EP4126782A1 - Procédé de culture de plantes - Google Patents

Procédé de culture de plantes

Info

Publication number
EP4126782A1
EP4126782A1 EP20717173.7A EP20717173A EP4126782A1 EP 4126782 A1 EP4126782 A1 EP 4126782A1 EP 20717173 A EP20717173 A EP 20717173A EP 4126782 A1 EP4126782 A1 EP 4126782A1
Authority
EP
European Patent Office
Prior art keywords
component
growth substrate
plasticizers
linkers
binder composition
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20717173.7A
Other languages
German (de)
English (en)
Inventor
Frank Hendrikus Peter Janssen
Dorte Bartnik JOHANSSON
Miroslav Nikolic
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rockwool AS
Original Assignee
Rockwool AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rockwool AS filed Critical Rockwool AS
Publication of EP4126782A1 publication Critical patent/EP4126782A1/fr
Pending legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01G—HORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
    • A01G24/00—Growth substrates; Culture media; Apparatus or methods therefor
    • A01G24/10—Growth substrates; Culture media; Apparatus or methods therefor based on or containing inorganic material
    • A01G24/18—Growth substrates; Culture media; Apparatus or methods therefor based on or containing inorganic material containing inorganic fibres, e.g. mineral wool
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
    • C08K5/0016—Plasticisers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/05—Alcohols; Metal alcoholates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/05—Alcohols; Metal alcoholates
    • C08K5/053—Polyhydroxylic alcohols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/10—Esters; Ether-esters
    • C08K5/101—Esters; Ether-esters of monocarboxylic acids
    • C08K5/103—Esters; Ether-esters of monocarboxylic acids with polyalcohols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/17—Amines; Quaternary ammonium compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/35—Heterocyclic compounds having nitrogen in the ring having also oxygen in the ring
    • C08K5/353—Five-membered rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/005—Lignin
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions

Definitions

  • the present invention relates to a method of growing plants in a coherent growth substrate, a coherent growth substrate product, and use of a coherent growth substrate.
  • MMVF man-made vitreous fibres
  • binders of choice have been phenol-formaldehyde resins and phenol-formaldehyde urea resins, such as those disclosed in WO2009/090053, WO2008/009467, WO2008/009462, WO2008/009461 , WO2008/009460 and WO2008/009465. These binders are economical to produce and provide excellent mechanical handling properties, which is highly important for plant growth substrates due to the use of automatic equipment in handling and the large amount of water held in the substrate. It is undesirable for the substrate to become damaged during handling or for the substrate to lose its rigidity and shape when holding water.
  • binder compositions for plant growth substrates have starting materials stemming from fossil fuels. There is an on- going trend for consumers to prefer products that are fully or at least partly produced from renewable materials and there is therefore a need to provide binders for plant growth substrates which are at least partly produced from renewable materials.
  • Binder compositions based on renewable materials have been proposed before, for example in WO2017/114723 and WO2017/114724.
  • MMVF products prepared with these binders in terms of mechanical properties, when compared with MMVF products prepared with phenol-formaldehyde resins.
  • binders are often made from expensive starting materials.
  • waste water containing nutrients is difficult to dispose of due to environmental legislation. It is therefore desirable to improve the water holding properties so that the amount of waste water (also called drain) is reduced
  • a binder that can be used in lower quantities than other binders, without comprising the mechanical properties. Therefore, it would be desirable to produce a binder for plant growth substrates which is formaldehyde-free but has equivalent or superior mechanical handling properties (e.g. compression strength) as phenol-formaldehyde binders. It would be desirable for such a binder to have improved water holding properties (e.g. water retention and water distribution over height), thus reducing water wastage and lower phytotoxicity. Furthermore, it would be desirable for such a binder to be economical to produce and be based predominantly on renewable sources. Finally, it would be desirable for such a binder to be used in reduced amounts and not to require the further addition of wetting agent.
  • mechanical handling properties e.g. compression strength
  • water holding properties e.g. water retention and water distribution over height
  • the plant growth substrate used in the present invention solves the above problems.
  • a method of growing plants in a coherent growth substrate product comprising:
  • MMVF man-made vitreous fibres
  • the aqueous binder composition prior to curing comprises: - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • a coherent growth substrate product comprising man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition, wherein the aqueous binder composition prior to curing comprises: - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • MMVF man-made vitreous fibres
  • an array of two or more coherent growth substrate products wherein the coherent growth substrate products comprise man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition, wherein the aqueous binder composition prior to curing comprises: - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers
  • MMVF man-made vitreous fibres
  • a coherent growth substrate product for growing plants, wherein the coherent growth substrate product comprises man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition, wherein the aqueous binder composition prior to curing comprises: - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers
  • MMVF man-made vitreous fibres
  • a method of making a growth substrate product comprising the steps of:
  • aqueous binder composition prior to curing comprises: - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • the present inventors have surprisingly discovered that it is possible to produce a formaldehyde-free binder which leads to a growth substrate that has equivalent or even superior mechanical handling properties (e.g. compression strength) to phenol-formaldehyde binders.
  • the inventors also produced such a binder that leads to a growth substrate with improved water holding properties (e.g. water retention) and lower phytotoxicity levels, which is highly desirable for plant growth and development. This results in reduced water wastage (i.e. drain).
  • the inventors produced such a binder that is economical and is based predominantly on renewable sources. Finally, this binder can be used in low quantities and does not require the addition of a wetting agent to the growth substrate.
  • Figures 1 A to 1 E show the results of compression strength tests.
  • Figure 2 shows the results of water retention tests.
  • Figure 3 shows the results of water distribution over height tests.
  • Figure 4 shows a section from a possible lignin structure.
  • Figure 5 shows lignin precursors and common interunit linkages.
  • Figure 6 shows four groups of technical lignins available in the market.
  • Figure 7 shows a summary of the properties of technical lignins.
  • the present invention relates to a method of growing plants in a coherent growth substrate product, the method comprising: - providing at least one coherent growth substrate product comprising man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition;
  • MMVF man-made vitreous fibres
  • the method of the present invention comprises a coherent growth substrate product comprising man-made vitreous fibres (MMVF).
  • MMVF man-made vitreous fibres
  • the man-made vitreous fibres (MMVF) can have any suitable oxide composition.
  • the fibres can be glass fibres, ceramic fibres, basalt fibres, slag fibres or rock or stone fibres.
  • the fibres are preferably of the types generally known as rock, stone or slag fibres, most preferably stone fibres.
  • Stone fibres commonly comprise the following oxides, in percent by weight:
  • the MMVF have the following levels of elements, calculated as oxides in wt%: SiO 2 : at least 30, 32, 35 or 37; not more than 51, 48, 45 or 43 Al 2 O 3 : at least 12, 16 or 17; not more than 30, 27 or 25 CaO: at least 8 or 10; not more than 30, 25 or 20 MgO: at least 2 or 5; not more than 25, 20 or 15 FeO (including Fe2O3): at least 4 or 5; not more than 15, 12 or 10 FeO+MgO: at least 10, 12 or 15; not more than 30, 25 or 20 Na 2 O+K 2 O: zero or at least 1; not more than 10 CaO+MgO: at least 10 or 15; not more than 30 or 25 TiO2: zero or at least 1; not more than 6, 4 or 2 TiO 2 +FeO: at least 4 or 6
  • Glass fibres can also contain the following oxides, in percent by weight: Na 2 O+K 2 O: 8 to 18, in particular Na 2 O+K 2 O greater than CaO+MgO B 2 O 3 : 3 to 12
  • Some glass fibre compositions can contain Al 2 O 3 less than 2%.
  • the geometric mean fibre diameter is often in the range of 1.5 to 10 microns, in particular 2 to 8 microns, preferably 2 to 5 microns. The inventors found that this range of geometric fibre diameter positively affects capillarity thus improving water distribution over height and water uptake in the growth substrate.
  • the growth substrate according to the invention comprises, prior to curing, an aqueous binder composition comprising:
  • the binders are formaldehyde free.
  • the term "formaldehyde free” is defined to characterize a mineral wool product where the emission is below 5 ⁇ g/m 2 /h of formaldehyde from the mineral wool product, preferably below 3 ⁇ g/m 2 /h.
  • the test is carried out in accordance with ISO 16000 for testing aldehyde emissions.
  • Component (i) is in form of one or more oxidized lignins.
  • Lignin, cellulose and hemicellulose are the three main organic compounds in a plant cell wall. Lignin can be thought of as the glue, that holds the cellulose fibres together. Lignin contains both hydrophilic and hydrophobic groups. It is the second most abundant natural polymer in the world, second only to cellulose, and is estimated to represent as much as 20-30% of the total carbon contained in the biomass, which is more than 1 billion tons globally.
  • Figure 4 shows a section from a possible lignin structure.
  • a possible fifth group, Biorefinery lignin, is a bit different as it is not described by the extraction process, but instead by the process origin, e.g. biorefining and it can thus be similar or different to any of the other groups mentioned.
  • Each group is different from each other and each is suitable for different applications.
  • Lignin is a complex, heterogenous material composed of up to three different phenyl propane monomers, depending on the source.
  • Softwood lignins are made mostly with units of coniferyl alcohol, see Figure 5 and as a result, they are more homogeneous than hardwood lignins, which has a higher content of syringyl alcohol, see Figure 5.
  • the appearance and consistency of lignin are quite variable and highly contingent on process.
  • Lignosulfonate from the sulfite pulping process remains the largest commercial available source of lignin, with capacity of 1.4 million tonnes. But taking these aside, the kraft process is currently the most used pulping process and is gradually replacing the sulfite process. An estimated 78 million tonnes per year of lignin are globally generated by kraft pulp production but most of it is burned for steam and energy. Current capacity for kraft recovery is estimated at 160,000 tonnes, but sources indicate that current recovery is only about 75,000 tonnes. Kraft lignin is developed from black liquour, the spent liquor from the sulfate or kraft process. At the moment, 3 well-known processes are used to produce the kraft lignin: LignoBoost, LignoForce and SLRP.
  • the kraft process introduces thiol groups, stilbene while some carbohydrates remain. Sodium sulphate is also present as an impurity due to precipitation of lignin from liquor with sulphuric acid but can potentially be avoided by altering the way lignin is isolated.
  • the kraft process leads to high amount of phenolic hydroxyl groups and this lignin is soluble in water when these groups are ionized (above pH ⁇ 10).
  • kraft lignin is generally higher in purity than lignosulfonates.
  • the molecular weight are 1000-3000 g/mol.s
  • Soda lignin originates from sodium hydroxide pulping processes, which are mainly used for wheat straw, bagasse and flax. Soda lignin properties are similar to kraft lignins one in terms of solubility and T g . This process does not utilize sulphur and there is no covalently bound sulphur. The ash level is very low. Soda lignin has a low solubility in neutral and acid media but is completely soluble at pH 12 and higher.
