WO2003000475A1 - Production d'un materiau composite a haute performance - Google Patents

Production d'un materiau composite a haute performance Download PDF

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Publication number
WO2003000475A1
WO2003000475A1 PCT/NZ2002/000088 NZ0200088W WO03000475A1 WO 2003000475 A1 WO2003000475 A1 WO 2003000475A1 NZ 0200088 W NZ0200088 W NZ 0200088W WO 03000475 A1 WO03000475 A1 WO 03000475A1
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WO
WIPO (PCT)
Prior art keywords
fibres
chemically modified
temperature
fractioned
curing
Prior art date
Application number
PCT/NZ2002/000088
Other languages
English (en)
Inventor
Deane William Smart
Michael Robert Reaburn
Donald John Jenkin
Sen Thin Chen
Xixian Deng, (Aka James)
Patrick Lyle Anthony
Original Assignee
Fletcher Building Products Limited
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 Fletcher Building Products Limited filed Critical Fletcher Building Products Limited
Publication of WO2003000475A1 publication Critical patent/WO2003000475A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off

Definitions

  • the present invention relates to the production of modified fibre and to the incorporation of the same fibre modification process into composite material production process to produce composite materials of enhanced character.
  • the present invention more particularly relates to processes for producing modified cellulosic fibres, processes for producing composite materials incorporating such fibres (eg; high performance with respect to dimensional stability and/or biodurability in the presence of moisture), methods for integrating the two aforementioned processes as one, products of either of the aforementioned processes and related methods, products and plant.
  • New Zealand Patent Specification 229080 of Convertech Group Limited discloses a process for preparing a hydrolysed lignocellulosic material which involves steam entrainment systems first to hydrolyse the lignocellulosic material (eg; wood chips) in conditions of elevated temperature and pressure conducive to hydrolysis at saturated steam conditions and thereafter, in a reduced pressure environment which gives rise to explosive disintegration (at least in part) of the hydrolysed matrix, to dry the entrained fibres in superheated steam conditions.
  • the treated material in a process analogous to that of Canadian Patent 1213711 of K Shen is thereafter capable of being pressed into a solid without a need for any added adhesive and/or binder.
  • Convertech conditions are more specifically disclosed in their New Zealand Patent Specification 248884.
  • NZ248854 there is disclosed a sequence of hydrolysis conditions, viz. (I) treatment at 24 bar (about 222°C), (ii) treatment at 35 bar (about 242°C) and (iii) at
  • Shell Internationale Research Maatschappij BV New Zealand Patent Specification No. 231798 discloses a process for rendering the cellulosic fibres of solid wood forms more moisture resistant. Such a procedure involves subjecting a light wood or the equivalent source of lignocellulosic material to first a softening stage and thereafter a curing stage.
  • the softening stage comprises exposing the discrete wooden masses to the action of an aqueous softening agent (eg; water and/or steam) at a temperature in the range of from 150°C to 220°C and at a pressure of at least the equilibrium vapour pressure of the softening agent at the operating temperature thereby at least partially disproportionating and hydrolysing the hemicellulose and lignin present in the cellulosic starting material.
  • the curing stage comprises drying the product of the softening stage at a temperature in the range of from 100°C to 220 °C to yield a cross linked cellulosic masses each still in the general form of the initial wooden masses.
  • the Shell process of NZ 231798 has a characteristic in that if the starting material is green sections of wood ranging in length from 25 to 65 cm and with a width (diameter in the case of branches) ranging from 3 to 12 cm the resultant products correspond to those shapes.
  • Such treated sections can be used as the aggregate.
  • Shell NZ 231798 discloses also the use of the output material in a lamination process to provide (by aggregation using appropriate adhesive) larger aggregate material.
  • Shell NZ 231798 is a prospect of incorporating into the aggregate, either during its formation or after, one or more monomers and, if necessary, one or more polymerisation catalysts. It is stated that the monomer is preferably incorporated during formation of the aggregate before the curing stage and that the aggregate is then subjected to conditions under which polymerisation of the monomer occurs. Particularly preferred monomers for inclusion in the aggregate are those which, when added during the process before the final curing stage, polymerise at the conditions prevailing in the curing stage either by themselves or by the addition of one or more polymerisation catalysts or temperature sensitive polymerisation starters. Examples disclosed are styrene and low molecular weight epoxy compounds.
  • Shell NZ 231798 is a preference to conduct both the softening and curing stage under an inert or substantially inert atmosphere, ie; one from which all or a substantial portion of the air has been displaced.
  • New Zealand Patent Specification No.329324 of Plato Beheer B.V. takes the technology of Shell NZ 231798 further in that the heat input to the softening stage is stated as being as a result of heat exchange contact from an aqueous steam, the initial temperature of which is substantially equal to the operating temperature of the softening agent, eg; 150 to 220°C (more preferably 160 to 200 °C). Again however discreet end materials corresponding to the discreet input materials results from the operation of the process.
