WO2010127422A1

WO2010127422A1 - Binder extender for producing chipboards and wood fiberboards

Info

Publication number: WO2010127422A1
Application number: PCT/BR2009/000133
Authority: WO
Inventors: Flavio Maluf
Original assignee: Flavio Maluf
Priority date: 2009-05-08
Filing date: 2009-05-08
Publication date: 2010-11-11
Also published as: BRPI0924244A2; BRPI0924244B1

Abstract

BINDER EXTENDER FOR PRODUCING CHIPBOARDS AND WOOD FIBERBOARDS, whose main characteristic is the use of black liquor as binder extender in the production of boards made of cellulosic materials, notably those traditionally called chipboards and MDF3 HDF wood type fiberboards and others.

Description

BINDER EXTENDER FOR PRODUCING CHIPBOARDS AND WOOD FIBERBOARDS. Field of the Invention.

More particularly, the present invention refers to the use of black liquor as binder extender in the production of boards made of cellulosic materials, notably those traditionally called chipboards and HDF, MDF wood type fiberboards and others. State of the Art.

The technology of cellulose production most common in Brazil is the Kraft process, which uses a solution of sodium hydroxide/sodium sulphide, white liquor, to separate cellulose from raw wood material, in the step called digestion, having the presence of black liquor, which is a fluid produced as a byproduct from the digester, an element that is responsible for cooking the wood to withdraw undesirable components from the paper manufacturing process, such as lignin, extractive compounds and alkaline products.

Therefore, in the cellulose and paper production process, large volumes of waste are generated,^' chiefly black liquor, which have a high diversity of toxic phenyl compounds. Generally speaking, the plants use modern environmental management programs, as in most advanced countries of the world, which reduces solid residues. However, both the treatment process of this waste, as the utilization thereof can still be significantly improved, because, as it is known, over recent years the utilization of black liquor has been of interest to those seeking to transform it into fuel to be used as a source of heat for different applications, notably in boilers or to generate energy or to recovering the chemical contents, as taught in many patent documents in Brazil: PI 8900209-1 process for reducing black liquor and equipment to pyrolize same; PI 8606701-1 process for recovering chemical compounds and energy from cellulose-waste liquors;

PI 9602866-1 process for treating gaseous waste and white or black liquor resulting from the Kraft process; PI 9708319-4 process for extracting chemical products and energy from cellulose spent liquor

PI 9304386-4 system and process of gasification of black solution; PI 9900877-7 alkaline aqueous solutions and their use in dyeing processes of cellulosic textile materials;

MU7102194-9 improvement in pumping process; PI 8304944-4 process and apparatus for recovering the thermal and chemical contents of spent pulping liquor;

PI 8503619-6 process for preparing lignin-modified phenol-formaldehyde adhesive; and modified phenol-formaldehyde adhesive containing lignosulphonate; PI 0604341-0 improved systems, processes and methods of fiber line; PI 0003970-5 high efficiency process for recovering high purity sterols; PI 8303864-7 process for treating with polysulphide of lignocellulosic material in alkaline pulp production;

PI 9203126-9 process for producing Kraft pulp and equipment for treatment of fragmented fibrous cellulosic material; PI 9106319-1 process and apparatus for generating heat and electricity in a sulphide pulp plant; PI 0511161-7 Kraft recovery boiler, and, methods for restoring and assembling a Kraft recovery boiler and to assemble a black liquor gasificator;

PI 9205048-4 method and process for inhibiting incrustation in evaporators for concentration of cane juice in sugar mills and of black liquor in the cellulose industry;

PI 9305510-2 process for producing wood paste and annual plants using as digestion liquor a hydroxide solution with the addition of anthraquinone and/or its derivatives;

PI 0403445-7 continuous heterogenic catalytic process for producing aromatic aldehydes obtained from ligninic black liquor from the sugar cane bagasse; PI 8607216-1 process for reducing the viscosity and improving the evaporability of black liquid of sulphate deriving from a cellulose cook;

PI 9813902-9 method for measuring properties of the stack and the corrosion of materials in a soda recovery unit; PI 8102935-7 system and process for reducing the oxygen consumption in the oxidation of black liquor;

PI 8503823-7 process of preparing cellulose from bamboo; PI 8504905-0 ammonium lignosulphonates; PI 8906617-0 process for continuous digestion of cellulosic fiber material; PI 9103450-7 process for obtaining cellulose from rice husk; PI 9206464-7 method for the combustion of waste liquids; PI 9206271-7 process for extracting chemical components and energy from spent cellulose liquors;

PI 9206270-9 process and arrangement for separating particles in fusion and preferably also solid particles from a gas flow;

PI 9300103-7 pulping process; PI 9306697-0 methods for determining and controlling the effective alkali in kraft liquors in a kraft pulp manufacturing process, to control the operation of a pulp digester, of a system of recaustification and of a recovery boiler in the preparation of kraft pulp and to monitor the black liquor for operating a pulp digester and the white liquor after the caustification in the preparation of kraft pulp; I 9406271-4 process for selective removal and liquid absorption of hydrogen sulphide and apparatus for said removal; PI 9407856-4 method for burning secondary sludge in a recovery boiler; MU 7402406-0 process for isolating and extracting virgin cellulose from small and medium-sized vegetables and farm surplus and use of apparatus;