  • the lignosulfonate process introduces large amount of sulphonate groups making the lignin soluble in water but also in acidic water solutions.
  • Lignosulfonates has up to 8% sulfur as sulphonate, whereas kraft lignin has 1- 2% sulfur, mostly bonded to the lignin.
  • the molecular weight of lignosulfonate is 15.000-50.000 g/mol. This lignin contains more leftover carbohydrates compared to other types and has a higher average molecular weight.
  • the typical hydrophobic core of lignin together with large number of ionized sulphonate groups make this lignin attractive as a surfactant and it often finds application in dispersing cement etc.
  • a further group of lignins becoming available is lignins resulting from biorefining processes in which the carbohydrates are separated from the lignin by chemical or biochemical processes to produce a carbohydrate rich fraction. This remaining lignin is referred to as biorefinery lignin. Biorefineries focus on producing energy, and producing substitutes for products obtained from fossil fuels and petrochemicals as well as lignin. The lignin from this process is in general considered a low value product or even a waste product mainly used for thermal combustion or used as low grade fodder or otherwise disposed of.
  • Organosolv lignin availability is still considered on the pilot scale.
  • the process involves extraction of lignin by using water together with various organic solvents (most often ethanol) and some organic acids.
  • An advantage of this process is the higher purity of the obtained lignin but at a much higher cost compared to other technical lignins and with the solubility in organic solvents and not in water.
  • lignin is used to replace oil derived chemicals, such as phenol in phenolic resins in binder applications or in bitumen. It is also used as cement and concrete additives and in some aspects as dispersants.
  • the cross-linking of a polymer in general should provide improved properties like mechanical, chemical and thermal resistance etc.
  • Lignin is especially abundant in phenolic and aliphatic hydroxyl groups that can be reacted leading to cross- linked structure of lignin.
  • Different lignins will also have other functional groups available that can potentially be used. The existence of these other groups is largely dependent on the way lignin was separated from cellulose and hemicellulose (thiols in kraft lignin, sulfonates in lignosulfonate etc.) depending on the source.
  • binder compositions for mineral fibres can be prepared which allow excellent properties of the mineral fibre product produced.
  • the component (i) is in form of one or more oxidized kraft lignins.
  • the component (i) is in form of one or more oxidized soda lignins.
  • the component (i) is in form of one or more ammonia- oxidized lignins.
  • ammonia- oxidized lignins is to be understood as a lignin that has been oxidized by an oxidation agent in the presence of ammonia.
  • AOL ammonia-oxidized lignin
  • ammonia is partially or fully replaced by an alkali metal hydroxide, in particular sodium hydroxide and/or potassium hydroxide.
  • a typical oxidation agent used for preparing the oxidized lignins is hydrogen peroxide.
  • the ammonia-oxidized lignin comprises one or more of the compounds selected from the group of ammonia, amines, hydroxides or any salts thereof.
  • the component (i) is having a carboxylic acid group content of 0.05 to 10 mmol/g, such as 0.1 to 5 mmol/g, such as 0.20 to 1.5 mmol/g, such as 0.40 to 1.2 mmol/g, such as 0.45 to 1.0 mmol/g, based on the dry weight of component (i).
  • the component (i) is having an average carboxylic acid group content of more than 1.5 groups per macromolecule of component (i), such as more than 2 groups, such as more than 2.5 groups.
  • the carboxylic acid group content of the oxidized lignins plays an important role in the surprising advantages of the aqueous binder compositions for mineral fibres according to the present invention.
  • the carboxylic acid group of the oxidized lignins improve the cross-linking properties and therefore allow better mechanical properties of the cured mineral fibre products.
  • Component (ii) is in form of one or more cross-linkers.
  • the component (ii) comprises in one embodiment one or more cross-linkers selected from ⁇ -hydroxyalkylamide-cross-linkers and/or oxazoline-cross-linkers.
  • ⁇ -hydroxyalkylamide-cross-linkers is a curing agent for the acid-functional macromolecules. It provides a hard, durable, corrosion resistant and solvent resistant cross-linked polymer network. It is believed the ⁇ -hydroxyalkylamide cross-linkers cure through esterification reaction to form multiple ester linkages.
  • the hydroxy functionality of the ⁇ -hydroxyalkylamide-cross-linkers should be an average of at least 2, preferably greater than 2 and more preferably 2-4 in order to obtain optimum curing response.
  • Oxazoline group containing cross-linkers are polymers containing one of more oxazoline groups in each molecule and generally, oxazoline containing crosslinkers can easily be obtained by polymerizing an oxazoline derivative.
  • the patent US6818699 B2 provides a disclosure for such a process.
  • the component (ii) is an epoxidised oil based on fatty acid triglyceride.
  • epoxidised oils based on fatty acid triglycerides are not considered hazardous and therefore the use of these compounds in the binder compositions according to the present invention do not render these compositions unsafe to handle.
  • the component (ii) is a molecule having 3 or more epoxy groups.
  • the component (ii) is one or more flexible oligomer or polymer, such as a low Tg acrylic based polymer, such as a low Tg vinyl based polymer, such as low Tg polyether, which contains reactive functional groups such as carbodiimide groups, such as anhydride groups, such as oxazoline groups, such as amino groups, such as epoxy groups.
  • component (ii) is selected from the group consisting of cross-linkers taking part in a curing reaction, such as hydroxyalkylamide, alkanolamine, a reaction product of an alkanolamine and a polycarboxylic acid.
  • cross-linkers taking part in a curing reaction, such as hydroxyalkylamide, alkanolamine, a reaction product of an alkanolamine and a polycarboxylic acid.
  • the reaction product of an alkanolamine and a polycarboxylic acid can be found in US6706853B1.
  • the present inventors believe it is believed that the very advantageous properties of the aqueous binder compositions are due to the interaction of the oxidized lignins used as component (i) and the cross-linkers mentioned above. It is believed that the presence of carboxylic acid groups in the oxidized lignins enable the very effective cross-linking of the oxidized lignins.
  • the component (ii) is one or more cross-linkers selected from the group consisting of multifunctional organic amines such as an alkanolamine, diamines, such as hexamethyldiamine, triamines.
  • the component (ii) is one or more cross-linkers selected from the group consisting of polyethylene imine, polyvinyl amine, fatty amines.
  • the component (ii) is one or more fatty amides.
  • the component (ii) is one or more cross-linkers selected from the group consisting of dimethoxyethanal, glycolaldehyde, glyoxalic acid.
  • the component (ii) is one or more cross-linkers selected from polyester polyols, such as polycaprolactone. In one embodiment, the component (ii) is one or more cross-linkers selected from the group consisting of starch, modified starch, CMC.
  • the component (ii) is one or more cross-linkers in form of aliphatic multifunctional carbodiimides.
  • the component (ii) is one or more cross-linkers selected from melamine based cross-linkers, such as a hexakis(methylmethoxy)melamine (HMMM) based cross-linkers.
  • melamine based cross-linkers such as a hexakis(methylmethoxy)melamine (HMMM) based cross-linkers.
  • Picassian XL 701 , 702, 725 (Stahl Polymers), such as ZOLDINE® XL-29SE (Angus Chemical Company), such as CX300 (DSM), such as Carbodilite V-02-L2 (Nisshinbo Chemical Inc.).
  • Component (ii) can also be any mixture of the above mentioned compounds.
  • the binder composition according to the present invention comprises component (ii) in an amount of 1 to 40 wt.-%, such as 4 to 20 wt.-%, such as 6 to 12 wt.-%, based on the dry weight of component (i).
  • Component (iii) is in form of one or more plasticizers.
  • component (iii) is in form of one or more plasticizers selected from the group consisting of polyols, such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyethylene glycol ethers, polyethers, phthalates and/or acids, such as adipic acid, vanillic acid, lactic acid and/or ferullic acid, acrylic polymers, polyvinyl alcohol, polyurethane dispersions, ethylene carbonate, propylene carbonate, lactones, lactams, lactides, acrylic based polymers with free carboxy groups and/or polyurethane dispersions with free carboxy groups, polyamides, amides such as carbamide/urea, or any mixtures thereof.
  • polyols such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyethylene glycol ethers,
  • component (iii) is in form of one or more plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, compounds with a structure similar to lignin like vanillin, acetosyringone, solvents used as coalescing agents like alcohol ethers, polyvinyl alcohol.
  • plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, compounds with a structure similar to lignin like vanillin, acetosyringone, solvents used as coalescing agents like alcohol ethers, polyvinyl alcohol.
  • component (iii) is in form of one or more non-reactive plasticizer selected from the group consisting of polyethylene glycols, polyethylene glycol ethers, polyethers, hydrogenated sugars, phthalates and/or other esters, solvents used as coalescing agents like alcohol ethers, acrylic polymers, polyvinyl alcohol.
  • non-reactive plasticizer selected from the group consisting of polyethylene glycols, polyethylene glycol ethers, polyethers, hydrogenated sugars, phthalates and/or other esters, solvents used as coalescing agents like alcohol ethers, acrylic polymers, polyvinyl alcohol.
  • component (iii) is one or more reactive plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, di- or tricarboxylic acids, such as adipic acid, or lactic acid, and/or vanillic acid and/or ferullic acid, polyurethane dispersions, acrylic based polymers with free carboxy groups, compounds with a structure similar to lignin like vanillin, acetosyringone.
  • carbonates such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, di- or tricarboxylic acids, such as adipic acid, or lactic acid, and/or vanillic acid and/or ferullic acid
  • polyurethane dispersions acrylic based polymers with free carboxy groups, compounds with a structure similar to lignin like vanillin, acetosyringone.
  • component (iii) is in form of one or more plasticizers selected from the group consisting of fatty alcohols, monohydroxy alcohols such as pentanol, stearyl alcohol.
  • component (iii) comprises one or more plasticizers selected from the group consisting of polyethylene glycols, polyethylene glycol ethers.
  • plasticizers having a boiling point of more than 100 °C, in particular 140 to 250 °C strongly improves the mechanical properties of the mineral fibre products according to the present invention although, in view of their boiling point, it is likely that these plasticizers will at least in part evaporate during the curing of the aqueous binders in contact with the mineral fibres.
  • component (iii) comprises one or more plasticizers having a boiling point of more than 100 °C, such as 110 to 280 °C, more preferred 120 to 260 °C, more preferred 140 to 250 °C. It is believed that the effectiveness of these plasticizers in the aqueous binder composition is associated with the effect of increasing the mobility of the oxidized lignins during the curing process. It is believed that the increased mobility of the lignins or oxidized lignins during the curing process facilitates the effective cross-linking.