  • Objects of the present invention include the provision of processes for treating lignocellulosic material (such as wood chips or other lignocellulosic furnish) which will generate as a preliminary product chemically modified fibres capable of subsequent reduction to individual fibres and heat curing or to provide in an overall process for providing a fibre including composite material fibres therein ensuring high performance of the composite material insofar as dimensional stability is concerned in the presence of moisture and/or biodurability as a result of either a property use of such chemically modified fibres or the integration of the processes aforesaid.
  • lignocellulosic material such as wood chips or other lignocellulosic furnish
  • form forming methodologies e.g. panels, mouldings, etc
  • MDF medium density fibre board
  • modified or adjusted plant eg a modified or adjusted MDF plant
  • intermediate and end point products resulting from such other objects are to provide chemically modified fibres and/or high performance composite materials embodying such modified fibres having characteristics determinable by reference to the products of the process of the present invention.
  • the present invention consists in a process for producing a chemically modified fibrous material from masses of lignocellulosic material, said process comprising or including subjecting the masses (whether after an optional pretreatment or not) to an aqueous environment at elevated temperature(s) and elevated pressure(s) to chemically modify or lead to chemical modification, at least in part (eg by thermohydrolysis), the lignocellulosic material masses, mechanically reducing the thus treated masses to individual fibres and/or smaller accumulations of fibres, and drying the mechanically reduced materials.
  • the drying may be above ambient temperature(s). Such temperature(s) [ideally less than 100°C] should not be sufficient high to cure the fibres.
  • the aqueous environment treatment is a softening procedure associated it is believed with at least partial thermal hydrolysis of some of the hydrolysable material thereof.
  • thermal hydrolysis and “thermohydrolysis” should be construed as meaning hydrolysis at elevated temperature.
  • Such a procedure it is believed leads to a chemical breaking down of the hemicellulose and/or lignin of the input lignocellulosic masses sufficient to enable the resultant material once dried sufficiently to be heat cured to provide cellulose having fewer sites for bound water.
  • the term "cured” therefore takes the appropriate meaning(s) .
  • the term "chemically modify” in respect of the precured fibres or “chemically modified fibres” prior to curing thereof means that complete or those still ensuing change(s) to the cellulosic fibres insofar as at least the associated hemicellulose(s) and/or lignin(s) thereof are (is) concerned, such change(s) meaning that subsequently when taken in non aqueous conditions to a sufficiently high temperature for curing to ensure, there is a reformation which results in fewer sites on the cellulose for binding moisture. Subsequently presented thereto.
  • the term “fraction” or “fractioned” in respect of such changed takes any appropriate meaning.
  • stable and “stability” as used herein refers to dimensional stability under fluctuating moisture or humidity conditions.
  • aqueous environment is a steam environment (i.e. rather than a water environment).
  • said aqueous environment is at a temperature in the range of from 165 to 200°C.
  • the elevated pressure(s) is such as to provide saturated steam conditions at said preferred elevated temperature(s).
  • said masses are subjected to thermohydrolysis conditions over a time period of from 3 to 20 minutes.
  • Preferably optional pretreatment occurs.
  • Preferably said pretreatment comprises or includes pre-steaming at ambient pressure conditions.
  • said pre-steaming is for a time less than 40 minutes and is at a temperature above ambient conditions but not exceeding 165 °C.
  • said pre-steaming is to a temperature in the range from ambient conditions to 100° C (inclusive).
  • said masses of lignocellulosic material are woodchips.
  • Other masses include saw dust, sawmill residues, flax, hemp, etc.
  • said woodchips have a moisture content of from 12 to 180% (on a dry material basis, ie; OD).
  • said input masses are woodchips typically of a size no greater than about 25 x about 20 x about 5 mm.
  • thermohydrolysis is performed in a continuous or batch digester into which the masses are introduced.
  • said mechanical reduction is performed at least in part in a steam environment.
  • said mechanical reduction is performed using a refiner, eg; a Sunds L44 defibrator.
  • a refiner eg; a Sunds L44 defibrator.
  • said mechanical reduction reduces the material to fibres of length from 0.5 to 3.0 mm.
  • drying is conducted using a cocurrent airflow the input air being above 100°C and the output being below 100°C.
  • the drying is such that the chemically modified fibres preferably do not reach a temperature beyond that at which the fractioned hemicellulose and lignin chemically modified fibres prematurely cure e.g. not beyond 100°C.
  • the time under the drying conditions is less than 20 seconds and most preferably less than 10 seconds (eg; from 3 to 6 seconds).
  • a wax e.g. paraffin
  • a 50 to 70°C melting range used in a rate of from 0 to 2% by weight (OD-ovendry basis) of the modified fibres (e.g. more preferably
  • the wax may be incorporated molten or emulsified e.g. in an aqueous carrier.
  • the present invention consists in the fibrous material produced by such a process.
  • the present invention consists in the use of the fibrous material as aforesaid in a downstream procedure whereby, in conjunction with appropriate binders and/or adhesives, a composite material is manufactured, eg; using hot pressing and hot curing.
