WO2008028183A1 - Method of making medium density fiberboard - Google Patents
Method of making medium density fiberboard Download PDFInfo
- Publication number
- WO2008028183A1 WO2008028183A1 PCT/US2007/077504 US2007077504W WO2008028183A1 WO 2008028183 A1 WO2008028183 A1 WO 2008028183A1 US 2007077504 W US2007077504 W US 2007077504W WO 2008028183 A1 WO2008028183 A1 WO 2008028183A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- treated
- reduced material
- medium density
- pulp
- fibrous
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000011094 fiberboard Substances 0.000 title claims description 14
- 238000000034 method Methods 0.000 claims abstract description 106
- 239000000463 material Substances 0.000 claims abstract description 82
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 53
- 235000000346 sugar Nutrition 0.000 claims abstract description 36
- 238000004537 pulping Methods 0.000 claims abstract description 35
- 238000000605 extraction Methods 0.000 claims abstract description 18
- 238000011282 treatment Methods 0.000 claims abstract description 13
- 239000000835 fiber Substances 0.000 claims description 27
- 150000008163 sugars Chemical class 0.000 claims description 26
- 239000000126 substance Substances 0.000 claims description 22
- 238000007670 refining Methods 0.000 claims description 20
- 241000534656 Pinus resinosa Species 0.000 claims description 15
- 235000018782 Dacrydium cupressinum Nutrition 0.000 claims description 14
- 235000013697 Pinus resinosa Nutrition 0.000 claims description 14
- 229920005989 resin Polymers 0.000 claims description 14
- 239000011347 resin Substances 0.000 claims description 14
- 238000012545 processing Methods 0.000 claims description 12
- 239000000123 paper Substances 0.000 claims description 11
- 150000001875 compounds Chemical class 0.000 claims description 10
- 229920002488 Hemicellulose Polymers 0.000 claims description 8
- 241000218657 Picea Species 0.000 claims description 8
- 235000008566 Pinus taeda Nutrition 0.000 claims description 7
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 claims description 6
- 125000000217 alkyl group Chemical group 0.000 claims description 6
- 241000183024 Populus tremula Species 0.000 claims description 5
- 150000001412 amines Chemical class 0.000 claims description 5
- 239000002245 particle Substances 0.000 claims description 5
- 102000004190 Enzymes Human genes 0.000 claims description 4
- 108090000790 Enzymes Proteins 0.000 claims description 4
- 235000005018 Pinus echinata Nutrition 0.000 claims description 4
- 241001236219 Pinus echinata Species 0.000 claims description 4
- 235000011334 Pinus elliottii Nutrition 0.000 claims description 4
- 235000017339 Pinus palustris Nutrition 0.000 claims description 4
- 125000004122 cyclic group Chemical group 0.000 claims description 4
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 3
- 241000218679 Pinus taeda Species 0.000 claims description 3
- 240000003021 Tsuga heterophylla Species 0.000 claims description 3
- 235000008554 Tsuga heterophylla Nutrition 0.000 claims description 3
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 3
- 229920001568 phenolic resin Polymers 0.000 claims description 3
- 229920006395 saturated elastomer Polymers 0.000 claims description 3
- 238000010411 cooking Methods 0.000 claims description 2
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 claims description 2
- 150000004820 halides Chemical class 0.000 claims 1
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 abstract description 81
- 235000006408 oxalic acid Nutrition 0.000 abstract description 27
- 150000002912 oxalic acid derivatives Chemical class 0.000 abstract description 19
- 150000002148 esters Chemical class 0.000 abstract description 5
- 239000010875 treated wood Substances 0.000 abstract description 4
- 239000012808 vapor phase Substances 0.000 abstract description 4
- 239000002023 wood Substances 0.000 description 74
- 239000000047 product Substances 0.000 description 15
- WYACBZDAHNBPPB-UHFFFAOYSA-N diethyl oxalate Chemical compound CCOC(=O)C(=O)OCC WYACBZDAHNBPPB-UHFFFAOYSA-N 0.000 description 11
- 238000000855 fermentation Methods 0.000 description 10
- 230000004151 fermentation Effects 0.000 description 10
- 238000009529 body temperature measurement Methods 0.000 description 9
- 229920005610 lignin Polymers 0.000 description 9
- 150000001720 carbohydrates Chemical class 0.000 description 8
- 235000014633 carbohydrates Nutrition 0.000 description 8
- 239000012978 lignocellulosic material Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- 238000005406 washing Methods 0.000 description 7
- SRBFZHDQGSBBOR-IOVATXLUSA-N D-xylopyranose Chemical compound O[C@@H]1COC(O)[C@H](O)[C@H]1O SRBFZHDQGSBBOR-IOVATXLUSA-N 0.000 description 6
- PYMYPHUHKUWMLA-UHFFFAOYSA-N arabinose Natural products OCC(O)C(O)C(O)C=O PYMYPHUHKUWMLA-UHFFFAOYSA-N 0.000 description 6
- SRBFZHDQGSBBOR-UHFFFAOYSA-N beta-D-Pyranose-Lyxose Natural products OC1COC(O)C(O)C1O SRBFZHDQGSBBOR-UHFFFAOYSA-N 0.000 description 6
- -1 e g. Chemical class 0.000 description 6
- 238000005265 energy consumption Methods 0.000 description 6
- 229920000642 polymer Polymers 0.000 description 6
- 229920002678 cellulose Polymers 0.000 description 5
- 239000001913 cellulose Substances 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 239000002253 acid Substances 0.000 description 4
- 239000011121 hardwood Substances 0.000 description 4
- 239000000523 sample Substances 0.000 description 4
- 239000011122 softwood Substances 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 3
- WQZGKKKJIJFFOK-QTVWNMPRSA-N D-mannopyranose Chemical compound OC[C@H]1OC(O)[C@@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-QTVWNMPRSA-N 0.000 description 3
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 3
- 229920001131 Pulp (paper) Polymers 0.000 description 3
- PYMYPHUHKUWMLA-WDCZJNDASA-N arabinose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)C=O PYMYPHUHKUWMLA-WDCZJNDASA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 230000006866 deterioration Effects 0.000 description 3
- 229930182830 galactose Natural products 0.000 description 3
- 239000008103 glucose Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 238000011020 pilot scale process Methods 0.000 description 3
- 230000000930 thermomechanical effect Effects 0.000 description 3
- 241000208140 Acer Species 0.000 description 2
- LOMVENUNSWAXEN-UHFFFAOYSA-N Methyl oxalate Chemical compound COC(=O)C(=O)OC LOMVENUNSWAXEN-UHFFFAOYSA-N 0.000 description 2
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 2
- 235000011613 Pinus brutia Nutrition 0.000 description 2
- 241000018646 Pinus brutia Species 0.000 description 2
- 241000801924 Sena Species 0.000 description 2
- 238000010793 Steam injection (oil industry) Methods 0.000 description 2
- 238000005903 acid hydrolysis reaction Methods 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 230000003466 anti-cipated effect Effects 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 244000005700 microbiome Species 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- GEVPUGOOGXGPIO-UHFFFAOYSA-N oxalic acid;dihydrate Chemical compound O.O.OC(=O)C(O)=O GEVPUGOOGXGPIO-UHFFFAOYSA-N 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000005871 repellent Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 241000894007 species Species 0.000 description 2
- 238000003809 water extraction Methods 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 241000218631 Coniferophyta Species 0.000 description 1
- 235000011609 Pinus massoniana Nutrition 0.000 description 1
- 241000018650 Pinus massoniana Species 0.000 description 1
- 241000219492 Quercus Species 0.000 description 1
- DWAQJAXMDSEUJJ-UHFFFAOYSA-M Sodium bisulfite Chemical compound [Na+].OS([O-])=O DWAQJAXMDSEUJJ-UHFFFAOYSA-M 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- WQZGKKKJIJFFOK-PHYPRBDBSA-N alpha-D-galactose Chemical compound OC[C@H]1O[C@H](O)[C@H](O)[C@@H](O)[C@H]1O WQZGKKKJIJFFOK-PHYPRBDBSA-N 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 1
- 206010061592 cardiac fibrillation Diseases 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000013256 coordination polymer Substances 0.000 description 1
- 150000005690 diesters Chemical class 0.000 description 1
- UIQVTGNLWAUODM-UHFFFAOYSA-N diethyl oxalate;oxalic acid Chemical class OC(=O)C(O)=O.CCOC(=O)C(=O)OCC UIQVTGNLWAUODM-UHFFFAOYSA-N 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- UNRAKWOCSPIIHT-UHFFFAOYSA-N dimethyl oxalate oxalic acid Chemical class OC(=O)C(O)=O.COC(=O)C(=O)OC UNRAKWOCSPIIHT-UHFFFAOYSA-N 0.000 description 1
- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002255 enzymatic effect Effects 0.000 description 1
- 230000032050 esterification Effects 0.000 description 1
- 238000005886 esterification reaction Methods 0.000 description 1
- 238000007380 fibre production Methods 0.000 description 1
- 230000002600 fibrillogenic effect Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000000413 hydrolysate Substances 0.000 description 1
- 238000011534 incubation Methods 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 239000006193 liquid solution Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000003701 mechanical milling Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000013641 positive control Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 235000010267 sodium hydrogen sulphite Nutrition 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C3/00—Pulping cellulose-containing materials
- D21C3/04—Pulping cellulose-containing materials with acids, acid salts or acid anhydrides
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C1/00—Pretreatment of the finely-divided materials before digesting
- D21C1/04—Pretreatment of the finely-divided materials before digesting with acid reacting compounds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C11/00—Regeneration of pulp liquors or effluent waste waters
- D21C11/0007—Recovery of by-products, i.e. compounds other than those necessary for pulping, for multiple uses or not otherwise provided for
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C5/00—Other processes for obtaining cellulose, e.g. cooking cotton linters ; Processes characterised by the choice of cellulose-containing starting materials
- D21C5/005—Treatment of cellulose-containing material with microorganisms or enzymes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1303—Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
Definitions
- the third major component of lignocellulose is lhc hemicellulose.