  • component (iii) comprises one or more polyethylene glycols having an average molecular weight of 150 to 50000 g/mol, in particular 150 to 4000 g/mol, more particular 150 to 1000 g/mol, preferably 150 to 500 g/mol, more preferably 200 to 400 g/mol.
  • component (iii) comprises one or more polyethylene glycols having an average molecular weight of 4000 to 25000 g/mol, in particular 4000 to 15000 g/mol, more particular 8000 to 12000 g/mol.
  • component (iii) is capable of forming covalent bonds with component (i) and/or component (ii) during the curing process.
  • a component would not evaporate and remain as part of the composition but will be effectively altered to not introduce unwanted side effects e.g. water absorption in the cured product.
  • Non-limiting examples of such a component are caprolactone and acrylic based polymers with free carboxyl groups.
  • component (iii) is selected from the group consisting of fatty alcohols, monohydroxy alcohols, such as pentanol, stearyl alcohol.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of alkoxylates such as ethoxylates such as butanol ethoxylates, such as butoxytriglycol.
  • component (iii) is selected from one or more propylene glycols.
  • component (iii) is selected from one or more glycol esters. In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of adipates, acetates, benzoates, cyclobenzoates, citrates, stearates, sorbates, sebacates, azelates, butyrates, valerates.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of phenol derivatives such as alkyl or aryl substituted phenols.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of silanols, siloxanes.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of sulfates such as alkyl sulfates, sulfonates such as alkyl aryl sulfonates such as alkyl sulfonates, phosphates such as tripolyphosphates; such as tributylphosphates.
  • plasticizers selected from the group consisting of sulfates such as alkyl sulfates, sulfonates such as alkyl aryl sulfonates such as alkyl sulfonates, phosphates such as tripolyphosphates; such as tributylphosphates.
  • component (iii) is selected from one or more hydroxy acids.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of monomeric amides such as acetamides, benzamide, fatty acid amides such as tall oil amides.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of quaternary ammonium compounds such as trimethylglycine, distearyldimethylammoniumchloride.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of vegetable oils such as castor oil, palm oil, linseed oil, tall oil, soybean oil.
  • component (iii) is selected from one or more plasticizers selected from the group consisting of hydrogenated oils, acetylated oils.
  • component (iii) is selected from one or more fatty acid methyl esters. In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, sorbitan esters.
  • plasticizers in the aqueous binder compositions strongly improves the mechanical properties of the growth substrate according to the invention.
  • plasticizer refers to a substance that is added to a material in order to make the material softer, more flexible (by decreasing the glass-transition temperature Tg) and easier to process.
  • Component (iii) can also be any mixture of the above mentioned compounds.
  • component (iii) is present in an amount of 0.5 to 50, preferably 2.5 to 25, more preferably 3 to 15 wt.-%, based on the dry weight of component (i).
  • Aqueous binder composition for mineral fibers comprising components (i) and (iia)
  • component (iia) in form of one or more modifiers.
  • the present inventors have found that the excellent binder properties can also be achieved by a two-component system which comprises component (i) in form of one or more oxidized lignins and a component (iia) in form of one or more modifiers, and optionally any of the other components mentioned above and below.
  • component (iia) is a modifier in form of one or more compounds selected from the group consisting of epoxidised oils based on fatty acid triglycerides.
  • component (iia) is a modifier in form of one or more compounds selected from molecules having 3 or more epoxy groups.
  • component (iia) is a modifier in form of one or more flexible oligomer or polymer, such as a low Tg acrylic based polymer, such as a low Tg vinyl based polymer, such as low Tg polyether, which contains reactive functional groups such as carbodiimide groups, such as anhydride groups, such as oxazoline groups, such as amino groups, such as epoxy groups.
  • a low Tg acrylic based polymer such as a low Tg vinyl based polymer, such as low Tg polyether
  • reactive functional groups such as carbodiimide groups, such as anhydride groups, such as oxazoline groups, such as amino groups, such as epoxy groups.
  • component (iia) is one or more modifiers selected from the group consisting of polyethylene imine, polyvinyl amine, fatty amines.
  • component (iia) is one or more modifiers selected from aliphatic multifunctional carbodiimides.
  • Component (iia) can also be any mixture of the above mentioned compounds.
  • the present inventors believe that the excellent binder properties achieved by the binder composition for mineral fibers comprising components (i) and (iia), and optional further components, are at least partly due to the effect that the modifiers used as components (iia) at least partly serve the function of a plasticizer and a crosslinker.
  • the aqueous binder composition comprises component (iia) in an amount of 1 to 40 wt.-%, such as 4 to 20 wt.-%, such as 6 to 12 wt.-%, based on the dry weight of the component (i).
  • component (iia) in an amount of 1 to 40 wt.-%, such as 4 to 20 wt.-%, such as 6 to 12 wt.-%, based on the dry weight of the component (i).
  • the aqueous binder composition comprises further components.
  • the aqueous binder composition comprises a catalyst selected from inorganic acids, such as sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and/or phosphoric acid, and/or any salts thereof such as sodium hypophosphite, and/or ammonium salts, such as ammonium salts of sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and/or phosphoric acid.
  • a catalyst selected from inorganic acids, such as sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and/or phosphoric acid, and/or any salts thereof such as sodium hypophosphite, and/or ammonium salts, such as ammonium salts of sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and/or phosphoric acid.
  • the presence of such a catalyst can improve
  • the aqueous binder composition comprises a catalyst selected from Lewis acids, which can accept an electron pair from a donor compound forming a Lewis adduct, such as ZnCI 2 , Mg (CIO4) 2 , Sn [N(SO 2 -n- C8F17) 2 ] 4 .
  • a catalyst selected from Lewis acids, which can accept an electron pair from a donor compound forming a Lewis adduct, such as ZnCI 2 , Mg (CIO4) 2 , Sn [N(SO 2 -n- C8F17) 2 ] 4 .
  • the aqueous binder composition comprises a catalyst selected from metal chlorides, such as KCI, MgCI 2 , ZnCI 2 , FeCl 3 and SnCI 2 .
  • the aqueous binder composition comprises a catalyst selected from organometallic compounds, such as titanate-based catalysts and stannum based catalysts.
  • the aqueous binder composition comprises a catalyst selected from chelating agents, such as transition metals, such as iron ions, chromium ions, manganese ions, copper ions.
  • chelating agents such as transition metals, such as iron ions, chromium ions, manganese ions, copper ions.
  • the aqueous binder composition further comprises a further component (iv) in form of one or more silanes.
  • the aqueous binder composition comprises a further component (iv) in form of one or more coupling agents, such as organofunctional silanes.
  • component (iv) is selected from group consisting of organofunctional silanes, such as primary or secondary amino functionalized silanes, epoxy functionalized silanes, such as polymeric or oligomeric epoxy functionalized silanes, methacrylate functionalized silanes, alkyl and aryl functionalized silanes, urea funtionalised silanes or vinyl functionalized silanes.
  • the aqueous binder composition further comprises a component (v) in form of one or more components selected from the group of ammonia, amines or any salts thereof.
  • ammonia, amines or any salts thereof as a further component can in particular be useful when oxidized lignins are used in component (i), which oxidised lignin have not been oxidized in the presence of ammonia.
  • the aqueous binder composition further comprises a further component in form of urea, in particular in an amount of 5 to 40 wt.-%, such as 10 to 30 wt.-%, 15 to 25 wt.-%, based on the dry weight of component (i).
  • the aqueous binder composition further comprises a further component in form of one or more carbohydrates selected from the group consisting of sucrose and reducing sugars in an amount of 5 to 50 wt.-%, such as 5 to less than 50 wt.-%, such as 10 to 40 wt.-%, such as 15 to 30 wt.-% based on the dry weight of component (i).
  • a binder composition having a sugar content of 50 wt.-% or more, based on the total dry weight of the binder components is considered to be a sugar based binder.
  • a binder composition having a sugar content of less than 50 wt.-%, based on the total dry weight of the binder components is considered a non-sugar based binder.
  • the aqueous adhesive further comprises a further component in form of one or more surface active agents that are in the form of non-ionic and/or ionic emulsifiers such as polyoxyethylenes (4) lauryl ether, such as soy lecithin, such as sodium dodecyl sulfate.
  • non-ionic and/or ionic emulsifiers such as polyoxyethylenes (4) lauryl ether, such as soy lecithin, such as sodium dodecyl sulfate.
  • the aqueous binder composition comprises
  • component (i) in form of one or more ammonia-oxidized lignins having a carboxylic acid group content of 0.05 to 10 mmol/g, such as 0.1 to 5 mmol/g, such as 0.20 to 1.5 mmol/g, such as 0.40 to 1.2 mmol/g, such as 0.45 to 1.0 mmol/g, based on the dry weight of component (i);
  • the aqueous binder composition comprises
  • component (i) in form of one or more ammonia-oxidized lignins having a carboxylic acid group content of 0.05 to 10 mmol/g, such as 0.1 to 5 mmol/g, such as 0.20 to 1.5 mmol/g, such as 0.40 to 1.2 mmol/g, such as 0.45 to 1.0 mmol/g, based on the dry weight of component (i);
  • the aqueous binder composition comprises
  • component (i) in form of one or more ammonia-oxidized lignins having an average carboxylic acid group content of more than 1.5 groups per macromolecule of component (i), such as more than 2 groups, such as more than 2.5 groups;
  • the aqueous binder composition comprises
  • component (i) in form of one or more ammonia-oxidized lignins having an average carboxylic acid group content of more than 1.5 groups per macromolecule of component (i), such as more than 2 groups, such as more than 2.5 groups;
  • the aqueous binder composition consists essentially of
  • component (iv) in form of one or more coupling agents such as organofunctional silanes
  • the aqueous binder composition consists essentially of - a component (i) in form of one or more oxidized lignins;
  • component (iv) in form of one or more coupling agents such as organofunctional silanes
  • component (iv) in form of one or more coupling agents such as organofunctional silanes
  • the growth substrate comprises 1.0 wt% to 6.0 wt% of the cured binder composition, preferably 2.0 wt% to 4.5 wt%, most preferably 2.5 wt% to 3.5 wt% based on the weight of the growth substrate.
  • Determination of binder content is performed according to DS/EN 13820:2003.
  • the binder content is taken as the loss on ignition.
  • the binder content includes any binder additives.
  • the above-described oxidized lignins in the aqueous binder composition can be prepared as follows.
  • Oxidised lignins which can be used as component for the binders used in the present invention can be prepared by a method comprising bringing into contact
  • component (a) comprising one or more lignins
  • component (b) comprising ammonia, one or more amine components, and/or any salt thereof.
  • component (c) comprising one or more oxidation agents.
  • Component (a) comprises one or more lignins.
