PROCESSING OF RESILIENT MATERIALS

Abstract: A chemically bonded medium is obtained from a resilient organic macromolecular material, in cut elongate of finely divided form (such as grass or peat). The material is dried (3, 4) under conditions permitting escape of water vapour, such that the dried material has a predominantly hydrophobic surface and a water content of not more than 10 % by weight; and then optionally flashed. The surface properties of the dried material are then equilibrated, under conditions inhibiting escape of water vapour and other volatiles, such that the predominantly hydrophobic surface is rendered predominantly hydrophilic. The product is then mixed (5) with a lignosulfonate, with application of heat in an amount sufficient to maintain the lignosulfonate in fluid form, such that the lignosulfonate forms a coating film on the surface. The lignosulfonate is caused to undergo partial polymerisation (6) (typically by heating and/or treatment with oxygen) on the surface of the dried material to produce a flowable, substantially non-resilient and non-tacky, chemically bonded medium. The bonded medium may be stored or shaped (8) under pressure to form agglomerates.

Description: Processing of resilient materials The present invention is concerned with processing of resilient organic macromolecular materials (and managing the propertieε of media bonded by such materials) , such that the resulting bonded media may be suitable for a variety of end-uses, such as, for example, animal feeds and fuels. There are many known resilient organic macromolecular materials, examples of which are peat, sewage sludge, grass, animal feedstuffs, wood chips, sawdust, straw, waste paper, municipal refuse, cardboard and shredded, milled or ground plastics material. It is often very difficult to process such materials reliably and reproducibly into useful products, because of the wide variations in material compositions and properties. For example, it is often difficult to compact such materials because of their resilience. I have devised a method of using and processing such macromolecular materials which is both reliable and reproducible, and which can result in compacted bonded media of carefully managed and controlled properties. According to the present invention, there is provided a method of producing a chemically bonded medium, from a starting material comprising a resilient organic macromolecular material, in which the organic macromolecular material is in cut elongate or finely divided form. The macromolecular material is at least partly thermally dried under conditions permitting escape of water vapour, such that the resulting dried material has a predominantly hydrophobic surface and a water content of not more than 10% by weight (the water content after this stage being preferably not more than 5%, more preferably 2 to 3%). The drying may include a subsequent step in which at least the surface of the dried material is flashed (for example using hot air at 350 to 450°C) . This flashing can drive off further moisture, and cause degradation and change of some compounds present in the resilient macromolecular material. (These may, for example, be waxes, lignins, cellulitic remains or resins when the resilient material is peat.) At least some of the dried material is then subjected to vapour pressure equilibration, under conditions inhibiting escape of water vapour and other volatiles, such that the predominantly hydrophobic surface is rendered hydrophilic. Such equilibration may, for example, be in a closed container (such as a hopper or bin unit maintained at say about 80°C) ; the equilibrated material has a wet, hydrophilic surface, with a substantially dry interior. The hydrophilic surfaced material is then mixed with an aqueous lignosulfonate, under conditions such that the lignosulfonate does not attain a predetermined temperature (preferably not exceeding 80°C) . Sufficient heat should, however, be applied to maintain the lignosulfonate in fluid form, such that the lignosulfonate forms a coating film (typically a monolayer or the like) on the hydrophilic surface; the lignosulfonate is then caused to undergo partial polymerisation at a temperature not exceeding 150°C on the surface of the finely divided material, so as to produce a flowable, substantially non- resilient, chemically bonded medium. For certain organic macromolecular materials (such as for example certain forms of sewage sludge) the required heating/drying prior to mixing with the aqueous lignosulfonate may be achieved using conventional heating/drying means. It is however believed that the mixing and subsequent partial polymerisation of such conventionally heated/dried material is both novel and inventive per se. Depending on the nature of the materials used in the method according to the invention, calcium (for example, as calcium oxide) may be added together with the lignosulfonate. The chemically bonded medium may be passed to a storage location before being further processed. If stored at this stage, the medium may be subsequently treated with water or steam (for