  • the present invention consists in a method for providing composite material forms which method comprises or includes subjecting individual masses of lignocellulosic material (whether after an optional pretreatment or not) to an aqueous environment at elevated temperature(s) and elevated pressure(s) to chemically modify or lead to chemical modification of, at least in part, (eg by thermohydrolysis) the lignocellulosic material masses, thereby at least partially fractioning and at least partially hydrolysing the hemicellulose and lignin present, mechanically reducing the thus treated masses to individual fibres and/or smaller accumulations of fibres, drying the mechanically reduced materials at a temperature or temperatures insufficient to cure the (at least part) fractioned and/or hydrolysed hemicellulose and the fractioned and/or hydrolysed lignin,
  • thermoset curable adhesive and/or binder material(s) with the individual fibres and/or smaller accumulations of fibres, preparing an accumulation of the individual fibres and/or smaller accumulations of fibres and the associated adhesive and/or binder material(s) for pressing, hot pressing to a form the thus accumulated material at an elevated temperature or temperatures above that or those of the drying step sufficient to (i) at least initiate the thermoset cure of the adhesive and/or binder material(s), and (ii) initiate the cure of the fractioned and/or hydrolysed hemicellulose and the fractioned and/or hydrolysed lignin, and holding the still hot pressed form [preferably in an environment low in oxygen] for a period where the material of the form is still above ambient temperature sufficient to allow the curing of the fractioned and/or hydrolysed hemicellulose and the fractioned and/or hydrolysed lignin.
  • said aqueous environment is a steam environment.
  • said aqueous environment is at a temperature in the range of from 165 to 200°C.
  • the elevated pressure(s) is such as to provide thermohydrolysis conditions at saturated steam conditions at said preferred elevated temperature(s).
  • said subjection to at least some thermohydrolysis is over a time period of from 3 to 20 minutes.
  • Preferably optional pretreatment occurs.
  • Preferably said pretreatment comprises or includes pre-steaming at ambient pressure conditions.
  • Preferably said pre-steaming is for a time less than 40 minutes and is at a temperature above ambient conditions but not exceeding 165 °C.
  • pre-steaming is to a temperature in the range from ambient conditions to 100°C (inclusive).
  • masses of lignocellulosic material are woodchips.
  • said woodchips have a moisture content of from 12 to 180% (on a dry material basis, ie; OD).
  • said input masses are woodchips typically of a size no greater than about 25 x about 20 x about 5 mm.
  • said aqueous environment treatment and/or thermohydrolysis is performed in a batch or continuous digester into which the masses are introduced.
  • said mechanical reduction is performed at least in part in a steam environment.
  • said mechanical reduction is performed using a refiner, eg; a defibrator such as the Sunds L44.
  • a refiner eg; a defibrator such as the Sunds L44.
  • said mechanical reduction reduces the material to chemically modified fibres of length from 0.5 to 3mm.
  • drying is conducted using a cocurrent airflow the input air being above 100°C and the output being below 100°C.
  • the drying is such that the modified fibres and/or any of the adhesive/binder system preferably do not reach a temperature beyond 100°C.
  • the time under the drying conditions is less than 20 seconds and most preferably less than 10 seconds (eg; from 3 to 6 seconds).
  • the adhesive and/or binder material(s) is added prior to or subsequent to the drying.
  • said adhesive and/or binder material(s) is added in a blow line which conveys the individual chemically modified fibres and/or smaller accumulations of chemically modified fibres to the dryer.
  • the adhesive and/or binder material(s) is selected from urea formaldehyde, melamine urea formaldehyde, melamine formaldehyde and phenol formaldehyde and isocyanate systems or any combination thereof.
  • Preferably said preparing of an accumulation of the fibres is the preparation of a so called "mattress" form to be subsequently hot pressed.
  • said hot pressing is at a temperature greater than 105 °C.
  • said hot pressing is in a single daylight, multi daylight (ie; multi panel forming) or continuous hot press.
  • the adhesive system comprises on a weight to weight basis from 5 to 30 % (more preferably 5 to 25%) of the dry modified fibre weight.
  • a particularly preferred adhesive/binder system is of phenol formaldehyde and/or phenol urea formaldehyde (available from Dynea NZ Limited) and which is preferably used in the range of from 8 to 18% weight of modified dry fibres.
  • a wax e.g. paraffin
  • a 50 to 70°C melting range used in a rate of from 0 to 2% by weight (OD) of the chemically modified fibres (e.g. more preferably MP of 50 to 55 °C and a rate of 0.5 to 1% by weight of the chemically modified fibres).
  • OD e.g. more preferably MP of 50 to 55 °C and a rate of 0.5 to 1% by weight of the chemically modified fibres.
  • the wax may be incorporated molten or emulsified e.g. in an aqueous carrier.
  • the pressed form from the hot press without any substantial cooling enters or is in a curing zone to reduce temperature loss [and preferably also access of oxygen] (eg; 200°C to ambient for up to 7 days).
  • any such curing zone there is preferably insulation about the form.
  • oxygen access to any part of any panel or other form in the cure zone is reduced.
  • the cure zone input temperature is from 75°C to 180°C and after a cure zone hold period of from at least 1 hour to 7 days the temperature is still above 55°C.