  • component (a) comprises one or more kraft lignins, one or more soda lignins, one or more lignosulfonate lignins, one or more organosolv lignins, one or more lignins from biorefining processess of lignocellulosic feedstocks, or any mixture thereof.
  • component (a) comprises one or more kraft lignins.
  • component (b) comprises ammonia, one or more amino components, and/or any salts thereof.
  • component (b) comprises ammonia, one or more amino components, and/or any salts thereof.
  • the present inventors believe that the improved fire resistance properties of the oxidised lignins when used in products where they are comprised in a binder composition, said oxidised lignins prepared by the method described herein, are at least partly due to the nitrogen content of the structure of the oxidised lignins.
  • component (b) comprises ammonia and/or any salt thereof.
  • the present inventors believe that the improved stability properties of the derivatized lignins prepared according to the present invention are at least partly due to the fact that ammonia is a volatile compound and therefore evaporates from the final product or can be easily removed and reused. In contrast to that, it has proven difficult to remove residual amounts of the alkali hydroxides used in the previously known oxidation process.
  • an alkali and/or earth alkali metal hydroxide such as sodium hydroxide and/or potassium hydroxide.
  • component (b) comprises alkali and/or earth alkali metal hydroxides, such as sodium hydroxide and/or potassium hydroxide, as a component in addition to the ammonia, one or more amino components, and/or any salts thereof
  • the amount of the alkali and/or earth alkali metal hydroxides is usually small, such as 5 to 70 weight parts, such as 10 to 20 weight parts alkali and/or earth alkali metal hydroxide, based on ammonia.
  • component (c) comprises one or more oxidation agents.
  • component (c) comprises one or more oxidation agents in form of hydrogen peroxide, organic or inorganic peroxides, molecular oxygen, ozone, air, halogen containing oxidation agents, or any mixture thereof.
  • active radicals from the oxidant will typically abstract the proton from the phenolic group as that bond has the lowest dissociation energy in lignin. Due to lignin’s potential to stabilize radicals through mesomerism multiple pathways open up to continue (but also terminate) the reaction and various intermediate and final products are obtained.
  • the average molecular weight can both increase and decrease due to this complexity (and chosen conditions) and in their experiments, the inventors have typically seen moderate increase of average molecular weight of around 30%.
  • component (c) comprises hydrogen peroxide.
  • Hydrogen peroxide is perhaps the most commonly employed oxidant due to combination of low price, good efficiency and relatively low environmental impact.
  • alkaline conditions and temperature are important due to the following reactions leading to radical formation:
  • the present inventors have found that the derivatized lignins prepared with the method described herein contain increased amounts of carboxylic acid groups as a result of the oxidation process. Without wanting to be bound by any particular theory, the present inventors believe that the carboxylic acid group content of the oxidised lignins prepared in the process plays an important role in the desirable reactivity properties of the derivatized lignins prepared by the method described herein.
  • Another advantage of the oxidation process is that the oxidised lignin is more hydrophilic. Higher hydrophilicity can enhance solubility in water and facilitate the adhesion to polar substrates such as mineral fibers.
  • the method of preparing oxidised lignins preferably comprises further components, in particular a component (d) in form of an oxidation catalyst, such as one or more transition metal catalyst, such as iron sulfate, such as manganese, palladium, selenium, tungsten containing catalysts.
  • a component (d) in form of an oxidation catalyst such as one or more transition metal catalyst, such as iron sulfate, such as manganese, palladium, selenium, tungsten containing catalysts.
  • Such oxidation catalysts can increase the rate of the reaction, thereby improving the properties of the oxidised lignins.
  • - a component (a) comprises one or more lignins
  • component (b) comprises ammonia
  • component (c) comprises one or more oxidation agents in form of hydrogen peroxide, wherein the mass ratios of lignin, ammonia and hydrogen peroxide are such that the amount of ammonia is 0.01 to 0.5 weight parts, such as 0.1 to 0.3, such as 0.15 to 0.25 weight parts ammonia, based on the dry weight of lignin, and wherein the amount of hydrogen peroxide is 0.025 to 1.0 weight parts, such as 0.05 to 0.2 weight parts, such as 0.075 to 0.125 weight parts hydrogen peroxide, based on the dry weight of lignin.
  • the mass ratios of lignin, ammonia and hydrogen peroxide are such that the amount of ammonia is 0.01 to 0.5 weight parts, such as 0.1 to 0.3, such as 0.15 to 0.25 weight parts ammonia, based on the dry weight of lignin, and wherein the amount of hydrogen peroxide is 0.025 to 1.0 weight parts, such as 0.05 to 0.2 weight parts, such as 0.075
  • the method comprises the steps of: - a step of providing component (a) in form of an aqueous solution and/or dispersion of one more lignins, the lignin content of the aqueous solution being 1 to 50 weight-%, such as 5 to 25 weight- %, such as 15 to 22 weight-%, such as 18 to 20 weight-%, based on the total weight of the aqueous solution; - a pH adjusting step by adding component (b) comprising an aqueous solution of ammonia, one or more amine components, and/or any salt thereof;
  • component (c) comprising an oxidation agent
  • the pH adjusting step is carried so that the resulting aqueous solution and/or dispersion is having a pH ⁇ 9, such as ⁇ 10, such as ⁇ 10.5.
  • the pH adjusting step is carried out so that the resulting aqueous solution and/or dispersion is having a pH in the range of 10.5 to 12.
  • the pH adjusting step is carried out so that the temperature is allowed to raise to ⁇ 25 °C and then controlled in the range of 25 - 50 °C, such as 30 - 45 °C, such as 35 - 40 °C.
  • the temperature is allowed to raise ⁇ 35 °C and is then controlled in the range of 35 - 150 °C, such as 40 - 90 °C, such as 45 - 80 °C.
  • the oxidation step is carried out for a time of 1 second to 48 hours, such as 10 seconds to 36 hours, such as 1 minute to 24 hours such as 2 - 5 hours.
  • Oxidised lignins which are used as component for the binders used in the present invention can be prepared by a method comprising bringing into contact
  • component (a) comprising one or more lignins
  • component (b) comprising ammonia and/or one or more amine components, and/or any salt thereof and/or an alkali and/or earth alkali metal hydroxide, such as sodium hydroxide and/or potassium hydroxide
  • component (c) comprising one or more oxidation agents
  • component (d) in form of one or more plasticizers in form of one or more plasticizers.
  • Component (a) comprises one or more lignins.
  • component (a) comprises one or more kraft lignins, one or more soda lignins, one or more lignosulfonate lignins, one or more organosolv lignins, one or more lignins from biorefining processess of lignocellulosic feedstocks, or any mixture thereof.
  • component (a) comprises one or more kraft lignins.
  • component (b) comprises ammonia, one or more amino components, and/or any salts thereof and/or an alkali and/or earth alkali metal hydroxide, such as sodium hydroxide and/or potassium hydroxide.
  • Ammonia-oxidized lignins is to be understood as a lignin that has been oxidized by an oxidation agent in the presence of ammonia.
  • the term “ammonia- oxidized lignin” is abbreviated as AOL.
  • component (b) comprises ammonia and/or any salt thereof.
  • the present inventors believe that the improved stability properties of the derivatized lignins prepared according to the present invention with component (b) being ammonia and/or any salt thereof are at least partly due to the fact that ammonia is a volatile compound and therefore evaporates from the final product or can be easily removed and reused.
  • component (b), besides ammonia, one or more amino components, and/or any salts thereof, also comprises a comparably small amount of an alkali and/or earth alkali metal hydroxide, such as sodium hydroxide and/or potassium hydroxide.
  • component (b) comprises alkali and/or earth alkali metal hydroxides, such as sodium hydroxide and/or potassium hydroxide, as a component in addition to the ammonia, one or more amino components, and/or any salts thereof
  • the amount of the alkali and/or earth alkali metal hydroxides is usually small, such as 5 to 70 weight parts, such as 10 to 20 weight parts alkali and/or earth alkali metal hydroxide, based on ammonia.
  • component (c) comprises one or more oxidation agents.
  • component (c) comprises one or more oxidation agents in form of hydrogen peroxide, organic or inorganic peroxides, molecular oxygen, ozone, air, halogen containing oxidation agents, or any mixture thereof.
  • active radicals from the oxidant will typically abstract the proton from the phenolic group as that bond has the lowest dissociation energy in lignin. Due to lignin’s potential to stabilize radicals through mesomerism, multiple pathways open up to continue (but also terminate) the reaction and various intermediate and final products are obtained.
  • the average molecular weight can both increase and decrease due to this complexity (and chosen conditions) and in their experiments, the inventors have typically seen moderate increase of average molecular weight of around 30%.
  • component (c) comprises hydrogen peroxide.
  • Hydrogen peroxide is perhaps the most commonly employed oxidant due to combination of low price, good efficiency and relatively low environmental impact.
  • alkaline conditions and temperature are important due to the following reactions leading to radical formation:
  • the present inventors have found that the derivatized lignins prepared with the method described herein contain increased amounts of carboxylic acid groups as a result of the oxidation process. Without wanting to be bound by any particular theory, the present inventors believe that the carboxylic acid group content of the oxidized lignins prepared in the process according to the present invention plays an important role in the desirable reactivity properties of the derivatized lignins prepared by the method described herein.
  • Another advantage of the oxidation process is that the oxidized lignin is more hydrophilic. Higher hydrophilicity can enhance solubility in water and facilitate the adhesion to polar substrates such as mineral fibres.
  • Component (d) comprises one or more plasticizers.
  • component (d) comprises one or more plasticizers in form of polyols, such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyethylene glycol ethers, polyethers, phthalates and/or acids, such as adipic acid, vanillic acid, lactic acid and/or ferullic acid, acrylic polymers, polyvinyl alcohol, polyurethane dispersions, ethylene carbonate, propylene carbonate, lactones, lactams, lactides, acrylic based polymers with free carboxy groups and/or polyurethane dispersions with free carboxy groups, polyamides, amides such as carbamide/urea., or any mixtures thereof.
  • polyols such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyethylene glycol ethers, polyethers, phthalates and
  • component (d) in form of one or more plasticizers provides a decrease of the viscosity of the reaction mixture which allows a very efficient method to produce oxidised lignins.
  • component (d) comprises one or more plasticizers in form of polyols, such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyvinyl alcohol, acrylic based polymers with free carboxy groups and/or polyurethane dispersions with free carboxy groups, polyamides, amides such as carbamide/urea, or any mixtures thereof.
  • polyols such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyvinyl alcohol, acrylic based polymers with free carboxy groups and/or polyurethane dispersions with free carboxy groups, polyamides, amides such as carbamide/urea, or any mixtures thereof.
  • component (d) comprises one or more plasticizers selected from the group of polyethylene glycols, polyvinyl alcohol, urea or any mixtures thereof.