example, saturated or superheated steam) before being further processed by, for example, agglomeration or compacting. The water-treated or steam-treated material may, in some embodiments of the invention, be subsequently cured (for example, by heating at 250 to 280°C for 1 to 1.5 hours). Either after such storage, or immediately following the partial polymerisation, the medium may be compacted and compressed (or agglomerated) ; the resulting compressed medium is substantially Non-resilient (devoid of the natural resilience of the original macromolecular material) such that the resulting compacted material does not tend to spring apart. The major influence on the mechanical properties of the resulting compacted material is the bonding between the particles. On compacting with heat, the compacted material attains chemical bonding which extends throughout the structure, establishing a metamorphic change throughout the compacted material structure. The nature of this bonding is important not only under test conditions, but also under service conditions. If the bonding were to be of a purely adhesive nature, there would be a separate phase at the interface between the particles; according to the invention, the bonding is chemical in nature and extends throughout the agglomerate structure. The particles become fused and chemically bonded to one another in such a way that the macromolecular material and any particulate organic material (such as a carbonaceous fuel) present in the mix cease to exist as separate entities, the whole compacted mass appearing to act as a single homogeneous mass. The use in the method according to the invention of a lignosulfonate, which is a material typically produced as a co- product in the cellulose pulp industry, results in a chemically bonded medium which is a substantially non-resilient friable material, but which can be regenerated into a pressure-sensitive, non-friable form (which is still non-resilient) by suitable re¬ activation (using, for example, water, urea or the like) . The lignosulfonate present in the bonded medium may be regenerated by reaction with urea or a urea derivative, which may contribute to the plasticity of the resulting mix. This reaction of lignin with urea or a urea derivative is one which is known per se. The ability to manage the properties of the resulting product makes it possible to provide lignin derivatives at various stages of the method according to the invention in forms analogous to those occurring in nature; for example, the lignosulfonate starting material is analogous to lignin present in thinner branches of a tree, while the lignosulfonate in a final pressed and compacted product is analogous to lignin present in the trunk of a tree. The lignosulfonate present in the partially polymerised medium is in an intermediate state. The lignosulfonate is preferably present in a minor amount, such as up to about 15% by weight, relative to the hydrophilic surfaced product, the amount referred to relating to lignosulfonate in aqueous form. The lignosulfonate may be used in aqueous form, such as an aqueous solution. A preferred aqueous solution contains 40 to 60% by weight (on a dry basis) of the lignosulfonate. The lignosulfonate may include any suitable cation or cations; examples of suitable cations include ammonium, sodium, calcium and magnesium. Calcium lignosulfonate is preferred for many end-uses of the bonded medium, for the following reasons: (a) when the final product is to be combusted, the calcium can react with sulfur dioxide to form calcium sulfate, and fuse with ash products; and (b) when the final product is to be used as animal feed, calcium is a useful nutrient. It is particularly preferred that the lignosulfonate should be substantially sugar-free (sugars and the like having been removed, typically by fermentation or the like) . When the lignosulfonate is in the form of the calcium salt, the calcium ions may cause separation of lignosulfonate into and β forms (which are defined according to the solubility of the lignin in a bisulfite solution - the α lignins produce lignosulfonates which are less heavily sulfonated than β lignins, and which are therefore more insoluble, when subjected to the same conditions) . In one preferred embodiment of the invention, the lignosulfonate may be in highly dilute form, containing smaller lignosulfonate molecules. Such dilute lignosulfonate may comprise the permeate residue from a process of ultrafiltration of a more concentrated lignosulfonate solution. The resilient organic material may be, for example, comminuted peat or sewage sludge, preferably in the form of flakes, powder or granules with a particle size of not more than 10 mm, more preferably less than 2 millimetres. Alternatively, it may be a cut elongate plant material, such as grass. Typical ways of achieving partial polymerisation of the lignosulfonate are as follows: (a) using oil-or steam-heated hollow mixing screws (typically a twin screw unit, of the type known commercially as "holoflite") , which can give excellent heat transfer to the finely divided material; (b) using a tumble action