  • Preferred for pinus radiata is from 97°C to 108°C for 24 hours.
  • the present invention consists in a method of providing a composite material forms which comprises or includes associating dried mechanically reduced individual chemically modified fibres and/or smaller accumulations of chemically modified fibres that have been prepared by a process as previously defined for producing a fibrous material from masses of lignocellulosic material with an appropriate thermoset curable adhesive and/or binder material(s), preparing an accumulation of such chemically modified fibres with the associated adhesive and/or binder material(s) for pressing, hot pressing the thus accumulated material to the form(s) at an elevated temperature sufficient to at least initiate the thermoset cure of the adhesive and/or binder material(s) and to encourage at least the initiation of the cure of the fractioned hemicellulose and lignin of such chemically modified fibres, and holding the still hot pressed form or forms in a cure zone [preferably in an environment low in oxygen] for a period where the material of the form(s) is still above ambient temperature sufficient to allow curing or further curing of the chemically modified fibres.
  • the cure zone input temperature is from 75°C to 180°C and still in that range after a cure zone hold period of from at least 1 hour.
  • Preferred for pinus radiata is from 97 °C to 108°C for 24 hours. Preferably the temperature is still above 55°C at 7 days.
  • Preferably said preparing of an accumulation of the chemically modified fibres is the preparation of a so called "mattress" form to be subsequently hot pressed (whether initially in discrete mattresses or as a continuous mattress).
  • the adhesive and/or binder material(s) is selected from urea formaldehyde, melamine urea formaldehyde, melamine formaldehyde and phenol formaldehyde and isocyanate systems or any combination thereof.
  • the adhesive system comprises on a weight to weight basis from 5 to 30 % (more preferably 5 to 25%) of the dry modified fibre weight.
  • a particularly preferred adhesive/binder system is of phenol formaldehyde and/or phenol urea formaldehyde (available from Dynea NZ Limited) and which is preferably used in the range of from 8 to 18% weight of modified dry fibres.
  • said hot pressing is at a temperature greater than 105°C.
  • said hot pressing is in a multi daylight (ie; multi panel forming) or continuous hot press.
  • any such curing zone there is preferably insulation provided for the curing form or forms.
  • oxygen access to any part of any panel or other form in the curing zone is reduced.
  • the present invention consists in a composite material provided by any of the methods previously defined.
  • the present invention consists in a panel form prepared by a process as previously described.
  • the present invention consists in a method for providing composite material which comprises or includes subjecting individual masses of woodchips (preferably after free steam pretreatment prior to digester entry) to an aqueous environment in a (batch or continuous) digester at elevated temperature(s) in the range 165 °C to 200 °C to modify or lead to chemical modification of the hemicellulose and/or lignin or fibres thereof ("the chemically modified fibres"), mechanically reducing the thus treated masses thereof in a refiner to individual chemically modified fibres and/or smaller accumulations of chemically modified fibres, air drying the mechanically reduced materials, at temperature(s) insufficient to cure the fractioned and/or hydrolysed hemicellulose and the fractioned and/or hydrolysed lignin, before, during and/or after the air drying associating suitable thermoset curable adhesive and/or binder material(s) with the chemically modified fibres
  • the maintaining step may be in an environment low in ambient oxygen for (all or some of) each form.
  • said form(s) is(are) that of a panel or panels.
  • the operating conditions are any one or more of those previously disclosed.
  • the present invention consists in an MDF plant at least in part modified to perform any of the processes of the present invention.
  • the present invention consists in apparatus for performing a method for providing composite material (which method comprises or includes subjecting individual masses of woodchips to an aqueous environment in a digester at elevated temperature(s) in the range 165 ° C to 200 ° C, mechanically reducing the at least partially modified masses in a refiner to individual chemically modified fibres and/or smaller accumulations of chemically modified fibres, air drying the mechanically reduced materials, before, during and/or after the air drying associating suitable thermoset curable adhesive and/or binder material(s) with the fibres, preparing mattress accumulations of the chemically modified fibres and the associated adhesive and/or binder material(s), hot pressing the mattress accumulations to their pressed form(s) at an elevated temperature sufficient to at least initiate the thermoset cure of the adhesive and/or binder material(s), and to at least initiate curing of the fractioned and/or hydrolysed hemicellulose and the fractioned and/or hydrolysed lignin, and maintaining the pressed form(s)
  • defibrator to receive the solids stream from the digester for mechanically reducing the at least partially thermohydrolysed masses to individual chemically modified fibres and/or smaller accumulations of chemically modified fibres
  • a drier for air drying the mechanically reduced materials at temperature(s) insufficient to cure the fractioned and/or hydrolysed hemicellulose and the fractioned and/or hydrolysed lignin
  • mixing apparatus or mixing means for associating suitable thermoset curable adhesive and/or binder material(s) with the chemically modified fibres before, during and/or after the drying
  • mattress forming apparatus for preparing a mattress or mattress accumulations of the chemically modified fibres and the associated adhesive and/or binder material(s)
  • pressing apparatus for hot pressing the mattress or mattress accumulations or divisions thereof to their pressed form(s) at an elevated temperature sufficient to at least initiate the thermoset cure of the adhesive and/or binder material(s) and at least sufficient to initiate the cure of the fractioned and/or hydrolysed hemicellulose
  • said apparatus includes apparatus to heat and moisten the woodchips prior to digester entry using live steam.