PI 9508080-5 process for recovering chemical products and energy from black liquor;

PI 9607440-0 control of viscosity of black liquor; PI 9601686-8 precipitation-radiation method for remedying paper industry effluents; P PII 99660099990077--00 method for re-processing a gas containing ozone present in a pulp bleaching facility;

PI 0214070-5 system for controlling the flow pattern of a recovery boiler; PI 0404054-6 process of oxidizing the wood cooking liquor; PI 0515247-0 method for separating lignin from black liquor;

PI 0517543-7 method for separating lignin from a sludge or liquid containing lignin;

PI 0516090-1 furnace for a recovery boiler; PI 0705223-5 method to reduce nitrogen oxide emissions of a recovery boiler, and, recovery boiler; P PlI 00770044667766--66 a method for producing cellulose pulp in a continuous digester in an energetically efficient way; and PI 0803334-0 air combustion system in recovery boiler with intermediary air doors vertically aligned in multiple levels of tertiary air doors. Therefore, today there is a noticeable ongoing concern to create techniques to characterize specially designed means, with a view to the ecologically correct utilization of black liquor.

As already stated, black liquor is a byproduct deriving from the delignification of wood by the sulfate (Kraft) process. The typical content of black liquor is: organic matter, lignin compound with highly binding properties, hemicelluloses and other carbohydrates partially degraded and inorganic compounds of alkaline origin, sodium hydroxide, sodium sulphurate, sodium sulphide, sodium carbonate and chlorate, in the approximate ratio of 50% for each compound (organic/inorganic) and water. Studies prove that black liquor can be treated to alter its pH sufficiently to be used as in the extender in the binding of particles or eucalyptus or pine wood fibers in a mixture with formol-urea, formol phenol adhesives, tannins, or other solubles in water, in percentages that may vary from 1% to 50%. The black liquor, byproduct of paper manufacturing by the process

Kraft (sulfate) is a complex colloidal system of lignin and residues of hemicelluloses and inorganic compounds used in the process, and soluble in water.

The lignin as chemical compound is part of a group of phenolic polymers having high molecular weight resulting from phenyl propane bonds which confer rigidity and cohesive strength to the cellular walls of the wood, this being the compound responsible for supporting the plant. Black liquor originating from the Kraft (sulfate) process from trees of the pine or eucalyptus species can be used. The lignin content in trees of the eucalyptus species may vary from

20% to 29%. After cellulose, lignin is the most abundant natural product in nature.

Objectives of the Invention.

The principal objective of the invention is ecologically correct utilization of black liquor, making it a component to be used as binder extender in the production of boards made of cellulosic materials, notably those traditionally called chipboards and MDF, HDF wood type fiberboard and others.

Approximate characteristics of eucalyptus black liquor: *pH - over 11 •Solid - 40% - 70% •Approximate Organic/Inorganic ratio 1 : 1

•Viscosity is a variable of the temperature and of the total solids to be used in the application system, and may vary from 200 to 20000 cps, and may present itself in paste state depending on its origin.

As already known, the binders used for internal gluing of fiber and chip boards, as a general rule, formol-urea or formol phenol based adhesives, products with high cost and that weigh heavily in the composition of the end cost of the product, accounting for between 30% and 40%. Accordingly, the black liquor byproduct and waste product of paper production, by virtue of its lignin content, allows it to be used as a glue extender of the urea-formol and/or phenol formol adhesives, or also other types of adhesives that are soluble in water and compatible with the black liquor with a significant reduction in cost, further allowing the upkeep of acceptable qualitative concepts within national and international standards.

Formol-based adhesives with high formol content and suitable catalysis manage to react in situ with the lignin contained in the black liquor through an application system of highly efficient pulverization, which permits a significant increase in the contact surface of the various chemical components separately, without pre-mixing, with the particles or wood fibers, under the conditions of pressure and temperature particular to the process, this technology is a success factor for the productive system described herein.

The entry of an activator/generator of lignin radicals and wood fibers permits a significant increase in reactive terminals offering the system a fast reaction and molecular crossover that is ideal to maintain the required productive and qualitative indices. This is important, because the black liquor due to its chemical characteristics, retards the global reaction speed of the system.

Another important advantage in the use of black liquor is that the polymerization reactions and interaction of the lignins with the urea-formol adhesives, act as suppressants or sequestrants of formol, this characteristic allows a board with healthy environmental quality to be obtained.

Another important advantage is the consumption of an aggressive polluent as coadjuvant of polymerization with adhesives urea-formol and/or phenol formol, without generating secondary effluent. Detailed description of the invention.