fluid bed system, similar to a conventional tablet coating pan, in which, typically, the pan is inclined and material in the pan caused to tumble by means of suitably profiled paddle blades, used together with hot air supply (the hot air supply being typically at a temperature in the range 300 to 500°C) ; and (c) using a hot air oven (typically at about 130°C) or a vacuum oven (typically at about 90°C and about 25in Hg) . As a general rule, however, the most significant parameters needed for control of the partial polymerisation are supply of heat and/or oxygen. The material which has been εubjected to vapour pressure equilibration, after it has been mixed with a lignosulfonate in the method according to the invention, may further be mixed with powdered or finely divided carbonaceous fuel. The partial polymerisation of the lignosulfonate may then be in the preεence of oxygen (for example, aε air) . The resulting flowable, substantially non-resilient and non-tacky, chemically bonded medium may be shaped under pressure (preferably following re-activation using, for example, water, urea or the like) to form agglomerates. Such agglomerates may be briquettes (formed between shaped dies or the like) , pellets, bodies formed by extrusion, pan agglomeration or the like. The mix to be agglomerated may be shaped by any suitable apparatus, such as a ring-roll press. When the agglomerates are in the form of briquettes, these are preferably pillow-shaped. When a carbonaceous fuel is present, it may be any suitable particulate carbonaceous material, such as petroleum coke, anthracite, bituminous or sub-bituminouε coal, coking coal or lignite. Such a fuel typically haε a particle εize in the range indicated above for the resilient material. The amount of the carbonaceouε fuel is typically from 30 to 70% by weight, based on the weight of the reεilient material. In a preferred embodiment of the invention, the resilient macromolecular material according to the invention may be an animal feedstuff, such as one comprising one or more of soya, beet pulp and grass. It is particularly preferred that the feedstuff comprises grass (a cut elongate plant material) , in which case, a significant advantage which can be achieved is that a stable processed material can be obtained which retains and enhances the desirable odour of fresh grasε for a prolonged period (such aε for εeveral monthε, εo that the proceεsed grass can be used in the form of blocks as winter forage) . The method according to the invention can therefore result in an enhanced controlled release fresh grass odour. The present invention will be illustrated, by way of example only, with reference to the accompanying drawing, which is a flow chart showing an exemplary sequence of operations in the method according to the invention. Referring to the flowchart, there are shown two possible start conditions (blocks 1,2) depending upon the organic macromolecular material which iε to be processed. Certain materials (block 1) which are not significantly hydrophobic following heat treatment may be conventionally heated and dried by conventional heating/drying (block 3) . Other start materials, which would otherwise be significantly hydrophobic following conventional heat treatment, are subjected to treatment in a three stage process (block 4) . The first stage comprises partly thermally drying the material under conditions permitting the escape of water vapour (such that the resulting dried material has a predominantly hydrophobic surface and substantially reduced water content) . Secondly the material may be flashed with a hot gas before a further stage in which the dried material is εubjected to vapour pressure equilibration under conditions inhibiting escape of water vapour and other volatiles. The predominantly hydrophobic surface of the material is thereby rendered predominantly hydrophilic. Dependant upon the particular starting material, heat conditioned material (from either procesε block 3 or block 4) is subsequently mixed and conditioned (block 5) with aqueous lignosulfonate in the manner described herein in order to form a coating film on the surface of the organic macromolecular material. At this stage (or prior to mixing with lignoεulfonate) the organic macromolecular material may be mixed with additional material εuch as particulate carbonaceous fuel (e.g. anthracite coal) . Subsequently, the material undergoes a partial (but reverεible) polymeriεation step (block 6) in which the lignoεulfonate iε heated to a level in the region of, but below, the temperature at which irreverεible polymerisation would occur. Following polymeriεation, the material may either be stored or used in its current form. Alternatively, following polymerisation (block 6) or storage, the material may be further processed typically by mixing or otherwise conditioning (block 7) typically compriεing regeneration utiliεing water/εteam and/or urea to a pressure sensitive material form. Subsequent processing may comprise compacting for example to form briquettes, pellets and so on (block 8) . The following Examples are further illuεtrative of the present invention. Example 1 Air dried peat with a moisture content of approx 15% and a particle size of approx 4 mm, was dried in a hot air oven set at 105°C to reduce the moisture content to approx 2% by weight. The dried peat was then allowed to equilibrate at 80°C. 50g of the dried peat was placed in a sealed container without compaction and placed in a hot air oven set at 80°C. 50g of anthracite coal with a moisture content of approx 1% by weight and a particle size approx 2mm, was heated to 80°C and allowed to equilibrate. 