  • thermohydrolysis is performed at substantially saturated steam conditions.
  • a blow-line transports the fibres to the drier from the refiner (e.g. a defibrator).
  • the refiner e.g. a defibrator
  • An example of a dryer is a dryer with a SKKV furnace or a FLAKT drier.
  • the mixing apparatus comprises the addition of the adhesive and/or binder material(s) into the process in such blow-line, (ie; prior to the drier) preferably using input nozzles.
  • a pre-press apparatus is provided for pre-pressing and thus degassing the formed mattresses for hot pressing.
  • said hot press is any one of a single opening hot press, a multi daylight hot press (ie; can provide pressing one mattress above the other without adhesion one to the other) or continuous.
  • the curing zone is zone where the forms can be congregated.
  • the present invention consists in apparatus for providing a composite material, said apparatus comprising or including apparatus or means to receive material of a chemically modified fibrous nature prepared by a process whereby masses of lignocellulosic material have been subjected to
  • a pre-press apparatus is provided for pre-pressing the formed mattresses for mattress feed to the hot press. This preferably degasses the material.
  • said hot press is any one of a single opening hot press, a multi daylight hot press (ie; can provide pressing one mattress above the other without adhesion one to the other) or continuous.
  • the means providing the curing zone allows forms to be congregated and preferably there is means provided or techniques can be used (whether with or without gas flushing and/or evacuation) whereby at least in part said environment low in oxygen.
  • said curing zone is thermally insulated (optionally where necessary with optional heat exchange).
  • the curing zone input temperature is from 75°C to 180°C and after a curing zone hold period of from at least 1 hour.
  • the temperature is still above 55°C at 7 days.
  • the present invention consists in panels formed from a thermoset of wood fibres that have been subject to any one of the processes of the present invention and/or operatively using apparatus as hereinbefore described.
  • Figure 1 is prior art MDF apparatus of a Sunds MDF process flowline
  • Figure 2 is Figure 19.5 from MODERN PARTICLE BOARD and DRY-PROCESS FIBREBOARD MANUFACTURING by Thomas M Maloney which shows a flow diagram of a European MDF plant (Wiecke 1990).
  • Figure 3 shows a process in accordance with the present invention for providing a composite material in a board form
  • Figure 4 is a process for producing substantially dry chemically modified fibres or chemically modified fibre accumulations for subsequent use or useful for subsequent use to provide a composite material including such chemically modified fibres or chemically modified fibre accumulations or both,
  • FIG. 5 is a more detailed flow diagram showing a full process to (by way of example) a board form (eg; useful as exterior furniture grade panels or internal and/or external wall panels [whether to provide horizontal, vertical or other surfaces] and/or as exterior cladding) that best makes the use of converted plant from an MDF manufacturing plant of a kind typically available and which provides the option of providing a process from the initial input lignocellulosic material masses fully through to the cured forms (eg; panels or other moulded forms) or to chemically modified fibres or chemically modified fibre accumulations in their dry post aqueous treatment state which can subsequently be used by third parties (if desired) or by the same plant operator as a midway input material, and
  • a board form eg; useful as exterior furniture grade panels or internal and/or external wall panels [whether to provide horizontal, vertical or other surfaces] and/or as exterior cladding
  • Figure 6 is a flow diagram commencing as in Figure 5 but showing how, if desired, the air dried chemically modified fibres can be subjected to heating and a fibre curing process (for example in an appropriate oven) to thereby provide already cured fibres or fibre accumulations that have reduced water binding sites for subsequently presenting moisture and how, if desired, such product can be used at a same plant or different plants, figure 6 also giving examples of three (A, B and C) of many options available for the usage of such cured chemically modified fibres, option A showing how as a variation of the downstream procedure at the top of bottom of Figure 5 and adhesive and/or bind it systems with appropriate hot pressing or other arrangements (no longer essential for curing the chemically modified fibres) can be used to form a composite product such as automobile doors or other components, showing also how such cured chemically modified fibres can be combined with appropriate cementitious materials to form by way of example more stable fibre reinforced cementitious panels or board, and showing how if desired such cured chemically modified fibres can be combined with gy
  • Figure 7 shows the effect varying the thermo hydrolysis time, the pressure of the hydrolysis zone (and thus the temperature of substantially saturated steam condition(s) of the thermo hydrolysis zone) and cure zone at 20 °C for pinus radiata input as described hereafter when rated by a 24 hour thickness swell of panels of the form hereafter described
  • Figure 8 similar to Figure 7 shows such effects on the same materials that the same parameters (but this time at a temperature of 105°C in the curing zone) has on the 24 hour thickness swell of the same panel types
  • Figure 9 in a manner similar to Figures 7 and 8 show for a higher temperature (180°C in the curing zone rather than the 105°C of Figure 8) similar results expressed in 24 hours thickness swell for the same panel types.