  • the method of preparing oxidised lignins preferably comprises further components, in particular a component (v) in form of an oxidation catalyst, such as one or more transition metal catalyst, such as iron sulfate, such as manganese, palladium, selenium, tungsten containing catalysts.
  • a component (v) in form of an oxidation catalyst such as one or more transition metal catalyst, such as iron sulfate, such as manganese, palladium, selenium, tungsten containing catalysts.
  • Such oxidation catalysts can increase the rate of the reaction, thereby improving the properties of the oxidized lignins prepared by the method.
  • the method is carried out such that the method comprises
  • component (a) comprises one or more lignins
  • component (b) comprises ammonia
  • component (c) comprises one more oxidation agents in form of hydrogen peroxide
  • a component (d) comprises one or more plasticizers selected from the group of polyethylene glycol, wherein the mass ratios of lignin, ammonia, hydrogen peroxide and polyethylene glycol are such that the amount of ammonia is 0.01 to 0.5 weight parts, such as 0.1 to 0.3, such as 0.15 to 0.25 weight parts ammonia (25 weight% solution in water), based on the dry weight of lignin, and wherein the amount of hydrogen peroxide (30 weight% solution in water) is 0.025 to 1.0 weight parts, such as 0.07 to 0.50 weight parts, such as 0.15 to 0.30 weight parts hydrogen peroxide, based on the dry weight of lignin, and wherein the amount of polyethylene glycol is 0.03 to 0.60 weight parts, such as 0.07 to 0.50 weight parts, such as 0.10 to 0.40 weight parts polyethylene glycol, based on the dry weight of lignin.
  • the "dry weight of lignin" is preferably defined as the weight of the lignin in the supplied form.
  • the method comprises the steps of:
  • component (a) in form of an aqueous solution and/or dispersion of one more lignins, the lignin content of the aqueous solution being 5 to 90 weight-%, such as 10 to 85 weight-
  • % such as 15 to 70 weight-%, based on the total weight of the aqueous solution
  • component (c) comprising an oxidation agent
  • the pH adjusting step is carried so that the resulting aqueous solution and/or dispersion is having a pH ⁇ 9, such as ⁇ 10, such as ⁇ 10.5.
  • the pH adjusting step is carried out so that the resulting aqueous solution and/or dispersion is having a pH in the range of 9.5 to 12. In one embodiment, the pH adjusting step is carried out so that the temperature is allowed to raise to > 25 °C and then controlled in the range of 25 - 50 °C, such as 30 - 45 °C, such as 35 - 40 °C.
  • the temperature is allowed to raise to ⁇ 35 °C and is then controlled in the range of 35 - 150 °C, such as 40 - 90 °C, such as 45 - 80 °C.
  • the oxidation step is carried out for a time of 1 seconds to 24 hours, such as 1 minutes to 12 hours, such as 10 minutes to 8 hours, such as 5 minutes to 1 hour.
  • the present inventors have found that the process as described herein allows to produce a high dry matter content of the reaction mixture and therefore a high throughput is possible in the process according to the present invention which allows the reaction product in form of the oxidised lignins to be used as a component in industrial mass production products such as mineral fibre products.
  • the method is carried out such that the dry matter content of the reaction mixture is 20 to 80 wt.%, such as 40 to 70 wt.%.
  • the method is carried out such that the viscosity of the oxidised lignin has a value of 100 cP to 100.000 cP, such as a value of 500 cP to 50.000 cP, such as a value of 1.000 cP to 25.000 cP.
  • viscosity is dynamic viscosity and is defined as the resistance of the liquid/paste to a change in shape, or movement of neighbouring portions relative to one another.
  • the viscosity is measured in centipoise (cP), which is the equivalent of 1 mPa s (milipascal second).
  • Viscosity is measured at 20°C using a viscometer.
  • the dynamic viscosity can be measured at 20°C by a Cone Plate Wells Brookfield Viscometer.
  • the method is carried out such that the method comprises a rotator-stator device.
  • the method is carried out such that the method is performed as a continuous or semi-continuous process.
  • Apparatus for performing the method is carried out such that the method is performed as a continuous or semi-continuous process.
  • the present invention is also directed to an apparatus for performing the method described above.
  • the apparatus for performing the method comprises:
  • the apparatus is constructed in such a way that the inlets for the premix of the components (a), (b) and (d) are to the rotor-stator device and the apparatus furthermore comprises a chamber, said chamber having an inlet for component (c) and said chamber having an outlet for an oxidised lignin.
  • a rotator-stator device is a device for processing materials comprising a stator configured as an inner cone provided with gear rings.
  • the stator cooperates with a rotor having arms projecting from a hub. Each of these arms bears teeth meshing with the teeth of the gear rings of the stator. With each turn of the rotor, the material to be processed is transported farther outward by one stage, while being subjected to an intensive shear effect, mixing and redistribution.
  • the rotor arm and the subjacent container chamber of the upright device allow for a permanent rearrangement of the material from the inside to the outside and provide for a multiple processing of dry and/or highly viscous matter so that the device is of excellent utility for the intensive mixing, kneading, fibrillating, disintegrating and similar processes important in industrial production.
  • the upright arrangement of the housing facilitates the material's falling back from the periphery toward the center of the device.
  • the rotator-stator device used in the method according to the present invention comprises a stator with gear rings and a rotor with teeth meshing with the teeth of the stator.
  • the rotator-stator device has the following features: Between arms of the rotor protrudes a guiding funnel that concentrates the material flow coming in from above to the central area of the container. The outer surface of the guiding funnel defines an annular gap throttling the material flow.
  • a feed screw is provided that feeds towards the working region of the device.
  • the guiding funnel retains the product in the active region of the device and the feed screw generates an increased material pressure in the center.
  • the method is carried out such that the method uses one rotator-stator device.
  • the mixing of the components and the reaction of the components is carried out in the same rotator-stator device.
  • the method is carried out such that the method uses two or more rotator-stator devices, wherein at least one rotator-stator device is used for the mixing of the components and at least one rotator-stator device is used for reacting the components.
  • This process can be divided into two steps:
  • Oxidization of the lignin mass Typically, two different types of rotor-/stator machines are used:
  • Inline rotor-/stator machine which has much higher shear forces - circumferential speeds of up to 55 m/s) - and creates beneficial conditions for a very quick chemical reaction.
  • the machine is to be used continuously.
  • the highly concentrated (45 to 50 wt-%) mass of Lignin/water is prepared.
  • the lignin powder is added slowly to the warm water (30 to 60 deg.C) in which the correct amount of watery ammonia and/or alkali base have been added. This can be done in batch mode, or the materials are added intermittently/continuously creating a continuous flow of mass to the next step.
  • the created mass should be kept at a temperature of about 60 deg. to keep the viscosity as low as possible and hence the material pumpable.
  • the hot mass of lignin/water at a pH of 9 to 12 is then transferred using a suitable pump, e.g. progressive cavity pump or another volumetric pump, to the oxidation step.
  • the oxidation is done in a closed rotor-/stator system in a continuous inline reaction.
  • a watery solution of ammonia and/or alkali base is dosed with a dosing pump into the rotor-/stator chamber at the point of highest turbulence/shear. This ensures a rapid oxidation reaction.
  • the oxidized material (AOL) leaves the inline-reactor and is collected in suitable tanks.
  • the present inventors have surprisingly found, that the oxidized lignins prepared have very desirable reactivity properties and at the same time display improved fire resistance properties when used in products where they are comprised in a binder composition, and improved long term stability over previously known oxidized lignins.
  • the oxidised lignin also displays improved hydrophilicity.
  • An important parameter for the reactivity of the oxidized lignins prepared is the carboxylic acid group content of the oxidized lignins.
  • the oxidized lignin prepared has a carboxylic acid group content of 0.05 to 10 mmol/g, such as 0.1 to 5 mmol/g, such as 0.20 to 2.0 mmol/g, such as 0.40 to 1.5 mmol/g, such as 0.45 to 1.0 mmol/g, based on the dry weight of component (a).
  • the oxidized lignin prepared has an average carboxylic acid group content of more than 1.5 groups per macromolecule of component (a), such as more than 2 groups, such as more than 2.5 groups.
  • Oxidised lignins which are used as a component for the binder used in the present invention can be prepared by a method comprising bringing into contact
  • component (a) comprising one or more lignins
  • component (b) comprising ammonia and/or one or more amine components, and/or any salt thereof and/or an alkali and/or earth alkali metal hydroxide, such as sodium hydroxide and/or potassium hydroxide
  • component (c) comprising one or more oxidation agents
  • a component (d) in form of one or more plasticizers optionally a component (d) in form of one or more plasticizers, and allowing a mixing/oxidation step, wherein an oxidised mixture is produced, followed by an oxidation step, wherein the oxidised mixture is allowed to continue to react for a dwell time of dwell time of 1 second to 10 hours, such as 10 seconds to 6 hours, such as 30 seconds to 2 hours.
  • Components (a), (b), (c) and (d) are as defined above under Method II to prepare oxidised lignins.
  • the process comprises a premixing step in which components are brought into contact with each other.
  • the premixing step is carried out as a separate step and the mixing/oxidation step is carried out subsequently to the premixing step.
  • component (c) is then added to the premixture produced in the premixing step.
  • the premixing step corresponds to the mixing/oxidation step.
  • the components for example component (a), component (b) and component (c) are mixed and an oxidation process is started at the same time. It is possible that the subsequent dwell time is performed in the same device as that used to perform the mixing/oxidation step.
  • component (c) is air.
  • the present inventors have found out that by allowing a mixing/oxidation step followed by an oxidation step, in which the reaction mixture is preferably not continued to be mixed, the oxidation rate can be controlled in a very efficient manner. At the same time, the costs for performing the method are reduced because the oxidation step subsequent to the mixing/oxidation step requires less complex equipment.
  • oxidized lignin which is produced is particularly stable.
  • the oxidized lignin produced is very well adjustable in terms of viscosity.
  • concentration of the oxidized lignin can be very high.
  • the dwell time is so chosen that the oxidation reaction is brought to the desired degree of completion, preferably to full completion.
  • system for performing the method comprises:
  • At least one reaction device in particular at least one reaction tube, which is arranged downstream in the process flow direction to at least one or more of the outlets.
  • the system comprises one or more inlets for component (c) and/or component (d).
  • the system comprises a premixing device.
  • the premixing device can comprise one or more inlets for water and/or component (a) and/or component (b) and/or component (c) and/or component
  • the premixing device comprises inlets for water and component (a) and component (b).