- TMP thermo-mechanical pulping
- CMP chemi-mechanica pulping
- chemical pulping methods wherein a chemical/water solution is generally used to dissolve the lignin and hemicelluiose to promote the separation of the fibers.
- thcrmo-m ⁇ chanical processes e.g. TMP and CTMP
- high temperatures are used Io help separate the fibers during refining.
- These processes generally require the refining to be carried out in one or more steps.
- the first step is usually a pressurized step wilh refining being performed at temperatures above 100 0 C and immediately below or at the softening temperature of lignin.
- the pulp is typically mechanically processed using the TMP method.
- the pressure and temperature is usually modulated to achieve the desired state of frceness between the fibers.
- MDF board from pulp from a fibrous lignocellulose material using a treatment or prctreatment step which exposes the material to oxalic acid or oxalic acid derivatives (particularly dialkyl ester derivatives, particularly in the vapor phase).
- the treated wood is then subjected to a sugar extraction wash and refined using any one of the several pulping methods to produce a final pulp product. Once this is done the pulp is used to make MDF boards having improved water repellency properties.
- the method includes heating the fibrous lignocellulose material (without reducing the material to a specific particle size) at a temperature of between about 9O 0 C and 17O 0 C, more suitably between 130° C and 140° C, in the presence of oxalic acid or oxalic acid derivatives (optionally in the vapor phase), prior to refining the material into a pulp.
- the dry weight amount of oxalic acid or oxalic acid derivative employed may be less man about 6%, or suitably less than about 5%, or more suitably between about 0.05% and 5%, or most suitably between about 1% and 3%, of the dry weight of the fibrous lignocellulose material.
- R 4 wherein R 3 and R 4 are independently a branched or unbranched, cyclic or linear, saturated or unsaturated, substituted or unsubstituted C
- the compound includes the proviso that at least one of Ri and R? is other than -OH.
- the reduced material is treated with less than 6 dry wt% of the compound.
- and R 2 are -ORj, and Rj is an ethyl.
- Ri and R 2 are -OR 3
- Rj is a methyl
- the reduced material is treated at a pressure less than 90 psig.
- the reduced material is treated for a duration less than 4 hours.
- the reduced material is treated for a duration in the range of 5 min. to 2 hours.
- the reduced material is treated at a temperature in the range of 130-14 ⁇ °C.
- the suitable resin is a phcnol- fo ⁇ naklehyde resin, and a wax is further added to the fibrous pulp.
- the medium density fiber board comprises 93.5 wt% fiber, 6 wt% resin, and 0.5% wax.
- the reduced material is provided by using a processing technique being mechanical pulping, thermo-mechanical pulping, or chemical treatment with mechanical pulping.
- the ratio of watc ⁇ fibrous ⁇ gnocellulose is in the range of 4:1 to 8:1.
- the fibrous lignocellulose includes one or more hardwoods or softwoods, such as southern yellow pine, red pine, spruce, western hemlock, aspen, loblolly pine and recovered paper.
- the particle size is in the range of 6-14 mm in length.
- the reduced material is further treated with one or more suitable enzymes and/or acetic acid.
- the present invention is a method for treating lignocellulosic materials so as to produce pulp which is used to make MDF boards.
- the present invention comprises a preireatmcnt step which exposes the material to oxalic acid or oxalic acid derivatives.
- the step includes heat treating the fibrous lignocellulosic material (e.g., wood) in combination with oxalic acid or oxalic acid derivatives.
- the treated fibrous material is then refined using any one of several pulping methods to produce a pulp product.
- the treated material is subjected to a sugar extraction process before or after refining, and lhc released sugars may be recovered for other products.
- Fibrous lignocellulosic materials treated in accordance with the present invention are defined to generally include materials containing cellulose polymers, hcmicellulosc polymers and lignin. Such materials may include, for example, hardwoods (i.e., broad-leafed species) and softwoods (i.e., conifers). More specifically, these materials may include the Southern Yellow Pines, Spruces, Western Hemlock, Aspens, and other smaller diameter trees. The material may also originate from either round wood (e.g., whole trees), residue (e.g., wood scraps left behind from forest and sawmill operations), or recovered paper.
- Recovered paper may include both pre-consumer recovered paper, such as trimmings and scraps from printing, carton manufacturing, or other converting processes which arc reused to make pulp without reaching the final consumer, or post-consumer paper, such as corrugated boxes, newspapers, magazines, and office paper which has been recycled.
- pre-consumer recovered paper such as trimmings and scraps from printing, carton manufacturing, or other converting processes which arc reused to make pulp without reaching the final consumer
- post-consumer paper such as corrugated boxes, newspapers, magazines, and office paper which has been recycled.
- Oxalic acid derivative or derivatives (used interchangeably) as used herein is to be broadly construed.
- alkyl and dialkyl mono and diesters of oxalic acid are intended.
- the alkyl moiety of the esters generally have from about 1 to about 10 carbon atoms, preferably about 1 to 6 and most preferably about 1 to 4 carbon atoms.
- the alkyl moiety may be substituted, unsubstitutcd, cyclic, linear, branched or unbranchcd but is predominantly hydrocarbon in character.
- Oxalic acid derivatives in one embodiment could include carboxylic acid derivatives other than esters, e g., amides, acid halidcs, and anhydrides.
- oxalic acid derivative in the practice of this invention arc the methyl and ethyl diesters of oxalic acid.
- the oxalic acid derivatives that can be used in the present invention include oxalic acid derivatives for formula (I)
- R ⁇ and R 4 arc independently a branched or unbranched, cyclic or linear, saturated or unsaturated, substituted or unsubstituted alkyl of from 1 to 10 carbon atoms; and wherein R
- the fibrous lignocellulose material is first reduced to a size appropriate for pulping.