  • the present invention will be described with respect to panel or board forms having improved stability with respect to dimension in the presence of moisture than would be the case were the same adhesive and/or binder system utilised with raw wood fibre such as that traditionally used without high cost acetylation in, for example, an MDF plant. It is also believed to provide better biodurality (e.g. against fungal and/or insect challenge) because of its lower equilibrium moisture content. Whilst reference is made to MDF, of course the system of the present invention lends itself to other panel or form forming technologies.
  • the apparatus is deployed so that, preferably with little in the way of expensive change, plant available for general MDF production can be retrofitted or reused for the production of moisture stabilised forms (particularly panels and/or boards - "boards" being used herein as being inclusive of panel forms and irrespective of whether or not of constant thickness).
  • FIG. 3 there is shown the use of a refiner such as Sunds Defibrator L44.
  • the output from this refiner is shown as going to two possibilities.
  • One is to the production of a dry fibre (eg; less than or equal to about 8% moisture content OD) that can be dealt with as a commodity (eg for preparing fibrocement products moulded packaging components, moulded automobile components etc) or as a retained product which might subsequently be reintroduced into the process (or a modification of the process if the fibres are already heat cured) should that at any stage prove desirable which may be the case where, for example, there is a desire to provide preventative maintenance to upstream plant components yet still run downstream plant components.
  • a dry fibre eg; less than or equal to about 8% moisture content OD
  • a commodity eg for preparing fibrocement products moulded packaging components, moulded automobile components etc
  • a retained product which might subsequently be reintroduced into the process (
  • lignocellulosic material can be provided as the feed material and each will have desired perimeters of hydrolysis for best usage downstream.
  • Options of sources of such materials include woodchips from tree stems, branch of trees, mill wastes (whether a sawmill or otherwise eg. sawdust) and the species of tree need not be restricted to soft wood conifers nor to conifers at all.
  • non conifer species that might be utilised wasted lignocellulosic materials from for example rubber plantations in for example Malaysia if broken down to appropriate masses for treatment could provide an excellent furnish.
  • Other harder wood species can be utilised.
  • the masses referred to are preferably those above woodchips but could by way of example include sawdust or wood shavings or strands such as might be used in particle board or oriented strand board.
  • the degree of mechanical reduction of the chemically modified fibres will vary. However there is nothing to prevent the mechanical reduction of masses of lignocellulosic materials to themselves favour the preparation of strands of the already chemically modified fibre masses to a form suitable for oriented strand board. There is also no reason why sawdust or smaller particles can not be offered in as furnish in conjunction with larger masses which will require mechanical reduction.
  • the feedstock materials is a source of lignocellulosic masses preferably in the form of woodchips.
  • such chips are from a conifer.
  • a conifer is a soft wood conifer such as that typified by pinus radiata.
  • the wood source extends at least to other choices of softwood pine (eg; Loblolly et al.) and to firs (eg. Douglas Fir).
  • chips of a conifer up to a maximum dimension of about 50 mm and preferably about 25mm only are used as the source lignocellulosic material.
  • the input chips are most preferably of a kind generally of a dimension of about 25 x 20 x 5 mm.
  • the moisture content of the input chips ranges from 12 to 180% OD.
  • the temperature of the chips eg; 75 °C to 95 °C
  • an optional pre- steaming step is provided whereby in an appropriate hopper or bin live steam at ambient pressures is played through the accumulated chips for a period of less than 40 minutes thereby raising the temperature of the chips above ambient but not above 100°C.
  • Upon entry into the digester preferably a gravity feed or a screw feed
  • an infeed temperature of 75 °C to 95 °C preferably a higher temperature environment of 165° to 200° is provided.
  • thermohydrolyse the preheated chips in about saturated steam conditions for a period of 3 to 20 minutes to fraction and/or hydrolyse the hemicelluloses and/or lignins.
  • a typical MDF type digester (modified to higher pressure and residence time if required) can be used as the digester.
  • the solids stream of at least partly thermohydrolysed masses is then fed to a refiner such as a defibrator typically used in an MDF plant, eg; Sunds L44 defibrator.
  • a refiner such as a defibrator typically used in an MDF plant, eg; Sunds L44 defibrator.
  • the masses are mechanically reduced to individual or small accumulations of fibre relative to the greater masses of any such accumulations provided in the input material.
  • the material preferably is past by a blowline into a continuous cocurrent suspension air drier where over a period of from 3 to 6 seconds the fibrous material is lowered in temperature significantly from an input temperature which may be up tp 200 °C (eg; about
  • a typical output temperature of such fibres or fibre accumulations is less than 100°C and may be, for example, about 65 °C.
  • thermoset adhesive binder materials such as those previously exemplified are added to the chemically modified fibres in the blowline or a blender and/or subsequent to the air drier (in a blender). At this stage other functional inclusions (eg; fungicides and insecticides can be added).