  • component (c) is also mixed with the three mentioned ingredients (water, component (a) and component (b)). It is then possible that the premixing device has a further inlet for component (c). If component (c) is air, it is possible that the premixing device is formed by an open mixing vessel, so that in this case component (c) is already brought into contact with the other components (water, component (a) and component (b)) through the opening of the vessel. Also in this embodiment of the invention, it is possible that the premixing device optionally comprises an inlet for component (d).
  • the system is constructed in such a way that the inlets for components (a), (b) and (d) are inlets of a premixing device, in particular of an open rotor-stator device, whereby the system furthermore comprises an additional rotor-stator device, said additional rotor-stator device having an inlet for component (c) and said additional rotor-stator device having an outlet for an oxidized lignin.
  • the premixing step and the mixing/oxidizing step are carried out simultaneously.
  • the premixing device and the mixing/oxidizing device are a single device, i. e. a rotor-stator device.
  • one rotator-stator device used in the method according to the present invention comprises a stator with gear rings and a rotor with teeth meshing with the teeth of the stator.
  • the rotator-stator device has the following features: Between arms of the rotor protrudes a guiding funnel that concentrates the material flow coming in from above to the central area of the container. The outer surface of the guiding funnel defines an annular gap throttling the material flow.
  • a feed screw is provided that feeds towards the working region of the device. The guiding funnel retains the product in the active region of the device and the feed screw generates an increased material pressure in the center.
  • the system for performing the method comprises: one or more inlets for water, components (a) and (b),
  • mixer/heat-exchanger which is arranged downstream in the process flow direction to the at least one or more of the outlets, whereby the mixer/heat-exchanger comprises a temperature control device.
  • the system comprises additional one or more inlets for component (c) and/or component (d).
  • the system comprises a premixing device.
  • the premixing device can comprise one or more inlets for water and/or component (a) and/or component (b) and/or component (c) and/or component (d).
  • the premixing device comprises inlets for water and component (a) and component (b).
  • component (c) is also mixed with the three mentioned ingredients (water, component (a) and component (b)). It is then possible that the premixing device has a further inlet for component (c). If component (c) is air, it is possible that the premixing device is formed by an open mixing vessel, so that in this case component (c) is already brought into contact with the other components (water, component (a) and component (b)) through the opening of the vessel. Also in this embodiment of the invention, it is possible that the premixing device optionally comprises an inlet for component (d).
  • the system is constructed in such a way that the inlets for components (a), (b) and (d) are inlets of an open rotor-stator device, whereby the system furthermore comprises a mixer/heat-exchanger, having an inlet for component (c) and an outlet for an oxidized lignin.
  • premixing step and the mixing/oxidizing step are carried out simultaneously.
  • the premixing device and the mixing/oxidizing device are a single device.
  • one rotator-stator device used in the method according to the present invention comprises a stator with gear rings and a rotor with teeth meshing with the teeth of the stator.
  • the rotator-stator device has the following features: Between arms of the rotor protrudes a guiding funnel that concentrates the material flow coming in from above to the central area of the container. The outer surface of the guiding funnel defines an annular gap throttling the material flow.
  • a feed screw is provided that feeds towards the working region of the device. The guiding funnel retains the product in the active region of the device and the feed screw generates an increased material pressure in the center.
  • premixing devices can also be used as premixing devices.
  • the premixing step is carried out in the mixing and oxidizing apparatus.
  • the mixing and oxidizing apparatus is a static mixer.
  • a static mixer is a device for the continuous mixing of fluid materials, without moving components.
  • One design of static mixer is the plate-type mixer and another common device type consists of mixer elements contained in a cylindrical (tube) or squared housing.
  • the mixer/heat-exchanger is constructed as multitube heat exchanger with mixing elements.
  • the mixing element are preferably fixed installations through which the mixture has to flow, whereby mixing is carried out as a result of the flowing through.
  • the mixer/heat-exchanger can be constructed as a plug flow reactor.
  • the growth substrate product according to the invention comprises at least 90 wt% man-made vitreous fibres by weight of the total solid content of the growth substrate.
  • An advantage of having such an amount of fibres present in the growth substrate product is that there are sufficient pores formed between the fibres to allow the growth substrate product to hold water and nutrients for the cutting, whilst maintaining the ability for roots of the plants to permeate the growth substrate product.
  • the remaining solid content may be made up primarily of binder.
  • the growth substrate product is in the form of a coherent mass. That is, the growth substrate is generally a coherent matrix of man-made vitreous fibres, which has been produced as such, but can also be formed by granulating a slab of mineral wool and consolidating the granulated material.
  • a coherent substrate is a single, unified substrate.
  • the growth substrate product according to the invention may optionally comprise a wetting agent.
  • a wetting agent has its normal meaning in the art, and may be a cationic, anionic or non-ionic surfactant.
  • the growth substrate product may comprise a non-ionic wetting agent such as Rewopal®.
  • the growth substrate product may comprise an ionic surfactant, more preferably an alkyl ether sulphate surfactant wetting agent.
  • the wetting agent may be an alkali metal alkyl ether sulphate or an ammonium alkyl ether sulphate.
  • the wetting agent is a sodium alkyl ether sulphate.
  • Alkyl ether sulphate surfactant wetting agents are commercially available.
  • the wetting agent may also be a linear alkyl benzene sulphonate anionic surfactant.
  • non-ionic wetting agents may be washed out of the MMVF substrate over time. It is therefore preferable to use an ionic wetting agent, especially an anionic wetting agent, such as linear alkyl benzene sulphonate.
  • the growth substrate product comprises 0.01 to 1 wt% wetting agent, preferably 0.05 to 0.5 wt% wetting agent, more preferably 0.1 to 0.3 wt% wetting agent.
  • the inventors discovered that a wetting agent is not essential for the growth substrate product according to the invention. This is believed to be due to the nature of the binder composition. Therefore, preferably the growth substrate does not comprise any wetting agent. By this, it is meant that the growth substrate preferably comprises no wetting agent i.e. comprises 0 wt% wetting agent.
  • wetting agents reduces the number of additives in the growth substrate product which is environmentally advantageous, and also saves costs.
  • wetting agents are made from non-renewable sources so it is beneficial to avoid their use.
  • wetting agents may be washed out of the growth substrate product. This is problematic because the wetting agent may contaminate the water supply and must be properly disposed of in line with environmental regulations. When a wetting agent is washed out this also changes the nature of the growth substrate product, which can lead to inconsistencies in the growing process.
  • wetting agents have the disadvantage that they can cause foam to be released from the product during use. Avoiding the use of a wetting agent avoids these problems.
  • the hydrophilicity of a sample of MMVF substrate can be measured by determining the sinking time of a sample.
  • a sample of MMVF substrate having dimensions of 100x100x65 mm is required for determining the sinking time.
  • a container with a minimum size of 200x200x200 mm is filled with water.
  • the sinking time is the time from when the sample first contacts the water surface to the time when the test specimen is completely submerged.
  • the sample is placed in contact with the water in such a way that a cross-section of 100x100 mm first touches the water.
  • the sample will then need to sink a distance of just over 65mm in order to be completely submerged. The faster the sample sinks, the more hydrophilic the sample is.
  • the MMVF substrate is considered hydrophilic if the sinking time is less than 120 s. Preferably the sinking time is less than 60 s. In practice, the MMVF substrate may have a sinking time of a few seconds, such as less than 10 seconds.
  • the hydrophilicity of the growth substrate product may be defined in terms of the contact angle with water.
  • the MMVF of the growth substrate product has a contact angle with water of less than 90°.
  • the contact angle is measured by a sessile drop measurement method. Any sessile drop method can be used, for example with a contact angle goniometer.
  • a droplet is placed on the solid surface and an image of the drop is recorded in time.
  • the static contact angle is then defined by fitting Young-Laplace equation around the droplet.
  • the contact angle is given by the angle between the calculated drop shape function and the sample surface, the projection of which in the drop image is referred to as the baseline.
  • the equilibrium contact angles are used for further evaluation and calculation of the surface free energy using the Owens, Wendt, Rabel and Kaeble method.
  • the method for calculating the contact angle between material and water is well-known to the skilled person.
  • the growth substrate product has a density in the range of 40 to 100 kg/m 3 , preferably 45 to 80 kg/m 3 . This density range was found to be optimal for root growth and product handling, allowing the roots to penetrate and ensuring that the product is not damaged during handling.
  • the growth substrate product preferably has a volume in the range 0.003 to 87 litres, such as 0.005 to 30 litres, preferably 0.008 to 20 litres.
  • the growth substrate product may be in the form of a product conventionally known as a plug, or in the form of a product conventionally known as a block, or in the form of a product conventionally known as a slab.
  • the growth substrate product has a height in the range of 10 mm to 200 mm.
  • the growth substrate product may have dimensions conventional for the product type commonly known as a plug. Thus it may have height from 20 to 35 mm, often 25 to 28 mm, and length and width in the range 15 to 25 mm, often around 20 mm. In this case the substrate is often substantially cylindrical with the end surfaces of the cylinder forming the top and bottom surfaces of the growth substrate.
  • the volume of the growth substrate product in the form of a plug is preferably not more than 150 cm 3 .
  • the volume of the growth substrate product in the form of a plug is in the range 3 to 150 cm 3 and preferably not more than 100 cm 3 , more preferably not more than 80 cm 3 , in particular not more than 75 cm 3 , most preferably not more than 70 cm 3 .
  • the minimum distance between the top and bottom surfaces of a plug is preferably less than 60 mm, more preferably less than 50 mm and in particular less than 40 mm or less.
  • Another embodiment of a plug has height from 30 to 50 mm, often around 40 mm and length and width in the range 20 to 40 mm, often around 30 mm.
  • the growth substrate in this case is often of cuboid form.
  • the volume of the growth substrate is often not more than 50 cm 3 , preferably not more than 40 cm 3 .
  • the growth substrate may be of the type of plug described as the first coherent MMVF growth substrate in our publication WO2010/003677.
  • the volume of the growth substrate product is most preferably in the range to 10 to 40 cm 3 .
  • the growth substrate product may have dimensions conventional for the product type commonly known as a block. Thus it may have height from 5 to 20 cm, often 6 to 15 cm, and length and width in the range 4 to 30 cm, often 10 to 20 cm. In this case the substrate is often substantially cuboidal.
  • the volume of the growth substrate product in the form of a block is preferably in the range 64 to 8000 cm 3 .
  • the growth substrate product may have dimensions conventional for the product type commonly known as a slab. Thus it may have height from 5 to 15 cm, often 7.5 to 12.5 cm, a width in the range of 5 to 30 cm, often 12 to 24 cm, and a length in the range 30 to 240 cm, often 40 to 200 cm. In this case the substrate is often substantially cuboidal.
  • the volume of the growth substrate product in the form of a slab is preferably in the range 750 to 86,400 cm 3 .
  • the growth substrate product may have a volume in the range 3 to 300 cm 3 . It may be a cube with dimensions of 4 cm by 4 cm by 4 cm.