- Methods of reducing fibrous lignoccllulosic material to appropriate sizes for pulping are conventional in the art. Reducing the size of the fibrous lignocellulose material aids in having the material sufficiently treated with the oxalic acid or oxalic acid derivative.
- the material to be treated is reduced to wood chips.
- Generally acceptable size for wood chips include chips in a size range of I mm to 100mm in length. It is anticipated, however, that the present method may also be effective with materials not reduced to wood chips, such as those materials derived from recovered paper or wood residues or logs themselves, it is also anticipated that the present method may be effective in treating pulp itself.
- the reduced fibrous lignocelltiosic material is then treated with an amount of oxalic acid or an oxalic acid derivative.
- the level of oxalic acid or oxalic acid derivative used is empirically derived for the species of wood and the end use of the fiber. Higher concentrations may be used to recover hemieelluloses from wood chips destined for chemical pulps or total saccharification (enzymatic or second acid hydrolysis) than can be used for those to be used for mechanical and thcrmomechanical pulps.
- the amount of oxalic acid or oxalic acid derivative employed, as expressed in dry weight percentage may be less than about 6%, or suitably less than about 5%, or more suitably between about 0.05% and 5%, or even more suitably between about 1 % and 3%, of the dry weight of the fibrous lignocellulosic material.
- the method comprises adding oxalic acid, dimethyloxalate or diethyloxalate oxalic acid esters in the presence of heated wood chips, pulp or any lignocellulosic source that has some water of hydration.
- the wood chips are first heated in a digester, using direct atmospheric steam injection to exclude air from the digester and bring the chips up to a temperature required for reaction.
- the digester is then suitably brought up to around 30 psig steam pressure (although 0 to 90 psig steam can be used) by a combination of steam injection and jacket pressure. This is continued until a stable temperature and pressure are obtained.
- the temperature used is generally greater than 100 0 C, typically between 13O 0 C and 14O 0 C. No upper limit has been established and temperatures of 17O 0 C have been used to extract sugars.
- Oxalic acid or oxalic acid derivatives of low volatility arc suitably applied by impregnating the steamed wood chips with a liquid solution.
- Volatile oxalic acid derivatives such as dimethyloxalate or diclhyloxalaie may alternatively be applied by injecting into the digester by gas pressure, suitably using carbon dioxide or nitrogen. Generally, the pressure of the reaction increases slightly due to the vaporization of the chemical and diminishes within 2-3 minutes.
- the diethyloxalate or dimethyloxalate oxalic acid esters rapidly vaporize allowing for the delivery of the chemical into wood chips.
- a range oi " 0 to 100 ml of oxalic acid or diethyl oxalate has been used for the treatment of aspen, oak, maple, southern yellow pine, red pine and spruce in a reactor with a total volume of 21.4 liters.
- increasing the wood chips from 1.25 kg to 2.5 kg oven dry basis
- Conventional hot water extraction may be used for hemicellulosic sugar extraction.
- the wood chips may be healed to 17O 0 C for 30 minutes with hot water at a water to wood ratio of 4: 1.
- the water may be collected for extractives including the sugars, etc. for fermentation or other uses.
- the treated wood chips are subjected to mechanical pulping
- dilution water is added to the treated material and the material is run through a mechanical refiner in a number of sequential passes.
- the number of passes of the treated material/pulp mixture will depend upon the freeness desired for the particular MDF to be made.
- the treated material/pulp mixture is repeatedly fed through refiners until the desired level of freeness is achieved.
- the pulp may also be dewatered as necessary between passes. Loblolly pine, treated using the procedures described above, requires between about 2 to 6 repeated passes to obtain a 100 ml CSF value in a single rotating 300 mm diameter disk atmospheric refiner.
- the overall energy efficiency of the process can be compared with that of a standard process by pulping untreated material in the same apparatus while at the same time monitoring the energy consumption of the refining mill.
- the treated material requires significantly less energy input through the refiner to achieve the same level of freeness in the resulting pulps.
- Aldrich was used in a quantity of 35 grams into 7500 ml. water at (0.33% wi. solution of oxalic acid) per 2.5-kilograms oven dried wood chips. Red pine wood chips were placed in a large rotating digester and steam introduced to displace air and bring the chips to temperature (100 0 C). The steam was stopped and a vacuum drawn on the digester and the oxalic acid solution was admitted and allowed to impregnate the chips. The excess solution was drained and the temperature brought to 135 0 C. When at temperature the chips were cooked for 10 minutes.
- Aldrich was used in a quantity of 20-ml. per 1 -kilogram oven dried wood chips. Red pine wood chips were placed in a large rotating digester and steam introduced to displace air and bring the chips to temperature (140 0 C). When at temperature the DEO was introduced by an injector pipe attached to the top of the digester and forced into the digester using carbon dioxide or nitrogen gas pressure. Externa! temperature measurement and an internal temperature measurement probe were used. Chips were cooked for 30 minutes at 14O 0 C. Following the cook, the wood chips were subjected to a sugar extraction procedure consisting of atmospheric hot water washing (- ⁇ 240 liters, a water to wood ratio of 8:1) at a temperature Of SO 0 C for 30 minutes to collect the extractives including the sugars, etc. for fermentation. The wood chips were then collected and stored at 4 ⁇ C until TMP processing for MDF fiber.
- TMP Production The cooked wood chips prepared as indicated above were fiberized in a Laboratory Pressurized Refiner (TMP).
- TMP Laboratory Pressurized Refiner
- the TMP is a 12-inch single disc pressurized mechanical Sprout-Bauer, model U 12- 1 CP.
- Energy consumption was measured using an Ohio Semitronic Model WH 30-1 1 195 Integrating Wattmeter attached to the power supply side of the 44.8 kW electric motor.
- the feed rate through the refiner was 1 kg/min. Energy was reported in W lt/kg.
- the refiner plate gap settings were approximately 0.005 inch.
- MDF production The fiberized wood as made into 19mm thick panels, made at
- the wood chips were subjected to the extraction procedure consisting of atmospheric hot water washing (-240 liters) to collect the extractives including the sugars, etc. for fermentation.
- Dicthyloxalate (DEO) obtained from Sigma Aldrich was used in a quantity of 20- ml. per 1 -kilogram oven dried wood chips.
- a rotating digester was used to cook the wood chips to the desired temperature and time. External temperature measurement and an internal temperature measurement probe were used. Chips were cooked for 30 minutes at 135 0 C.
- the wood chips were subjected to the extraction procedure consisting of atmospheric hot water washing (-240 liters) to collect the extractives including the sugars, etc. for fermentation.
- Pine wood chips were subjected to hot water extraction. The wood chips were heated to 17CfC for 30 minutes with hot water, where the water to wood ratio was 4:1. Following the cook, the water was collected for extractives including the sugars, etc. for fermentation.
- TMP Laboratory Pressurized Refiner
- the TMP was a 12-inch single disc pressurized mechanical Sprout-Bauer, Model #12-1CP. Energy consumption was measured using an Ohio Semiironic Model WH 30-1 1 195 integrating a Wattmeter attached to the power supply side of the 44.8 kW electric motor. Feed rate through the refiner was 1 kg/min. Energy is reported in W'h/kg. Refiner plate gap settings were approximately 0.005 inch.
- the Andritz facility is known to provide refining results similar to industrial scale such that data obtained can be used for scaled up with confidence.
- the procedures used to process both the red pine and the spruce wood used in the refining tests at Andritz were the same procedures as described above for materials and methods.
- Carbohydrate is the total identified carbohydrate (mannosc + xylose + arabinose + glucose + galactose, m decreasing order) released as a percentage of the weight of the wood chips.
- Carbohydrate is the total identified carbohydrate (mannose + xylose + arabinose + glucose + galactose, in decreasing order) released as a percentage of the weight of the wood chips.