  • a wax to act as a sizing agent is added (preferably as a melt or as an aqueous suspension or other suspension).
  • the blended material is formed as a mattress form to a much greater thickness than that required in the resultant composite board.
  • That mattress form is then subjected to pre-pressing to degas the material prior to passing into a hot press which, for example, for already discreet mattress forms that have been subjected to pre-pressing is preferably of the multi daylight type that can receive accumulations thereof one above the other (but preferably spaced apart for pressing) at a temperature greater than ambient and (preferably a temperature of from 135 °C to 210°C) which is sufficiently hot and for sufficiently long to ensure at least the commencement of the curing of the fractioned hemicelluloses and/or fractioned lignins and to at least initiate the thermoset cure the adhesive/binder system.
  • the curing zone preferably excludes some if not all ambient gaseous oxygen.
  • a low pressure can be drawn about the forms to remove any gases being generated and/or to maintain a oxygen low status against ambient air infusion.
  • the curing zone is such that the temperature regime previously described is maintained for a period of up to 7 days (but could be longer). At least 1 hour at or near the pressing temperature is desirable to allow the appropriate curing.
  • a corresponding system is preferably utilised optionally with pre-pressing for any recommencement of the composite board forming procedure whether carried out at the same plant or by a customer of the treated fibre feedstock.
  • Radiata pine green chip typically used in an MDF plant was used as raw material. It originated from Kaingaroa Forest. The moisture content was about 134% (OD basis) with screen size distribution as in Table 1.
  • the chip was thermohydrolysed in conditions shown on the bottom axis of each of the plots of Figures 7, 8 and 9.
  • the resin loading was 10% w/w and wax 0.5% w/w (solid content based on dry fibre).
  • the resin/wax associated chemically modified fibres were then dried through a drier with an inlet temperature of 150°C and outlet temperature about 100°C.
  • the resinated fibres were formed into a mat and hot pressed into a 13.5 mm panel.
  • the panels were pressed at 175°C using a press cycle time of 220 seconds.
  • the density of the panel was 750 kg/m3.
  • the panel was immediately stored for 24 hours at the temperatures of 20°C, 105°C and 180°C.
  • Such curing condition(s) were with or without exposure to substantial quantities of ambient oxygen.
  • Table 2 shows enhanced biodurability arising from the use of the process with Pinus
  • Table 3 shows thickness swell of MDF lab panels that were prepared using different wood species at the preparative conditions expressed.
  • Optimisation of a hardwood species will involve digester temperatures below (eg; about 10°C less) those for softwood species (eg; the conifers referred to in Table 3).

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Reinforced Plastic Materials (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

La présente invention concerne la production d'un matériau composite dans laquelle des copeaux de bois (qui ont éventuellement subi un traitement préalable d'étuvage) sont soumis à une thermohydrolyse dans un digesteur du type à fibres de densité moyenne (FDM) à des températures élevées; les copeaux de bois ainsi traités sont ensuite réduits mécaniquement, dans un raffineur, en amas plus petits de fibres chimiquement modifiées; les matières réduites mécaniquement sont ensuite séchées à l'air à des température insuffisantes pour traiter/durcir l'hémicellulose fractionnée et/ou hydrolysée et la lignine fractionnée et/ou hydrolysée, une ou plusieurs matières de liant thermodurcissable durci étant associées aux fibres chimiquement modifiées (avant, pendant et/ou après le séchage); des accumulations sous forme de mats de fibres chimiquement modifiées et des matières de liant associées sont ensuite préparées, ces accumulations de mats étant ensuite pressées à chaud pour présenter leurs formes pressées, à des températures élevées suffisantes pour au moins commencer le thermodurcissement des matières de liant et pour au moins commencer le durcissement de l'hémicellulose et de la lignine fractionnée et/ou hydrolysée; puis lesdites formes pressées sont maintenues à une température supérieure à la température ambiante pendant une durée suffisante pour assurer le durcissement ou un autre traitement de l'hémicellulose et de la lignine fractionnée et/ou hydrolysée des fibres chimiquement modifiées.
PCT/NZ2002/000088 2001-05-09 2002-05-07 Production d'un materiau composite a haute performance WO2003000475A1 (fr)

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NZ51160701A NZ511607A (en) 2001-05-09 2001-05-09 High performance composite material production

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1022548C2 (nl) * 2003-01-31 2004-08-03 Plato Internat Technology B V Werkwijze voor het veredelen van houtdelen.
