thermal stability of LDPE [119]. A waterproofing resin composition was developed from CNSL by heating CNSL with shellac at 100 ◦ C. A heat-resistant resin can be developed from CNSL when it is subjected to phase transfer-catalysed KMnO4 oxidation or when it is polymerized with TiCl4 or ZnCl4 in the presence of a Grignard reagent in an inert atmosphere. CNSL can be used for making an ablative fiber-reinforced polymer by the introduction of bromine into the phosphorylated prepolymer [120]. The reaction products of CNSL and fatty acids have been reacted with glycerin to obtain resins suitable for electri- 148 M. C. Lubi and E. T. Thachil cal insulations. The epoxy derivative of CNSL can be used as a stabilizer for PVC [121]. CNSL reduces the rate of dehydrochlorination of PVC [122]. Sulfurated CNSL is used as a plasticizer [123] and cardanol condensed with epichlorohydrin is used as a stabilizer [124] for PVC. CNSL can be used as a chemical modifier for asphalt to improve low- and hightemperature performance [125]. Polymerized CNSL can be reacted with furfural to give resins suitable for insulation parts for storage batteries, because of their resistance to acids and alkalies. Methylation with dimethyl sulfate and acetylation with anhydride and acetic acid can give epoxide products with a pale color obtained from CNSL for use as a plasticizer [126]. Curing agents for epoxy resins are prepared by the reaction of CNSL with diethylene tetramine. Phenolic polyamines for curing epoxy resins are also prepared by using mixtures of CNSL with phenol, cresol or other alkylated phenols. Linseed oil-modified CNSL –HCHO resin has outstanding flexibility and chemical resistance [127]. CNSL can be condensed with cyanuric chloride to improve the thermal properties of the products [128]. CNSL dimethylol urea isogel resin has been prepared by treating urea with formaline and CNSL. Rigid polyurethane foam has been prepared by treating CNSL with HCHO and ethanolamine at 70– 90 ◦ C, blending the reaction mixture with polyols, and treating the mixture with polyisocyanate and blowing agent at less than 25 ◦ C. The addition of CNSL can increase the heat resistance of a phenolic molding composition. A phenolic resole molding composition useful in the manufacture of commutators has been reported. A phenolic molding composition for dynamic transmission has been developed using a mixture of CNSL-modified phenolic resin, chopped vinyl fibers, and nitrile rubber. Moldings having a wood-like feel and good antistatic and electromagnetic properties and coatability useful for building materials have been prepared from CNSL resins. Molding compounds without blisters based on CNSL have been reported. 7.8. Miscellaneous applications CNSL is used for the treatment of acne vulgaris. It is also used as an antibacterial agent [129]. CNSL finds use as a rubefacient and vesicant in treating skin diseases. A range of drug analogues of warfarin, phenol phthalein, saligenin, salicylamide, and salicylanilide have been prepared from 3-pentadecyl phenol and 5-pentadecyl resorcinol [130]. CNSL is used as an antioxidant for food and cosmetics. Insecticidal compositions have been made from chlorinated products of CNSL by blending with rotenone, DDT, etc. CNSL has been used for the stabilization of pyrethrine. CNSL is treated with AS2 O3 or boric acid to improve its toxicity towards termites [131]. CNSL can be used as a superplasticizer for cement paste and mortar [132]. Cashew polymers react with HCHO to give a rubbery gel, which can be used as a cement-hardening agent over a period. The set mass adheres well to porous brickwork, steel, and carbon blocks, and is not affected by acids or alkalis. It can Cashew nut shell liquid 149 be used for the cementing of floors subject to chemical attack. Chemically resistant covering sheets useful as table tops and floor coverings are made by treating CNSL with aldehydes and compounding the hard gel with NR and curing systems. Acidpolymerized CNSL reacted in the cold with paraformaldehyde or furfural gives a cold-setting composition with excellent acid and alkali resistance. These products find extensive use as stopping and filling compounds in the electrical industry in industrial flooring and chemical plants. CNSL –HCHO reaction products have been used for floor coverings and insulated air plane ignition conductors in combination with cellulose ethers, PVA, etc. Polymerized CNSL –HCHO resins with carbon or graphite fillers are used to make chemically resistant linings and joints in chemical plants. Cation exchange resins can be prepared by the reaction of CNSL with H2 SO4 , and anionic exchange resins by the reaction with tetraethylene pentamine. Cation exchange resins inert to alkali have also been developed. Rubber-based cation exchange resin membranes are made from CNSL and aldehyde by milling with crepe rubber [133]. Various types of lubricants have been prepared from CNSL [134]. Activated carbon can be prepared from CNSL using CO2 and KOH as activating agents. The rate of moisture absorption can be reduced by using CNSL in kerosene and methylated spirit [135]. Organometallic preservatives can be prepared from CNSL [136]. CNSL –HCHO resin suitably compounded has been used for coating coarse cloth to give linoleum. Fish nets can be coated with CNSL to prolong their lives. Heat-processed reaction products from CNSL were found to confer water-proofing properties to cardboard and cotton fabrics. High boiling solvents and heat exchange media have also been developed from CNSL. Phenolic resins made from CNSL and aldehyde can be modified by reaction with amide and can be used as a substitute for vegetable wax. Slow-acting fertilizers have been developed from CNSL. CNSL can be reacted with glycerin and other polyhydric alcohols to give substances which are resistant to flame, and acids. CNSL is also used as a hypergolic rocket fuel [137]. Various types of surfactants and additives have been derived from CNSL. Ionic conducting films have been prepared from CNSL [138]. New dyes and inks have also been developed from CNSL. The spontaneous combustion characteristics of CNSL –HCHO products can be considerably reduced by the incorporation of a small amount of aniline. When china-wood oil or linseed oil is heated with CNSL, there is no danger of overheating in contrast to when they are heated alone [139]. The moisture absorption of superphosphate can be reduced by coating with a solution of CNSL in kerosene or methylated spirit [140]. A number of products based on CNSL have been reported to be extremely useful additives, such as antioxidants, stabilizers and de-emulsifiers for petroleum products. 150 M. C. Lubi and E. T. Thachil 8. OUTLOOK FOR THE FUTURE In spite of the massive literature accumulated on the applications of CNSL, many areas remain which have yet to utilize this attractive raw material. Disadvantages such as non-uniformity in the quality of the oil and its composition when it comes from different locations and the unattractive color have been stumbling blocks in its large-scale utilization. It is hard to believe that organic chemists have exhausted all possibilities of synthesizing more valuable and useful derivatives from CNSL, which has a most unusual structure for a starting material. The cracking of this high-molecular-weight product is one area which merits more detailed information. The use of CNSL in the field of engineering polymers has not been widely reported. While the possibility of making useful thermoset polymers such as polyurethanes, epoxies, and polyester has been demonstrated, there has not been sizable consumption of the oil for this purpose. This can be an attractive proposition in view of the dwindling global petroleum resources. While forest resources being depleted at a fast rate, the manufacture and use of wood substitutes based on CNSL, utilizing wastewood, sawdust, woodchips, etc., can be an attractive proposal. CNSL has outstanding anti-microbial properties which can help mankind fight parasites and harmful micro-organisms in the agricultural and medicinal fields. It can be a valuable alternative to many of the troublesome chemical agents in use today. 9. CONCLUSIONS The present survey has demonstated the immense potential of CNSL to satisfy many of our material requirements in diverse fields. Certain problems such as variation in the composition and quality of the oil have to be solved by proper blending and quality control. Considering the large number of different polymer materials that can be synthesized from CNSL, it is surprising that very little global effort is directed towards greater and fuller utilization of this versatile starting material. 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