- Methods currently in use to improve the water repellency of MDF involve the addition of water-repellent materials to the MDF. Additional binding resin and/or specific water repellency materials can be added to the MDF.
- additional water repellent materials need not be added to the MDF. This is because the improved water repellency is achieved through an initial chemically-induced modification to the lignocellulosic material itself before the MDF is formed. The modified Iignocellulosic fibers remain compatible with the binding resin used to form the board.
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Abstract
The present invention provides a method for producing an MDF board from pulp from a fibrous lignocellulose material using a treatment or pretreatment step which exposes the material to oxalic acid or oxalic acid derivatives (particularly dialkyl ester derivatives, particularly in the vapor phase). The treated wood is then subjected to a sugar extraction wash and refined using any one of the several pulping methods to produce a final pulp product. Once this is done the pulp is used to make MDF boards having improved water repellency properties.
Description
M ETHOD OF MAKING MEDIUM DENSITY FIBERBOARD
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Serial No.
60/824,383 Tiled on September 1 , 2006
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPM RNT
[0002] This invention was made with United Slates government support awarded by the following agency: DOE Grant U R530539 and DOA U DE-FG45-O2R53O539. The United Slates has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003J Lignocellulosic materials are sources for the generation of a variety of products.
Some of the products retain significant structural components of the lignocellulose such as mechanical pulp fibers from wood chips. Other compounds such as sugars derived from the carbohydrate in lignocellulose are made into products by fermentation or chemical conversion, The lignocellulose can be made into products that represent a continuum of structured to molecular products. The continuum of products is generated by a variety of physical, chemical, biological and thermal processes.
[0004] Medium-density fibcrboard (MDF) is an engineered wood product formed by lignocellulosic fibers glued under heat, pressure and a small amount of resin. In manufacturing MDF from wood, the wood is first reduced to an intermediate stage in which the fibers in the wood are separated from their natural environment and transformed into a pulp like suspension. One of the components of wood is lignocellulose. The most abundant component of lignocellulose is the cellulose polymers. These are the most desired polymers in the final product. The second most abundant polymer is lignin. Lignin is useful as a material which allows fibers to adhere in MDF.
[0005J The third major component of lignocellulose is lhc hemicellulose.
Hemicelluloses are polymers of sugars that are more heterogeneous than cellulose. The hemicelluloses are comprised of oligomeric sugars derived from arabinose, galactose, xylose and mannose in addition to glucose. The hemicellulose and the lignin are intermixed with the cellulose in lignocellulose and serve to protect the cellulose from damage by organisms,
enzymes or chemicals. Removal of the hemiecllυlose and lignin is often a portion of lignocellulose processing.
[0006] Pulp suitable for MDF production may be produced from various types of lignocellulose using any one of several techniques. The simplest of these techniques is the refiner mechanical pulping (RMP) method in which a mechanical milling operation grinds or abrades wood in water until a desired state of freencss (an arbitrary measure of water drainage) is achieved between its fibers. The RMP method is high yield, typically converting approximately 95% of the dry weight of the wood into pulp. The RMP method leaves most of the lignin and hemicelliilose in the pulp.
[0007] Other mechanical pulping methodologies include Ihermo-mechanical pulping
(TMP), chemical treatment with thermo-mechanical pulping (CTMP), and chemi-mechanica) pulping (CMP). Alternatively there are also chemical pulping methods, wherein a chemical/water solution is generally used to dissolve the lignin and hemicelluiose to promote the separation of the fibers.
[0008] In thcrmo-mεchanical processes (e.g. TMP and CTMP), high temperatures are used Io help separate the fibers during refining. These processes generally require the refining to be carried out in one or more steps. The first step is usually a pressurized step wilh refining being performed at temperatures above 1000C and immediately below or at the softening temperature of lignin. During this step, the pulp is typically mechanically processed using the TMP method. In subsequent steps, the pressure and temperature is usually modulated to achieve the desired state of frceness between the fibers.
[0009] Relatively high total electric energy amounts or high quantities of input lignocellulose arc required to produce pulps using the above mentioned mechanical pulping techniques. In particular, high energy inputs are generally required to obtain fiber separation in woods rich in lignin as such woods typically call for extended refining periods and higher refining temperatures or pressures. Recent studies have also suggested that even thermal or chemical softening treatments of such woods do not guarantee a lower total energy consumption. This is because unprocessed fibers which are only mildly separated by the thermal or chemical treatments arc difficult to fibrillale during the mechanical refining process. [0010] Fibrillation is necessary to increase the flexibility of the fibers and bring about the fine material characteristics of quality processed pulp. In fact, it has been suggested that a decrease in the energy consumption from an established level in various TMP and CTM?
processes has been associated with the deterioration of certain pulp properties, including a reduction in the long fiber content of the pulp (See U.S. Pat. No. 5,853,534, which is incorporated by reference here in its entirety). As a result, high energy consumption in TMP and CTMP processes has been generally necessary in today's pulping practices. [001 1 ] Along with the problems of the high energy cost of pulping, MDF has the problem of generally having low moisture tolerance. MDF, therefore, often swells when contacted with water and is therefore of more limited use in outdoor settings and in applications that encounter moisture such as furniture surfaces. Absorption of moisture also often causes significant deterioration in the mechanical integrity of the MDF.
[0012] In regards to reducing the energy costs of pulping, applicants invented a method for producing pulp from fibrous lignocellulose material using a treatment step which exposes the material to oxalic acid, or oxalic acid and sodium bisulfite, prior to pulping. Applicants discovered that pulping the resulting product actually required less energy inpul and provided a pulp with enhanced physical properties as compared Io untreated fibrous lignoccllulose material (see, U.S. Patent Publication No. 20030041985). From this applicants determined that prctreatment with oxalic acid or oxalic acid derivatives reduced energy requirements in mechanical refining for making paper. This technology is different from that which is described hercinbelow for MDF, as the properties of fibers relevant to making paper sheets are specific to paper products and are not related to the properties that fibers will exhibit when formed into MDF. In particular, the methods described below produce MDF that has, in-part, improved water repellency, a resulting characteristic that is not observable in the papεrmakmg process. fOO 13] Accordingly, an improved method is needed for producing pulp which is energy efficient and is able to produce MDF having improved water repellency properties.
SUMMARY OF THE INVENTION
[0014] Briefly, in one aspect, the present invention is a novel method for producing an
MDF board from pulp from a fibrous lignocellulose material using a treatment or prctreatment step which exposes the material to oxalic acid or oxalic acid derivatives (particularly dialkyl ester derivatives, particularly in the vapor phase). The treated wood is then subjected to a sugar extraction wash and refined using any one of the several pulping methods to produce a final pulp product. Once this is done the pulp is used to make MDF boards having improved water repellency properties.
[0015] In one embodiment, the method includes heating the fibrous lignocellulose material (without reducing the material to a specific particle size) at a temperature of between about 9O0C and 17O0C, more suitably between 130° C and 140° C, in the presence of oxalic acid or oxalic acid derivatives (optionally in the vapor phase), prior to refining the material into a pulp. The dry weight amount of oxalic acid or oxalic acid derivative employed may be less man about 6%, or suitably less than about 5%, or more suitably between about 0.05% and 5%, or most suitably between about 1% and 3%, of the dry weight of the fibrous lignocellulose material. The treatment may be conducted at ambient pressures or higher, and for a period of time sufficient to allow the treated product to be later refined at reduced energy input levels as compared to untreated materials, typically less than about 4 hours. [0016] Another aspect of the invention is a method of making medium density fiberboard having improved moisture tolerance comprising the steps or acts of providing a reduced material in water comprising one or more fibrous lignocelluloses having particle sizes in the range of 1 -100 mm in length, treating the reduced material with a compound having the
formula
, wherein Ri and R2 are independently a member selected from the group consisting of -OH, halidc, substituted amine, unsubstituted amine, -OR3, and
R4, wherein R3 and R4 are independently a branched or unbranched, cyclic or linear, saturated or unsaturated, substituted or unsubstituted C|.ιo alkyl, at a temperature in the range of 90- 17O0C generating a treated reduced material, extracting hemicellulose sugars from the treated reduced material before or after refining it to a pulp, adding a suitable resin to the fibrous pulp, and forming the fibrous pulp into medium density fiber board. In an alternative embodiment, the compound includes the proviso that at least one of Ri and R? is other than -OH. [0017] In an exemplary embodiment of the method, the reduced material is treated with less than 6 dry wt% of the compound.