WO2004106632A1 (fr) * 2003-05-21 2004-12-09 Masonite Corporation Systeme de separation de vapeur de raffineur pour une reduction d'emissions de dispositif de sechage
EP1806213A1 (fr) * 2005-12-27 2007-07-11 Jakob Friederich Werz Procédé d'imprégnation de copeaux de bois
EP1968775A1 (fr) * 2005-12-22 2008-09-17 New Zealand Forest Research Institute Limited Procede pour la production de produits composites de fibre de bois
WO2009122018A2 (fr) * 2008-04-02 2009-10-08 Hannu Ilvesniemi Procédé pour traiter de la biomasse
EP2181818A2 (fr) * 2008-10-28 2010-05-05 IHD Institut für Holztechnologie Dresden gGmbH Procédé de fabrication de matières premières en fibres de bois et matières premières en fibres de bois ayant des émissions réduites en VOC volatiles
EP2450168A1 (fr) * 2007-05-30 2012-05-09 Fujitsu Limited Procédé de fabrication de produit moulé par compression utilisant un matériau de plante
WO2013045551A1 (fr) * 2011-09-28 2013-04-04 Titan Wood Limited Panneaux de plaque de fibres de moyenne densité

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CN106182284A (zh) * 2016-07-11 2016-12-07 中国林业科学研究院木材工业研究所 微波处理材染色装饰薄木及其制备方法

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US5017319A (en) * 1984-03-30 1991-05-21 Shen Kuo C Method of making composite products from lignocellulosic materials
US5656129A (en) * 1995-05-31 1997-08-12 Masonite Corporation Method of producing fibers from a straw and board products made therefrom
DE19858079A1 (de) * 1998-12-16 2000-06-21 Edmone Roffael Verfahren zur Herstellung von mitteldichten Faserplatten (MDF) mit niedriger Dickenquellung und Wasseraufnahme
US6174485B1 (en) * 1996-12-09 2001-01-16 Plato Beheer B.V. Process for preparing cellulosic fibrous aggregates

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US5017319A (en) * 1984-03-30 1991-05-21 Shen Kuo C Method of making composite products from lignocellulosic materials
US5656129A (en) * 1995-05-31 1997-08-12 Masonite Corporation Method of producing fibers from a straw and board products made therefrom
US6174485B1 (en) * 1996-12-09 2001-01-16 Plato Beheer B.V. Process for preparing cellulosic fibrous aggregates
DE19858079A1 (de) * 1998-12-16 2000-06-21 Edmone Roffael Verfahren zur Herstellung von mitteldichten Faserplatten (MDF) mit niedriger Dickenquellung und Wasseraufnahme

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1022548C2 (nl) * 2003-01-31 2004-08-03 Plato Internat Technology B V Werkwijze voor het veredelen van houtdelen.
WO2004067240A1 (fr) * 2003-01-31 2004-08-12 Plato International Technology B.V. Procede de traitement de pieces en bois
WO2004106632A1 (fr) * 2003-05-21 2004-12-09 Masonite Corporation Systeme de separation de vapeur de raffineur pour une reduction d'emissions de dispositif de sechage
US7368037B2 (en) 2003-05-21 2008-05-06 Masonite Corporation Refiner steam separation system for reduction of dryer emissions
EP1968775A1 (fr) * 2005-12-22 2008-09-17 New Zealand Forest Research Institute Limited Procede pour la production de produits composites de fibre de bois
EP1968775A4 (fr) * 2005-12-22 2012-11-14 New Zealand Forest Res Inst Ltd Procede pour la production de produits composites de fibre de bois
EP1806213A1 (fr) * 2005-12-27 2007-07-11 Jakob Friederich Werz Procédé d'imprégnation de copeaux de bois
US8262960B2 (en) 2007-05-30 2012-09-11 Fujitsu Limited Compression-molded product using plant material and method for manufacturing the same
EP2450168A1 (fr) * 2007-05-30 2012-05-09 Fujitsu Limited Procédé de fabrication de produit moulé par compression utilisant un matériau de plante
JP2011523349A (ja) * 2008-04-02 2011-08-11 イルヴェスニーミ ハンヌ バイオマスの処理方法
WO2009122018A3 (fr) * 2008-04-02 2009-12-23 Hannu Ilvesniemi Procédé pour traiter de la biomasse
WO2009122018A2 (fr) * 2008-04-02 2009-10-08 Hannu Ilvesniemi Procédé pour traiter de la biomasse
EP2181818A2 (fr) * 2008-10-28 2010-05-05 IHD Institut für Holztechnologie Dresden gGmbH Procédé de fabrication de matières premières en fibres de bois et matières premières en fibres de bois ayant des émissions réduites en VOC volatiles
EP2181818A3 (fr) * 2008-10-28 2012-08-22 IHD Institut für Holztechnologie Dresden gGmbH Procédé de fabrication de matières premières en fibres de bois et matières premières en fibres de bois ayant des émissions réduites en VOC volatiles
WO2013045551A1 (fr) * 2011-09-28 2013-04-04 Titan Wood Limited Panneaux de plaque de fibres de moyenne densité
CN103958137A (zh) * 2011-09-28 2014-07-30 泰坦木业有限公司 中密度纤维板面板
EP2760652A1 (fr) * 2011-09-28 2014-08-06 Titan Wood Limited Panneaux de plaque de fibres de moyenne densité
EA037317B1 (ru) * 2011-09-28 2021-03-11 Тайтен Вуд Лимитед Панели из древесно-волокнистой плиты средней плотности
EP2760652B1 (fr) * 2011-09-28 2021-07-14 Titan Wood Limited Panneaux de fibres de densité moyenne

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