  • the growth substrate product may be also cylindrical. Preferably it has a length 50 mm and a diameter or 46 mm, or a length of 40 mm and a diameter of 36 mm, or a length of 27 mm and a diameter of 22 mm.
  • the growth substrate product may be of any appropriate shape including cylindrical, cuboidal and cubic. Usually the top and bottom surfaces are substantially planar.
  • the term “height” means the distance from the bottom surface to the top surface when the substrate is in use.
  • the top surface is the surface that faces upwardly when the product is positioned as intended to be used and the bottom surface is the surface that faces downwardly (and on which the product rests) when the product is positioned as intended to be used.
  • the term “length” means the longest distance between two sides i.e. the distance from one end to the other end when the substrate is in use.
  • the term “width” is the distance between two sides, perpendicular to the length.
  • the growth substrate product according to the invention may have a seed hole. Alternatively, it may not have a seed hole.
  • the term seed hole has its normal meaning in the art, and can also be called a plant hole or cavity.
  • a seed hole is an indentation in the top surface of a growth substrate, into which a seed, seedling, cutting or plant is placed.
  • the growth substrate product comprises a liquid impermeable covering surrounding at least the side surfaces of the substrate.
  • the liquid impermeable covering is plastic.
  • the growth substrate product may comprise a liquid impermeable covering encasing the entire substrate, wherein the covering has at least one opening for a drain hole and at least one opening on the upper surface to allow contact between the growth substrate and a further growth substrate.
  • seed, seedling, cutting and plant have their normal meaning in the art.
  • the seeds, seedlings, cuttings and plants may be that of cucumbers, tomatoes, eggplant, sweet peppers, strawberries, lettuce, perennial plants such as roses; gerberas or medicinal cannabis.
  • the growth substrate product is irrigated.
  • it is irrigated with water and nutrients. This can be done using any of the methods known to the skilled person.
  • the seed, seedling, cutting or plant is placed in contact with the growth substrate product.
  • the seed, seedling, cutting or plant may be placed directly into the substrate, for example into a seed hole.
  • it can be positioned such that it grows into the substrate, for example from a further growth substrate.
  • Any part of the seed, seedling, cutting or plant may be in contact with any part of the growth substrate product.
  • the present invention also relates to a coherent growth substrate product comprising man-made vitreous fibres (MMVF) bonded with a cured binder composition, wherein the binder composition prior to curing comprises - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • MMVF man-made vitreous fibres
  • the coherent growth substrate product is as described above. This embodiment may have any of the preferred features described above for the method of the invention.
  • the present invention also relates to an array of two or more coherent growth substrate products, wherein the coherent growth substrate products comprise man-made vitreous fibres (MMVF) bonded with a cured binder composition, wherein the binder composition prior to curing comprises - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • MMVF man-made vitreous fibres
  • one or more of the coherent growth substrate products may have any of the preferred features described above for the method of the invention.
  • the at least two coherent growth substrate product may be identical.
  • it may be two identical coherent growth substrate products positioned beside each other.
  • the at least two growth substrate products may not be identical.
  • the array comprises one growth substrate product positioned in contact with the second growth substrate product.
  • one growth substrate is positioned on the top surface of the second growth substrate, for example in a plug/block, block/slab, block/block, plug/block/slab or plug/block/block arrangement.
  • a substrate described as a plug above is positioned in contact with a substrate described as a block above.
  • the plug may be inserted into a cavity in the block.
  • a substrate described as a block above is positioned in contact with a substrate described as a slab above.
  • the block is positioned on the top surface of the slab.
  • a block is positioned in contact with another block, for example, it may be positioned on the top surface of the other block.
  • a plug, block, slab arrangement a plug is positioned in contact with a block, which in turn is positioned in contact with a slab.
  • a plug/block/block arrangement a plug is positioned in contact with another block, which in turn is positioned in contact with a block.
  • the present invention is also directed to use of a coherent growth substrate product for growing plants, wherein the coherent growth substrate product comprises man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition, wherein the aqueous binder composition prior to curing comprises - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • MMVF man-made vitreous fibres
  • This embodiment of the invention may have any of the additional features described above for the method of the invention.
  • the present invention also relates to a method of making a growth substrate product comprising the steps of: (i) providing MMVF;
  • aqueous binder composition (iv) curing the aqueous binder composition; wherein the aqueous binder composition prior to curing comprises - a component (i) in form of one or more oxidized lignins; - a component (ii) in form of one or more cross-linkers; - a component (iii) in form of one or more plasticizers.
  • This embodiment of the invention may have any of the additional features described above for the method of the invention or growth substrate of the invention.
  • Man-made vitreous fibres can be made from a mineral melt.
  • a mineral melt is provided in a conventional manner by providing mineral materials and melting them in a furnace.
  • This furnace can be any of the types of furnace known for production of mineral melts for MMVF, for instance a shaft furnace such as a cupola furnace, a tank furnace, or a cyclone furnace.
  • the fiberization can be by a spinning cup process in which melt is centrifugally extruded through orifices in the walls of a rotating cup (spinning cup, also known as internal centrifugation).
  • the fiberization can be by centrifugal fiberization by projecting the melt onto and spinning off the outer surface of one fiberizing rotor, or off a cascade of a plurality of fiberizing rotors, which rotate about a substantially horizontal axis (cascade spinner).
  • the melt is thus formed into a cloud of fibres entrained in air and the fibres are collected as a web on a conveyor and carried away from the fiberizing apparatus.
  • the web of fibres is then consolidated, which can involve cross- lapping and/or longitudinal compression and/or vertical compression and/or winding around a mandrel to produce a cylindrical product for pipe insulation. Other consolidation processes may also be performed.
  • the binder composition is applied to the fibres preferably when they are a cloud entrained in air. Alternatively it can be applied after collection on the conveyor but this is less preferred. After consolidation the consolidated web of fibres is passed into a curing device to cure the binder.
  • the curing is carried out at temperatures from 100 to 300°C, such as 170 to 270°C, such as 180 to 250°C, such as 190 to 230°C.
  • the curing takes place in a conventional curing oven for mineral wool production, preferably operating at a temperature of from 150 to 300°C, such as 170 to 270°C, such as 180 to 250°C, such as 190 to 230°C.
  • the curing takes place for a time of 30 seconds to 20 minutes, such as 1 to 15 minutes, such as 2 to 10 minutes.
  • curing takes place at a temperature of 150 to 250 °C for a time of 30 seconds to 20 minutes.
  • the curing process may commence immediately after application of the binder to the fibres.
  • the curing is defined as a process whereby the binder composition undergoes a physical and/or chemical reaction which in case of a chemical reaction usually increases the molecular weight of the compounds in the binder composition and thereby increases the viscosity of the binder composition, usually until the binder composition reaches a solid state.
  • the cured binder composition binds the fibres to form a structurally coherent matrix of fibres.
  • the curing of the binder in contact with the mineral fibres takes place in a heat press.
  • the curing of a binder in contact with the mineral fibres in a heat press has the particular advantage that it enables the production of high-density products.
  • the curing process comprises drying by pressure.
  • the pressure may be applied by blowing air or gas through/over the mixture of mineral fibres and binder. Examples
  • the phytotoxicity of a binder according to the invention was compared to a PUF binder. Each binder was diluted in a nutrient solution to various concentrations. These solutions were then used to grow cucumber plants. The results are shown below in Table 1.
  • the length of the first two leaves of the cucumber seedlings were measured.
  • the length of this leaf pair is called the cotyledon leaf length.
  • a reference without addition of binder was measured and set on 100%. If the added binder reduces the plant growth, the length of the leaf pair will be less, and the reduction in length is then calculated (see column growth inhibition).
  • the binder of the invention was made as follows:
  • the PUF binder was made as follows:
  • Primid XL552 has the following structure:
  • the binder of the invention performs slightly better compared to the PUF binder.
  • Product 1 MMVF growth substrate comprising 2.1 wt% formaldehyde-free binder according to the present invention; density of 76 kg/m 3 ; 3.5 litres/ton (0.15 wt%) of wetting agent (Texapon®).
  • the binder in this product was made as described above for Example 1.
  • Product 2 MMVF growth substrate comprising 2.1 wt% formaldehyde-free binder according to the present invention; density of 76 kg/m 3 ; no wetting agent.
  • the binder in this product is the same as described above for Product 1.
  • Comparative Product 1 MMVF growth substrate comprising 2.6 wt% PUF binder; density of 77 kg/m 3 ; 5.7 litres/ton of wetting agent (linear alkyl sulphonate). The binder in this product was made as described above in Example 1.
  • Comparative Product 2 MMVF growth substrate comprising 2.6 wt% PUF binder; density of 77 kg/m 3 ; 3.5 litres/ton of wetting agent (Texapon®).
  • the binder in this product is the same as described above for Comparative Product 1.
  • Comparative Product 3 MMVF growth substrate comprising 2.8 wt% formaldehyde-free binder; density of 78 kg/m 3 ; 6.7 litres/ton of wetting agent (linear alkyl sulphonate).
  • the binder in this product was made by reacting the following together:
  • the AAA resin was made as follows:
  • DEA diethanolamine
  • THPA tetrahydrophthalic anhydride
  • TMA trimellitic anhydride
  • Comparative Product 4 MMVF growth substrate comprising 2.8 wt% formaldehyde-free binder; density of 78 kg/m 3 ; 3.5 litres/ton of wetting agent (Texapon®).
  • the binder in this product is the same as described above for Comparative Product 3.
  • the initial deformation X 0 and the critical compressive strength ⁇ 0 and ⁇ e are not calculated. •
  • the EN standards for insulation materials require that the test specimens have to be stored and measured at (23 ⁇ 5)°C. In case of dispute, storage and measurement shall be carried out at (23 ⁇ 2)°C and (50 ⁇ 5)% R.H., as it is considered not having any influence on mineral wool.
  • the binder amount used in Products 1 and 2 of the invention is significantly lower than the amounts used in Comparative Products 1 to 4.
  • comparable compression results are seen when compared with the PUF binder and another formaldehyde-free binder. Therefore, using lower amounts of the binder of the invention, equivalent compression strength is achieved. It would be expected that increasing the binder amount of the invention to 2.8 wt% would result in improved compression strength.
  • having comparable compression results at lower amounts provides the added advantage of reducing the total amount of binder in the product.
  • WC -10 The content of water (in vol-%), after a fully saturated specimen has stabilized on an underpressure identical to a 10cm water column.
  • Re-saturation The content of water (in vol-%), after a 50 vol-% specimen has been re-saturated for 24 hrs in 0.5 cm water.