[0018] In another exemplary embodiment of the method, the reduced material is treated with 0.05-5 dry wt% of the compound.
[0019] In another exemplary embodiment of the method, the reduced material is treated with 1 -3 dry wt% of the compound.
[0020] In another exemplary embodiment of the method, Ri and R2 arc -OH.
[0021 ] In another exemplary embodiment of the method, R| and R2 are -ORj, and Rj is an ethyl.
[0022] In another exemplary embodiment of the method, Ri and R2 are -OR3, and Rj is a methyl.
[0023] In another exemplary embodiment of the method, the reduced material is treated at a pressure less than 90 psig.
[00241 In another exemplary embodiment of the method, the reduced material is treated for a duration less than 4 hours.
[0025] In another exemplary embodiment of the method, the reduced material is treated for a duration in the range of 5 min. to 2 hours.
[0026] In another exemplary embodiment of the method, the reduced material is treated at a temperature in the range of 130-14ϋ°C.
[0027] In another exemplary embodiment of the method, the suitable resin is a phcnol- foπnaklehyde resin, and a wax is further added to the fibrous pulp.
[0028] In another exemplary embodiment of the method, the medium density fiber board comprises 93.5 wt% fiber, 6 wt% resin, and 0.5% wax.
[0029] In another exemplary embodiment of the method, the reduced material is provided by using a processing technique being mechanical pulping, thermo-mechanical pulping, or chemical treatment with mechanical pulping.
[0030] In another exemplary embodiment of the method, the method further includes the steps or acts of mechanically refining the treated reduced material one or more times to achieve a predetermined level of frccncss of the treated reduced material, and, dewatering the refined and treated reduced material one or more times. The treated reduced material may be mechanically refined 2-6 times, whereby a frecness value of 100 ml CSF (Canadian Standard
Freeness) is achieved.
[0031] In another exemplary embodiment of the method, the ratio of watcπfibrous ϋgnocellulose is in the range of 4:1 to 8:1.
[0032] In another exemplary embodiment of the method, the fibrous lignocellulose includes one or more hardwoods or softwoods, such as southern yellow pine, red pine, spruce, western hemlock, aspen, loblolly pine and recovered paper.
[0033] In another exemplary embodiment of the method, the particle size is in the range of 6-14 mm in length.
[0034] In another exemplary embodiment of the method, the reduced material is further treated with one or more suitable enzymes and/or acetic acid.
[0035] Another aspect of the invention is a medium density fiber board made by any one of the methods set forth herein.
10036] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including", "having" and
"comprising" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
[0037] It also is understood that any numerical value recited herein includes all values from the lower value to the upper value. For example, if a temperature range is stated as 100° C to 170° C, it is intended that values such as 101« C to 1 10° C, 102° C to 105" C, etc., are expressly enumerated in this specification. These arc only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application.
[0038] Other objects, advantages and features of the present invention will become apparent from the following specification and claims.
DETAILED DESCRIPTION OF THR EXEMPLARY EMBODIMENTS [0039J The present invention is a method for treating lignocellulosic materials so as to produce pulp which is used to make MDF boards. The present invention comprises a preireatmcnt step which exposes the material to oxalic acid or oxalic acid derivatives. In general, the step includes heat treating the fibrous lignocellulosic material (e.g., wood) in combination with oxalic acid or oxalic acid derivatives. The treated fibrous material is then refined using any one of several pulping methods to produce a pulp product. The treated
material is subjected to a sugar extraction process before or after refining, and lhc released sugars may be recovered for other products.
[0040] The treatment method of the invention removes hemicellulose from both hardwoods and softwoods. Since the method releases hcmicellulosic sugars it can be used in systems where hemicellulose is present and might be available for recovery and may or may not have to be removed to create another product from the material. Thus hardwood, softwood chips and bark could be used as well as pulp products and agricultural residues. The treatment of lignocellulosic materials by this process provides a hemieellulosic hydrolysate directly, but the saccharification of lignoccllulosc to sugars can further be enhanced by enzymes or further acid hydrolysis. The method also provides electrical energy savings in the production of pulp. The subsequent pulp is used to produce MDF boards having improved water repellency characteristics.
[0041] Fibrous lignocellulosic materials treated in accordance with the present invention are defined to generally include materials containing cellulose polymers, hcmicellulosc polymers and lignin. Such materials may include, for example, hardwoods (i.e., broad-leafed species) and softwoods (i.e., conifers). More specifically, these materials may include the Southern Yellow Pines, Spruces, Western Hemlock, Aspens, and other smaller diameter trees. The material may also originate from either round wood (e.g., whole trees), residue (e.g., wood scraps left behind from forest and sawmill operations), or recovered paper. Recovered paper may include both pre-consumer recovered paper, such as trimmings and scraps from printing, carton manufacturing, or other converting processes which arc reused to make pulp without reaching the final consumer, or post-consumer paper, such as corrugated boxes, newspapers, magazines, and office paper which has been recycled.
[0042J Oxalic acid derivative or derivatives (used interchangeably) as used herein is to be broadly construed. In the first instance alkyl and dialkyl mono and diesters of oxalic acid are intended. The alkyl moiety of the esters generally have from about 1 to about 10 carbon atoms, preferably about 1 to 6 and most preferably about 1 to 4 carbon atoms. The alkyl moiety may be substituted, unsubstitutcd, cyclic, linear, branched or unbranchcd but is predominantly hydrocarbon in character. Oxalic acid derivatives, in one embodiment could include carboxylic acid derivatives other than esters, e g., amides, acid halidcs, and anhydrides. Preferred oxalic acid derivative in the practice of this invention arc the methyl and ethyl diesters of oxalic acid.
Generally, the oxalic acid derivatives that can be used in the present invention, include oxalic acid derivatives for formula (I)
wherein Ri and R2 are independently hydroxy!, oxygen, a halidc, a substituted or unsubstituted amine, OR3 or a side chain of formula (11):
wherein R^ and R4 arc independently a branched or unbranched, cyclic or linear, saturated or unsaturated, substituted or unsubstituted alkyl of from 1 to 10 carbon atoms; and wherein R| and R2 cannot both be hydroxyl.
[0043] [n general, prior to beginning the pretrealment process, the fibrous lignocellulose material is first reduced to a size appropriate for pulping. Methods of reducing fibrous lignoccllulosic material to appropriate sizes for pulping are conventional in the art. Reducing the size of the fibrous lignocellulose material aids in having the material sufficiently treated with the oxalic acid or oxalic acid derivative. In one embodiment, the material to be treated is reduced to wood chips. Generally acceptable size for wood chips include chips in a size range of I mm to 100mm in length. It is anticipated, however, that the present method may also be effective with materials not reduced to wood chips, such as those materials derived from recovered paper or wood residues or logs themselves, it is also anticipated that the present method may be effective in treating pulp itself.