50g of the anthracite was then placed in a sealed container such that the 50g fills the container without compaction. The vapour presεure in both the peat and anthracite εealed containerε was allowed to equilibrate; the equilibrated vapour pressure being retained for 2 hours. The surface of the particles were thus rendered hydrophilic. The peat and anthracite were then transferred to a Beaken double shafted blade mixer with a water jacket maintained at 80°C and mixed for 1 minute with the mixer lid closed. The product was then added over a period of 5s, with 15g of 50% solids aqueous calcium lignosulfonate which had been heated in a water bath at 80°C. The material was then mixed for 2.5 minutes with the lid cloεed and conditioned in the mixer for 2 minuteε with the lid open. The conditioned and relatively free flowing material was then transferred to a hot air oven set at 130°C and processed so as to achieve semi-polymeriεation of the lignoεulfonate over a period of 1.5 hrs. The semi-polymerised material was then transferred to the Beaken mixer and allowed to equilibrate with the water jacket at a temperature of 80°C. 2g of urea waε added to the mix incremental over a period of 20 sees and mixed for 1 minute with the lid shut; lg of water at 80°C waε then added and further mixed for 2.5 minutes with the lid closed. The lid was opened and the material was conditioned for 2 minutes. The relatively free flowing conditioned material was transferred to a floating ring die, preheated to 60°C, for pressing; a strong green briquette with no resilience cracks was produced. The briquettes produced by this method were tested for thermal shock by placing the briquettes at ambient temperature in a muffled furnace set at 800°C. Briquettes were supported on a three point contact stand. There was no degradation or flaking of the briquettes; the briquettes ignited and retained their integrity until only ash was left. The briquettes produced by the above method were alεo ignited in a small hearth. Radiant heat measurements were made using a pyrometer; when these measurements were compared with propriety premium anthracite briquettes the indicated radiant heat levels were as high as twice that produced with the 100% anthracite briquette. The peat and ash formed are capable of converting convection heat produced by the anthracite to radiant heat. Example 2 Air dried peat with a moisture content of approx 15% and a particle size of approx 4 mm, was processed in a tumbling fluid bed with a gas input temperature of approx 300°C to reduce the moisture content to approx 2% by weight. The dried peat was then allowed to equilibrate at 80°C. lKg of the dried peat was placed in a sealed container so as to fill the container without compaction. The contanier waε placed in a hot air oven set at 80°C. Anthracite with a moisture content of approx 1% by weight and a particle size approx 2 mm waε heated to 80°C and allowed to equilibrate. lKg of the anthracite was then placed in a sealed container so aε to fill the container without compaction. The vapour preεεure in both the peat and anthracite εealed containers was allowed to equilibrate; the equilibrated vapour presεure being retained for 2 hrs. whereby the surface of the particles were rendered hydrophilic. The peat and anthracite were then transferred to a Baker Perkins double shafted blade mixer with a water jacket maintained at 80°C and mixed for 1 minute with the mixer lid closed. 300g of 50% solids aqueous calcium lignosulfonate which had been heated in a water bath at 80°C was then added over a period of 5s. The material was then mixed for 2.5 mins with the lid closed and conditioned in the mixer for a 2 mins with the lid open. The conditioned and relatively free flowing material was then transferred to a twin screw Denver holoflite laboratory dryer. The holoflite screws and the jacket were heated with thermal transfer oil at 300°C from a Churchill heater circulator and processed in the heated holoflite screws so as to achieve semi-polymerisation of the lignosulfonate over a period of 30 minε. The semi-polymerised material was then transferred to the Baker Perkins mixer and allowed to equilibrate with the water jacket at a temperature of 80°C. 30g of urea was added to the mix incremental over a period of 20 εecs and mixed for 1 min with the lid closed; lOg of water at 80°C was then added and further mixed for 2.5 minutes with the lid closed. The lid was opened and the material was conditioned for 2 minutes. The relatively free flowing conditioned material was then presεed and tested as in