  • Water column the height of a water column, starting at the half of the thickness of the test specimen or block. Apparatus:
  • Used sand-type is typically sandblast quality (FEPA grade F100)
  • both Product 1 and Product 2 are significantly more wet compared to PUF containing products (Comparative Products 1 and 2).
  • the products of the invention show improved water retention in comparison with PUF binder, and comparable water retention in comparison to another formaldehyde-free binder.
  • Example 1 Six products as defined above under Example 1 were tested for water distribution over height. The results are shown in Figure 3. Water distribution was measured in accordance with the following method.
  • a binder as used in the growth substrate of the invention was prepared as follows:
  • a foam dampening agent (Skumdaemper 11-10 from NCA-Verodan ) is added. The temperature of the batch is maintained at 40°C.
  • AOL resin a binder was formulated by addition of 270 kg polyethylene glycol 200 and 433 kg of a 31% solution of Primid XL-552 in water.
  • Example IA – lignin oxidation in ammonia aqueous solution by hydrogen peroxide The amounts of ingredients used according to the example IA are provided in table IA 1.1 and IA 1.2. Although kraft lignin is soluble in water at relatively high pH, it is known that at certain weight percentage the viscosity of the solution will strongly increase. It is typically believed that the reason for the viscosity increase lies in a combination of strong hydrogen bonding and interactions of ⁇ -electrons of numerous aromatic rings present in lignin.
  • V ⁇ s and Vi s are endpoint volumes of a sample while V 2b and V 1b are the volume for the blank.
  • C acid is 0.1 M HCI in this case and m s is the weight of the sample.
  • Table IA4 The values obtained from aqueous titration before and after oxidation are shown in table IA4.
  • the average COOH functionality can also be quantified by a saponification value which represents the number of mg of KOH required to saponify 1 g lignin. Such a method can be found in AOCS Official Method Cd 3-25.
  • Average molecular weight was also determined before and after oxidation with a PSS PolarSil column (9:1 (v/v) dimethyl sulphoxide/water eluent with 0.05 M LiBr) and UV detector at 280nm. Combination of COOH concentration and average molecular weight also allowed calculating average carboxylic acid group content per lignin macromolecule and these results are shown in table IA5.
  • the first scale up step was done from 1 L (lab scale) to 9 L using a professional mixer in stainless steel with very efficient mechanical mixing
  • the next scale up step was done in a closed 200 L reactor with efficient water jacket and an efficient propeller stirrer.
  • the scale was this time 180 L and hydrogen peroxide was added in two steps with appr. 30 minute separation.
  • This up-scaling went relatively well, though quite some foaming was an issue partly due to the high degree reactor filling.
  • To control the foaming a small amount of food grade defoamer was sprayed on to the foam. Most importantly the temperature controllable and end temperatures below 70 °C were obtained using external water-cooling.
  • the pilot scale reactions were performed in an 800 L reactor with a water cooling jacket and a twin blade propeller stirring. 158 kg of lignin (UPM LignoBoost TM BioPiva 100) with a dry-matter content of 67 wt.-% was de-lumped and suspended in 224 kg of water and stirred to form a homogenous suspension. With continued stirring 103 kg of 25% ammonia in water was pumped into the reactor and stirred another 2 hours to from a dark viscous solution of lignin.
  • UPM LignoBoost TM BioPiva 100 UPM LignoBoost TM BioPiva 100
  • Table IA 5 Table IA 5. Number (Mn) and weight (Mw) average molar masses as determined by size exclusion chromatography expressed in g/mol together with average carboxylic acid group content per lignin macromolecule before and after oxidation
  • the content of each of the components in a given oxidised lignin solution is based on the anhydrous mass of the components or as stated below.
  • Kraft lignin was supplier by UPM as BioPiva100TM as dry powder.
  • NH 4 OH 25% was supplied by Sigma-Aldrich and used in supplied form.
  • H 2 O 2 , 30% was supplied by Sigma-Aldrich and used in supplied form or by dilution with water.
  • PEG 200 was supplied by Sigma-Aldrich and were assumed anhydrous for simplicity and used as such.
  • PVA Mw 89.000-98.000, Mw 85.000- 124.000, Mw 130.000, Mw 146.000-186.000
  • Cas no 9002-89-5 were supplied by Sigma-Aldrich and were assumed anhydrous for simplicity and used as such.
  • Urea (Cas no 57-13-6) was supplied by Sigma-Aldrich and used in supplied form or diluted with water.
  • Glycerol (Cas no 56-81-5) was supplied by Sigma-Aldrich and was assumed anhydrous for simplicity and used as such.
  • Oxidised lignin solids The content of the oxidised lignin after heating to 200 °C for 1h is termed “Dry solid matter” and stated as a percentage of remaining weight after the heating.
  • Disc-shaped stone wool samples (diameter: 5 cm; height 1 cm) were cut out of stone wool and heat-treated at 580 °C for at least 30 minutes to remove all organics.
  • the solids of the binder mixture were measured by distributing a sample of the binder mixture (approx. 2 g) onto a heat treated stone wool disc in a tin foil container. The weight of the tin foil container containing the stone wool disc was weighed before and directly after addition of the binder mixture. Two such binder mixture loaded stone wool discs in tin foil containers were produced and they were then heated at 200 °C for 1 hour. After cooling and storing at room temperature for 10 minutes, the samples were weighed and the dry solids matter was calculated as an average of the two results.
  • the change in COOH group content was also determined by aqueous titration and utilization of the following formula: Where V 2s and V 1s are endpoint volumes of a sample while V 2b and V 1b are the volume for a blank sample. C acid is 0.1 M HCI in this case and m s,g is the weight of the sample.
  • Method of producing an oxidised lignin 1) Water and lignin was mixed in a 3-necked glass bottomed flask at water bath at room temperature (20-25°C) during agitation connected with a condenser and a temperature logging device. Stirred for 1 h.
  • a Cavitron CD1000 rotor-stator device was used to carry out the mixing/oxidation step.
  • the rotor-stator device was run at 250 Hz (55 m/s circumferential speed) with a counter pressure at 2 bar.
  • the dwell time in the reaction tube was 3,2 minutes and in the reaction vessel 2 hours.
  • This premixture was then transferred to a static mixer and a mixer/heat- exchanger, where the oxidation was made by use of H2O2 (35 vol%). Dosage of the premixture was 600 l/h and the H2O2 was dosed at 17,2 l/h. The dwell time in the mixer/heat-exchanger was 20 minutes.
  • the temperature of the mixture increased during the oxidation step up to 95 °C.
  • the final product was analysed for the COOH group content, dry solid matter, pH, viscosity and remaining H2O2 .
  • a binder was made based on this AOL: 49,3 g AOL (19,0 % solids), 0,8 g primid XL552 (100 % solids) and 2,4 g PEG200 (100 % solids) were mixed with 0,8 g water to yield 19% solids; and then used for test of mechanical properties in bar tests.
  • the mechanical strength of the binders was tested in a bar test. For each binder, 16 bars were manufactured from a mixture of the binder and stone wool shots from the stone wool spinning production.
  • the aged bars as well as five unaged bars were broken in a 3 point bending test (test speed: 10.0 mm/min; rupture level: 50%; nominal strength: 30 N/mm 2 ; support distance: 40 mm; max deflection 20 mm; nominal e- module 10000 N/mm 2 ) on a Bent Tram machine to investigate their mechanical strengths.

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Abstract

La présente invention concerne un procédé de culture de plantes dans un produit à base d'un substrat de culture homogène, le procédé comprenant les étapes consistant à : utiliser au moins un produit à base d'un substrat de culture homogène comprenant des fibres vitreuses synthétiques liées à une composition de liant aqueuse durcie ; positionner un ou plusieurs semis, graines, boutures ou plantes en contact avec le produit à base de substrat de culture ; arroser le produit à base de substrat de culture. La composition de liant aqueuse comprend, avant durcissement : un composant (i) se présentant sous la forme d'une ou plusieurs lignines oxydées ;-un composant (ii) se présentant sous la forme d'un ou plusieurs agents de réticulation ; un composant (iii) se présentant sous la forme d'un ou plusieurs plastifiants.
EP20717173.7A 2020-04-03 2020-04-03 Procédé de culture de plantes Pending EP4126782A1 (fr)

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Publication number Priority date Publication date Assignee Title
NL1008041C2 (nl) 1998-01-16 1999-07-19 Tidis B V I O Toepassing van een wateroplosbaar bindmiddelsysteem voor de productie van glas- of steenwol.
JP4968993B2 (ja) 2000-09-28 2012-07-04 ユニチカ株式会社 ポリエステル樹脂水性分散体およびその製造方法
ATE301495T1 (de) 2001-08-29 2005-08-15 Cavitron V Hagen & Funke Gmbh Vorrichtung zur bearbeitung von materialien
EP1880596A1 (fr) 2006-07-20 2008-01-23 Rockwool International A/S Substrats de croissance, leurs production et leur utilisation
EP1880600A1 (fr) 2006-07-20 2008-01-23 Rockwool International A/S Substrats de croissance, leur production et leur utilisation
EP1880599A1 (fr) 2006-07-20 2008-01-23 Rockwool International A/S Substrats de croissance, leur production et leur utilisation
EP1880598A1 (fr) 2006-07-20 2008-01-23 Rockwool International A/S Substrats de croissance, leurs production et leur utilisation
EP1880597A1 (fr) 2006-07-20 2008-01-23 Rockwool International A/S Substrats de croissance, leur production et leur utilisation
EP1897433A1 (fr) * 2006-09-06 2008-03-12 Rockwool International A/S Composition aqueuse de liant pour fibres minérales
EP2080431A1 (fr) 2008-01-18 2009-07-22 Rockwool International A/S Procédé pour la culture de plantes
EP2143321A1 (fr) 2008-07-10 2010-01-13 Rockwool International A/S Procédé pour la culture de plantes
CA2725896C (fr) * 2009-12-30 2013-11-19 Rohm And Haas Company Liants a base de lignine carboxylee
FR2964012B1 (fr) 2010-08-31 2017-07-21 Rockwool Int Culture de plantes dans un substrat a base de laine minerale comprenant un liant
KR102037839B1 (ko) * 2015-05-20 2019-10-31 주식회사 케이씨씨 바인더 조성물 및 이를 사용하여 섬유상 재료를 결속하는 방법
CA3008961A1 (fr) 2015-12-29 2017-07-06 Rockwool International A/S Produit sous forme de substrat de croissance
EP3397044A1 (fr) 2015-12-29 2018-11-07 Rockwool International A/S Produit de type substrat de croissance
EP3632866A1 (fr) * 2018-10-05 2020-04-08 Rockwool International A/S Composition de liant aqueux

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CA3174400A1 (fr) 2021-10-07
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KR20220165259A (ko) 2022-12-14
CN115943129A (zh) 2023-04-07

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