[0044] The reduced fibrous lignocelltiosic material is then treated with an amount of oxalic acid or an oxalic acid derivative. The level of oxalic acid or oxalic acid derivative used is empirically derived for the species of wood and the end use of the fiber. Higher concentrations may be used to recover hemieelluloses from wood chips destined for chemical pulps or total saccharification (enzymatic or second acid hydrolysis) than can be used for those to be used for mechanical and thcrmomechanical pulps. Generally, the amount of oxalic acid or oxalic acid derivative employed, as expressed in dry weight percentage, may be less than about 6%, or
suitably less than about 5%, or more suitably between about 0.05% and 5%, or even more suitably between about 1 % and 3%, of the dry weight of the fibrous lignocellulosic material. [0045] In one embodiment, the method comprises adding oxalic acid, dimethyloxalate or diethyloxalate oxalic acid esters in the presence of heated wood chips, pulp or any lignocellulosic source that has some water of hydration. Suitably the wood chips are first heated in a digester, using direct atmospheric steam injection to exclude air from the digester and bring the chips up to a temperature required for reaction. The digester is then suitably brought up to around 30 psig steam pressure (although 0 to 90 psig steam can be used) by a combination of steam injection and jacket pressure. This is continued until a stable temperature and pressure are obtained. The temperature used is generally greater than 1000C, typically between 13O0C and 14O0C. No upper limit has been established and temperatures of 17O0C have been used to extract sugars.
[0046] Oxalic acid or oxalic acid derivatives of low volatility arc suitably applied by impregnating the steamed wood chips with a liquid solution. Volatile oxalic acid derivatives such as dimethyloxalate or diclhyloxalaie may alternatively be applied by injecting into the digester by gas pressure, suitably using carbon dioxide or nitrogen. Generally, the pressure of the reaction increases slightly due to the vaporization of the chemical and diminishes within 2-3 minutes. The diethyloxalate or dimethyloxalate oxalic acid esters rapidly vaporize allowing for the delivery of the chemical into wood chips. The vaporized chemical contacts water present within the wood chips and at least one ester hydrolyzes to liberate acid which acidifies the water. Since the water is kept to a minimum the acid concentration is high and proportional to the amount of chemical injected. The elevated temperature and localized acidity combine to hydrolyze the hcmicellulosic sugars present in the wood chips. Other reactions such as esterification and transesterification arc also possible during this incubation. The delivery of the reactants via the vapor phase provides a high concentration of acid at the water surface layer in the chips.
[0047] The oxalate ester will generate a vapor concentration of the chemical that is dependant on the volume of the vessel and amount of chemical used. Increasing the concentration of the oxalate ester in the vessel will increase the amount of carbohydrate liberated from a given weight of wood chips. A threshold value of oxalate ester has been observed, under a set time and temperature, in pine and spruce where the increase in sugars liberated decreases relative to the increase of oxalate ester used. This threshold value has not been observed for
liberation of hemicellulosic sugars from aspen and maple. In one embodiment, a range oi"0 to 100 ml of oxalic acid or diethyl oxalate has been used for the treatment of aspen, oak, maple, southern yellow pine, red pine and spruce in a reactor with a total volume of 21.4 liters. In this embodiment, increasing the wood chips (from 1.25 kg to 2.5 kg oven dry basis) increased the amount of hemicellulosic sugars liberated from the wood chips.
[0048] Suitably, the treated wood chips are maintained at a steady temperature for a time period of between 5 minutes and 2 hours. Maintaining the wood chips in the digester for a more extended time will release more hemicellulosic sugars. Increasing the temperature of reaction or chemical loading will also release more hemicellulosic sugars. A temperature systematically increasing and/or decreasing in time may also be employed.
[0049] Conventional hot water extraction may be used for hemicellulosic sugar extraction. Suitably, the wood chips may be healed to 17O0C for 30 minutes with hot water at a water to wood ratio of 4: 1. The water may be collected for extractives including the sugars, etc. for fermentation or other uses.
[0050] The extracted, washed wood chips are then ready for pulping. Many pulping methods are suitable for the present invention including mechanical and chemical pulping methods. Mechanical pulping methods include mechanical pulping, thermo-mechanical pulping (TMP), chemical treatment with ihermo-mcchanical pulping (CTMP), and chcmi-mechanical pulping (CMP). Chemical pulping methods include chemical pulping, sulfate (kraft) and sulfite processes. Suitably, the wood chips are used for thermomechanical pulp generation. Thermomcchanical pulp generation with treated chips have been shown to provide energy savings from 25 to 50%.
[0051 ] In one embodiment, when the treated wood chips are subjected to mechanical pulping, dilution water is added to the treated material and the material is run through a mechanical refiner in a number of sequential passes. The number of passes of the treated material/pulp mixture will depend upon the freeness desired for the particular MDF to be made. The treated material/pulp mixture is repeatedly fed through refiners until the desired level of freeness is achieved. The pulp may also be dewatered as necessary between passes. Loblolly pine, treated using the procedures described above, requires between about 2 to 6 repeated passes to obtain a 100 ml CSF value in a single rotating 300 mm diameter disk atmospheric refiner.
[0052] The overall energy efficiency of the process can be compared with that of a standard process by pulping untreated material in the same apparatus while at the same time monitoring the energy consumption of the refining mill. Generally speaking the treated material requires significantly less energy input through the refiner to achieve the same level of freeness in the resulting pulps.
[0053] The pulps made through this procedure may then be made into MDF boards using standard techniques.
[0054] The present invention is further explained by the following examples which should not be construed by way of limiting the scope of the present invention.
EXAMPLES
EXAMPLE 1
[0055] Properties of MDF made from wood pretreated with OA and DEO. Red pine logs were obtained from SENA. Logs were debarked and chipped at FPL to a nominal size of 6- 14 mm. Chips were placed in barrels and frozen to prevent the growth of contaminating microorganisms. Their moisture content was 42%.
[0056] Processing of control chips. Untreated (control) red pine wood chips were placed in a large rotating digester and steam was introduced to displace air and bring the chips to temperature (135-14O0C). External temperature measurement was used as well as an internal probe as a secondary source of temperature measurement. The chips were cooked for 30 minutes at 1350C. Following the cook, the wood chips were subjected to a sugar extraction procedure consisting of atmospheric hot water washing (-240 liters, a water to wood ratio of 8:1) at a temperature of SO0C for 30 minutes to collect the extractives including the sugars, etc. for fermentation. The wood chips were then collected and stored at 40C until TMP processing for MDF fiber.
[0057] Processing of Hot Water Chips. Untreated (control) red pine wood chips were placed in a large rotating digester along with water (at a water to wood ratio of 4:1). The temperature was raised to 17O0C and then held at that temperature for 15 minutes. External temperature measurement was used to monitor the temperature. Following the cook, the wood chips were subjected to a sugar extraction procedure consisting of atmospheric hot water washing (increasing the water volume to 240 liters, in a final water to wood ratio of 8:1 ) at a temperature of 8O0C for 30 minutes to collect the extractives including the sugars, etc. for
fermentation. The wood chips were then collected and stored at 40C until TM? processing for MDF fiber
[0058] Processing of oxalic acid (OA) treated chips. Oxalic acid dihydrate from Sigma-
Aldrich was used in a quantity of 35 grams into 7500 ml. water at (0.33% wi. solution of oxalic acid) per 2.5-kilograms oven dried wood chips. Red pine wood chips were placed in a large rotating digester and steam introduced to displace air and bring the chips to temperature (1000C). The steam was stopped and a vacuum drawn on the digester and the oxalic acid solution was admitted and allowed to impregnate the chips. The excess solution was drained and the temperature brought to 1350C. When at temperature the chips were cooked for 10 minutes. Following the cook, the wood chips were subjected to a sugar extraction procedure consisting of atmospheric hot water washing (-~240 liters, a water to wood ratio of 8:1) at a temperature of SO0C for 30 minutes to collect the extractives including the sugars, etc. for fermentation. The wood chips were then collected and stored at 4"C until TMP processing for MDF fiber. [0059] Processing of diethyloxalate (DEO) treated chips. Diethyloxalate from Sigma
Aldrich was used in a quantity of 20-ml. per 1 -kilogram oven dried wood chips. Red pine wood chips were placed in a large rotating digester and steam introduced to displace air and bring the chips to temperature (1400C). When at temperature the DEO was introduced by an injector pipe attached to the top of the digester and forced into the digester using carbon dioxide or nitrogen gas pressure. Externa! temperature measurement and an internal temperature measurement probe were used. Chips were cooked for 30 minutes at 14O0C. Following the cook, the wood chips were subjected to a sugar extraction procedure consisting of atmospheric hot water washing (-~240 liters, a water to wood ratio of 8:1) at a temperature Of SO0C for 30 minutes to collect the extractives including the sugars, etc. for fermentation. The wood chips were then collected and stored at 4υC until TMP processing for MDF fiber.