The productive system comprises a sequential additivation by pulverization of chemical compounds on the fibers and/or particles of eucalyptus or pine wood, in a continuous manner in a mechanical gluer with a system of blades in constant movement, allowing a perfect mixture of the different compounds and their interaction with the fibers and/or particles of eucalyptus or pine wood, forming a homogeneous combination. The same interaction with the fibers and/or particles can be obtained by pulverization in the blow line after defibration, allowing drying by evaporation of residual water a temperature de 100° to 18O⁰C obtaining a final residual humidity between 1.5% to 2.0%.

These fibers and/or particles will undergo a layer- forming system, allowing the manufacture of boards, and by continuous process of pressure and temperature, will be pressed achieving a state of solid and rigid compactness and/or agglomeration, having specific characteristics, in various sizes and thicknesses.

The pressing times, i.e. the linear velocity in m/min of the production line as well as the temperatures used were the same as in the normal manufacturing process normal, i.e. using only urea-formol adhesive as inner binder of the board. Operational Formulation

•Paraffin Emulsion - 0.1% - 5.0% (on fiber or dry particle) •Black liquor - 1.0% - 12.0% (dry base / on fiber or dry particle) •UF Adhesive - 2.0% - 12.0% (dry base / on fiber or dry particle) 'Ammonium Chlorate - 1.0% - 10.0% (on UF adhesive / dry base) •Activator/Generator of radicals - up to 25 % on solid lignin Characteristics of the chemical compounds.

•Paraffin emulsion - solids 58% - 60% •Black liquor - solids 40% - 70% •Formol-urea adhesive — solids 65% - 68%

(Molar ratio: 1 of urea / 1.65 up to 1.9 of foraiol) •Ammonium Chlorate - solids 25% to 35% •Activator/Generator of radicals Solution: 50 p/p of Oxygenated Water at 30% 10 p/p of solution of 6 mg/1 of ferrous sulphate pentahydrate.

It is understood that certain characteristics of the composition and the combinations of black liquor in relation to the formula components may vary considerably, whilst being within the same inventive concept, consequently, the detailed description above is presented merely as an example and is clearly subject to variations, however, always within the scope of the inventive concept, now revealed, of the use of black liquor as binder extender in the production of boards made of cellulosic materials, and since many changes can be made in the means now detailed in accordance with the descriptive requirements of the law, it is understood that the details herein should be interpreted as being illustrative and not limitative.

Claims

CLAIMS1) BINDER EXTENDER FOR PRODUCING CHIPBOARDS AND WOOD FIBERBOARDS, characterized by using black liquor, as glue extender of urea-formol and/or phenol formol adhesives, or other adhesives that are soluble in water and compatible with the black liquor.2) BINDER EXTENDER FOR PRODUCING CHIPBOARDS AND WOOD FIBERBOARDS, according to claim 1, characterized wherein the black liquor if originating preferably from eucalyptus presents the following approximate characteristics: pH >11, solids of 40% to 70%, approximate organic/inorganic ratio 1:1, viscosity is a variable of the temperature and the total solids to be used in the application system, and may vary from 200 to 20000 cps, and may present itself in paste state depending on its origin.3) BINDER EXTENDER FOR PRODUCING CHIPBOARDS AND WOOD FIBERBOARDS, according to claim 1, characterized wherein, in a conventional manufacturing process, the following formulation is preferably used:0.1% to 5.0% of paraffin emulsion (on fiber or dry particle) with 58% to 60% of solids;

1.0% to 12.0% of black liquor de (dry base / on fiber or dry particle) with 40% to 70% solids;

2.0% to 12.0% of formol-urea adhesive (dry base / on fiber or dry particle) with 65% to 68% of solids and molar ratio = 1 of urea / 1.65 up to 1.9 of formol);

1.0% to 10.0% of ammonium chlorate (on UF adhesive/ dry base) with 25% to 35% of solids; and up to 25 % of activator/generator of radicals on solid lignin according to a solution: 50 p/p of oxygenated water at 30% 10 p/p of solution of 6 mg/1 of ferrous sulphate pentahydrate.

4) BINDER EXTENDER FOR PRODUCING CHIPBOARDS AND WOOD FIBERBOARDS, according to claim 1, characterized by sequential additivation by pulverization of the chemical compounds on the fibers and/or particles of eucalyptus or pine wood, in a continuous manner inside a mechanical gluer with a system of blades in constant movement, cooperative for mixing the different compounds and their interaction with the fibers and/or particles of eucalyptus or pine wood, forming a homogeneous combination, the same interaction with the fibers and/or particles can be obtained by pulverization in the "blow line" after defibration, allowing drying by evaporation of the residual water at a temperature of 100 to 18O⁰C obtaining a final residual humidity between 1.5% to 2.0%; said fibers and/or particles will undergo a layer-forming system allowing the manufacture of boards, and by continuous process of pressure and temperature, will be pressed achieving a state of solid and rigid compactness and/or agglomeration, with particular characteristics, in various sizes and thicknesses; the pressing times, i.e. the linear velocity in m/min of the production line as well as the temperatures used were the same as in the normal manufacturing process, i.e. using only formol-urea adhesive as internal binder of the board.