[0060] TMP Production. The cooked wood chips prepared as indicated above were fiberized in a Laboratory Pressurized Refiner (TMP). The TMP is a 12-inch single disc pressurized mechanical Sprout-Bauer, model U 12- 1 CP. Energy consumption was measured using an Ohio Semitronic Model WH 30-1 1 195 Integrating Wattmeter attached to the power supply side of the 44.8 kW electric motor. The feed rate through the refiner was 1 kg/min. Energy was reported in W lt/kg. The refiner plate gap settings were approximately 0.005 inch. [0061] MDF production. The fiberized wood as made into 19mm thick panels, made at
5% moisture content using a commercial phenol-formaldehyde resin. After preparation the
boards were cut and physical properties of the boards determined using the standard testing techniques found in the (ASTM D 1037-78, 2005) American Society for Testing and Materials. 2005. Annual book of ASTM Standards. Vol. 04.10 Wood. ASTM International, West Conshohocken, PA., which is incorporated by reference here in its entirety. The study shows that hemicdtulosic sugars can be removed and recovered prior to MDF production and the MDF has enhanced properties compared to the control. The results for the study arc shown in Table 1.
TABLE 1
Table 1 Red pine medium density fiberboard tests and extent of carbohydrate removal. MDF properties from boards containing 93.5% fiber, 6% resin and 0.5% wax.
[0062J It was not evident that the samples would have increased water repcllency as a result of the OA and DEO pretreatmcius and subsequent extraction,. The normal extraction procedures that arc done with hot water have not been shown to have this benefit to the MDF production.
EXAMPLE 2
[0063] Materials and Methods. Wood chips. Red pine logs were obtained from SENA.
Logs were debarked and chipped at FPL to a nominal size of 6-14 mm. Chips were placed in barrels and frozen to prevent the growth of contaminating microorganisms. Moisture content was 42%. After the experimental cooking procedures, the wood chips were collected and stored at 40C until TMP processing for MDF fiber.
[0064J Experimental cooks. Control red pine wood chips were subjected to time and temperature and extraction protocols, but without chemical cook (positive control). Following the cook, the wood chips were subjected to the extraction procedure consisting of atmospheric hot water washing (-240 liters) to collect the extractives including the sugars, etc. for fermentation.
[0065] Oxalic acid dihydrate obtained from Sigma-Aldrich was used in a quantity of 35 grams into 7500 ml. water at 7O0C (0.33% solution of oxalic acid) per 2.5-kilograms oven dried wood chips. A rotating digester was used to cook the wood chips to the desired temperature and time. External temperature measurement and an internal temperature measurement probe were used. The chips were cooked for 10 minutes at 1350C. Following the cook, the wood chips were subjected to the extraction procedure consisting of atmospheric hot water washing (-240 liters) to collect the extractives including the sugars, etc. for fermentation. [0066] Dicthyloxalate (DEO) obtained from Sigma Aldrich was used in a quantity of 20- ml. per 1 -kilogram oven dried wood chips. A rotating digester was used to cook the wood chips to the desired temperature and time. External temperature measurement and an internal temperature measurement probe were used. Chips were cooked for 30 minutes at 1350C. Following the cook, the wood chips were subjected to the extraction procedure consisting of atmospheric hot water washing (-240 liters) to collect the extractives including the sugars, etc. for fermentation.
[0067] Pine wood chips were subjected to hot water extraction. The wood chips were heated to 17CfC for 30 minutes with hot water, where the water to wood ratio was 4:1. Following the cook, the water was collected for extractives including the sugars, etc. for fermentation.
[0068] Fiber production for the TMP process. Cooked wood chips were fibcrized in a
Laboratory Pressurized Refiner (TMP). The TMP was a 12-inch single disc pressurized mechanical Sprout-Bauer, Model #12-1CP. Energy consumption was measured using an Ohio Semiironic Model WH 30-1 1 195 integrating a Wattmeter attached to the power supply side of the 44.8 kW electric motor. Feed rate through the refiner was 1 kg/min. Energy is reported in W'h/kg. Refiner plate gap settings were approximately 0.005 inch.
[0069] MDF production. 19 mm thick panels were made at 5% moisture content using a commercial phenol-formaldehyde resin. Alter preparation, the boards were cut and physical properties of the boards determined using the standard testing techniques found in ASTM D 1037-78, 2005. American Society for Testing and Materials (2005), Annual book of ASTM Standards, Vol. 04.10, Wood, ASTM International, West Conshohocken, PA. [0070] Results. After OA and DEO pretrcatments, hcmicellulosic sugars can be removed and recovered prior to MDF production and the MDF has enhanced properties compared to both the raw control and the hot water control.
TABLE 2
[0071] Red pine medium density fibcrboard tests and extent of carbohydrate removal.
Note: MDF properties from boards containing 93.5% fiber, 6% resin and 0.5% wax.
[0072] Unexpected superior results. It was not evident that the samples would have increased water repel lency as a result of the OA and DEO prctrcatnients and subsequent sugar extractions. The normal extraction procedures that are done with hot water have not been shown to have this benefit to the MDF production. We were surprised to see this result.
EXAMPLE 3
[0073] Pilot scale data were generated at the Andritz Research and Development
Laboratory in Springfield, OH. The Andritz facility is known to provide refining results similar to industrial scale such that data obtained can be used for scaled up with confidence. The procedures used to process both the red pine and the spruce wood used in the refining tests at Andritz were the same procedures as described above for materials and methods.
TABLE 3
[0074J Pilot-scale refining results from Andritz on spruce.
Note: MDF properties from boards containing 93.5% fiber, 6% resin and 0.5% wax. Carbohydrate is the total identified carbohydrate (mannosc + xylose + arabinose + glucose + galactose, m decreasing order) released as a percentage of the weight of the wood chips.
TABLE 4
[0075] Pilot-scale refining results from Andritz on red pine.
Note: MDF properties from boards containing 93.5% fiber, 6% resin and 0.5% wax. Carbohydrate is the total identified carbohydrate (mannose + xylose + arabinose + glucose + galactose, in decreasing order) released as a percentage of the weight of the wood chips.
[0076] For the treated red pine wood chips, the resulting MDF strength was slightly lower than (he control. However, the unexpected water rcpellency was evident. For the treated spruce wood chips, the water rcpellency was again unexpectedly increased over the control, and the strength of the resulting MDF was also surprisingly enhanced. The red pine species in Table
4 was very similar to that shown in Table 2.
[0077] Utility of the Described Embodiments
[0078] MDF is widely used as a structural material in objects such as buildings and furniture. In many of these uses the MDF may become exposed to water. It is well known that exposure to water causes deterioration of conventionally-produced MDF, resulting in losses of mechanical integrity, dimensional stability, and asthcϋc appearance. Because of this it is
common to restrict the use of MDF to applications free from moisture exposure, and/or to apply protective paints, varnishes, or other coatings in an attempt to ameliorate the negative effects of moisture on the material. These applied coatings represent an additional cost and may not be fully satisfactory for various uses.
[0079] Methods currently in use to improve the water repellency of MDF involve the addition of water-repellent materials to the MDF. Additional binding resin and/or specific water repellency materials can be added to the MDF. A useful and distinguishing feature of applicants1 invention is that additional water repellent materials need not be added to the MDF. This is because the improved water repellency is achieved through an initial chemically-induced modification to the lignocellulosic material itself before the MDF is formed. The modified Iignocellulosic fibers remain compatible with the binding resin used to form the board. [0080J While the present invention has now been described and exemplified with some specificity, those skilled in the art will appreciate the various modifications, including variations, additions, and omissions that may be made in what has been described. Accordingly, it is intended that these modifications also be encompassed by the present invention and that the scope of the present invention be limited solely by the broadest interpretation that lawfully can be accorded the appended claims.
Claims
CLAfMS
We claim:
I . A method of making Medium Density Fibcrboard (MDK) having improved moisture tolerance comprising: providing a fibrous lignocellulose material; treating the material with a compound having the formula
wherein Ri and Ri are independently a member selected from the group consisting of -
O
OH, halide, substituted amine, unsubslituted amine, -OR3, and ° R4, wherein Rx and R4 are independently a branched or unbranched, cyclic or linear, saturated or unsaturated, substituted or unsubstitulcd Cι.ιo alkyl, at a temperature in the range of 90-1700C generating a treated material; extracting hemicellulose sugars from the treated material; refining the treated material to generate a fibrous pulp, wherein the refining step can be performed either before or after the extraction step; adding a suitable resin to the fibrous pulp; and forming the fibrous pulp into medium density fiberboard.
2. The method of claim 1, wherein the fibrous lignocellulose material is reduced to a particle size in the range of 1-100 mm in length.
3. The method of claim 2, wherein the reduced material is treated with less than 6 dry wt% of the compound.
4. The method of claim 2, wherein the reduced material is treated with 0.05-5 dry wt% of the compound.
5. The method of claim 2, wherein the reduced material is treated with 1-3 dry wt% of the compound.
6. The method of any one of claims 2-5. wherein Rj and Rj are -OH.
7. The method of any one of claims 2-5, wherein Ri and Ri are -OR3, and wherein R$ is an ethyl.
8. The method of any one of claims 2-5. wherein R] and Ri are -ORj, and wherein R3 is a methyl.
9. The method of claim 2, wherein the reduced material is treated at a pressure less than 90 psig.
10. The method of claim 2, wherein the reduced material is treated for a duration less than 4 hours.
1 1. The method of claim 2, wherein the reduced material is treated for a duration in the range of 5 min. to 2 hours.
12. The method of claim 2, wherein the reduced material is treated at a temperature in the range or 130-140"C.
13. The method of claim 2, wherein the suitable resin is a phenol- formaldehyde resin, and wherein a wax is further added to the fibrous pulp.
14. The method of claim 13, wherein the medium density fiber board comprises 93.5 wl% fiber, 6 wt% resin, and 0.5% wax.
15. The method of claim 2, wherein the reduced material is refined by using a processing technique selected from the group consisting of mechanical pulping, thermo- mochanical pulping, and chemical treatment with mechanical pulping.
16. The method of claim 2, further comprising: mechanically refining the treated reduced material one or more times to achieve a predetermined level of frccncss of the treated reduced material; and dewatering the refined and treated reduced material one or more times.
17. The method of claim 16, wherein the treated reduced material is mechanically refined 2-6 times, and wherein a freencss value of 100 ml CSF is achieved.
18. The method of claim 1, wherein the ratio of water: fibrous lignocellulose is in the range of 4:1 to 8: 1.
19. The method of claim 2, wherein the fibrous lignocclluiosc includes one or more members selected from the group consisting of southern yellow pine, red pine, spruce, western hemlock, aspen, loblolly pine and recovered paper.
20. The method of claim 19, wherein the particle size is in the range of 6-14 mm in length.
21. The method of claim 2, wherein the step of treating the reduced material includes cooking the material at a temperature in the range of 90-1700C.
22. The method of claim 2, wherein the reduced material is further treated with one or more suitable enzymes and/or acetic acid.
23. The method of claim 1, wherein the refining step can be performed either before or after the sugar extraction step.
24. Λ medium density fiber board made by any one of the methods of claims 2-5.
25. A medium density fiber board made by claim 6.
26. A medium density fiber board made by claim 7.
27. A medium density fiber board made by claim 8.
28. Λ medium density fiber board made by any one of claims 9-23.
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US82438306P | 2006-09-01 | 2006-09-01 | |
US60/824,383 | 2006-09-01 |
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PCT/US2007/077504 WO2008028183A1 (en) | 2006-09-01 | 2007-09-04 | Method of making medium density fiberboard |
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FR2932815A1 (en) * | 2008-06-23 | 2009-12-25 | Cie Ind De La Matiere Vegetale | PROCESS FOR PRETREATING PLANT RAW MATERIAL FOR PRODUCING SACCHARIFEROUS AND LIGNOCELLULOSIC RESOURCES, BIOETHANOL AND / OR SUGAR, AND. |
WO2014107767A1 (en) * | 2013-01-11 | 2014-07-17 | Mmw Equine Therapy Pty Ltd | Composite boards comprising cellulosic plant material |
DE102014009884A1 (en) * | 2014-07-04 | 2016-01-07 | Fritz Egger Gmbh & Co. Og | Process for producing a fiberboard |
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US20100175840A1 (en) * | 2007-06-12 | 2010-07-15 | Hart Peter W | High yield and enhanced performance fiber |
US20080308239A1 (en) * | 2007-06-12 | 2008-12-18 | Hart Peter W | Fiber blend having high yield and enhanced pulp performance and method for making same |
WO2008153565A1 (en) | 2007-06-12 | 2008-12-18 | Meadwestvaco Corporation | A fiber blend having high yield and enhanced pulp performance and method for making same |
AU2009290407B2 (en) * | 2008-07-21 | 2013-06-06 | Praj Industries Limited | A process for production of ethanol from lignocellulosic material |
CA2722003A1 (en) * | 2009-11-23 | 2011-05-23 | The University Of Maine System Board Of Trustees | Composite from hemicellulose extracted wood with improved performance and reduced emissions |
AU2012289828A1 (en) * | 2011-08-01 | 2014-02-20 | Mmw Equine Therapy Pty Ltd | Engineered cellulosic products |
JP2015517588A (en) * | 2012-05-09 | 2015-06-22 | バイオ プラズマー リミテッド | Mixtures for biodegradable articles |
CN102758384A (en) * | 2012-05-24 | 2012-10-31 | 湖北工业大学 | Fabricating method of formaldehyde-free wheat straw medium density fiberboard |
US10006166B2 (en) | 2016-02-05 | 2018-06-26 | The United States Of America As Represented By The Secretary Of Agriculture | Integrating the production of carboxylated cellulose nanofibrils and cellulose nanocrystals using recyclable organic acids |
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FR2932815A1 (en) * | 2008-06-23 | 2009-12-25 | Cie Ind De La Matiere Vegetale | PROCESS FOR PRETREATING PLANT RAW MATERIAL FOR PRODUCING SACCHARIFEROUS AND LIGNOCELLULOSIC RESOURCES, BIOETHANOL AND / OR SUGAR, AND. |
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WO2014107767A1 (en) * | 2013-01-11 | 2014-07-17 | Mmw Equine Therapy Pty Ltd | Composite boards comprising cellulosic plant material |
DE102014009884A1 (en) * | 2014-07-04 | 2016-01-07 | Fritz Egger Gmbh & Co. Og | Process for producing a fiberboard |
EP2974841A1 (en) | 2014-07-04 | 2016-01-20 | Fritz Egger GmbH & Co. OG | Method for producing a fibreboard panel |
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US20080264588A1 (en) | 2008-10-30 |
US20100300634A1 (en) | 2010-12-02 |
US8123904B2 (en) | 2012-02-28 |
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