example 1. Example 3 Air dried peat with a moiεture content of approx 15% and a particle εize of approx 4 mm, was proceεεed in a tumbling fluid bed with a gas input temperature of approx 300°C to reduce the moiεture content to approx 2% by weight. The dried peat waε then allowed to equilibrate at 80°C. 2Kg of the dried peat waε placed in a εealed container so as to fill the container without compaction. The container was placed in a hot air oven set at 80°C. The temperature was maintained accurately at 80°C by means of an external controller. The vapour presεure in the εealed container was allowed to equilibrate; the equilibrated vapour presεure being retained for 2 hrs. The surface of the particles were thus rendered hydrophilic. The peat was then transferred to a Baker Perkinε double shafted blade mixer with a water jacket maintained at 80°C. 3OOg of 50% solids aqueous calcium lignosulfonate which had been heated in a water bath at 80°C was then added over a period of 5s to the product. The material was then mixed for 2.5mins with the lid closed and conditioned in the mixer for a 2 mins with the lid open. The conditioned and relatively free flowing material was then transferred to a twin screw Denver holoflite laboratory dryer. The holoflite screws and the jacket were heated with thermal transfer oil at 300°C from a Churchill heater circulator and processed in the heated holoflite screws so as to achieve semi-polymerisation of the lignosulfonate over a period of 30 mins. The semi-polymerised material was then transferred to the Baker Perkins mixer and the temperature allowed to equilibrate with the water jacket at a temperature of 80°C. 30g of urea was added to the mix incremental over a period of 20 sees and mixed for 1 minute with the lid closed; lOg of water at 80°C was then added and further mixed for 2.5 minutes with the lid closed. The lid was opened and the material was conditioned for 2 minutes. The relatively free flowing conditioned material was then transferred to the floating ring die (preheated to 60°C) for presεing. A εtrong green briquette with no reεilience crackε was produced. The briquettes produced by this method were tested for thermal shock by placing briquettes at ambient temperature in a muffled furnace set at 800°C and briquettes were supported on a three point contact stand. There waε no degradation or flaking of the briquetteε. The briquetteε ignited and retained their integrity until only aεh was left. Example 4 Propriety proceεεed long graεε approx 20-70 mm long was processed in a tumbling fluid bed with a gas input temperature of approx 300°C to reduce the moisture content to approx 4% by weight. The long graεε waε then allowed to equilibrate to 80°C. 1.5Kg of the long grass was placed in a sealed container εo as to fill the container without compaction and placed in a hot air oven set at 80°C. The vapour presεure in the εealed container was allowed to equilibrate; the equilibrated vapour pressure being retained for 2 hrs whereby the surface of the grass was rendered hydrophilic. The long grass was then transferred to a Baker Perkins double shafted blade mixer with a water jacket maintained at 80°C. 150g of 50% solids aqueous calcium lignosulfonate which had been heated in a water bath at 80°C was then added over a period of 5s to the grasε. The material waε then mixed for 2.5 mins with the lid closed and conditioned in the mixer for a 2 mins with the lid open. The conditioned and relatively free flowing material was then tranεferred to the tumbling fluid bed and exposed to tumbling fluidising action of hot air at 300°C εo aε to achieve εe i-polymeriεation of the lignoεulfonate over a period of 5 minuteε. The semi-polymerised material was then transferred to the Baker Perkins mixer and allowed to equilibrate with the water jacket at a temperature of 80°C. 30g of urea powder was added to the mix incremental over a period of 20 sees and mixed for 1 min with the lid closed; lOg of water at 80°C was then added and further mixed for 2.5 mins with the lid closed. The lid was then opened and the material waε conditioned for 2 minuteε. The relatively free flowing conditioned material was transferred to a cylindrical block die preheated to 60°C for preεεing. A εtrong hard block waε produced which waε 65 mm long and 40 mm in diameter; there was no resilience cracking. The natural odour of fresh grasε was very strong and enhanced; this grass odour was stronger than that produced by the original long grass. Example 5 A mixture was prepared containing 600g of propriety processed long grass approx 20-70mm long, 600g of soya bean meal and 600g of beet pulp. The mixture was processed in a tumbling fluid bed with a gas input temperature of approx 300°C to reduce the moisture content to approx 4% by weight. The mixture was then allowed to equilibrate at 80°C. 1.5Kg of the mixture was placed in a sealed container so as to fill the container without compaction and placed in a hot air oven set at 80°C. The vapour pressure in the sealed container was allowed to equilibrate; the equilibrated vapour pressure being retained for 2 hrs. The surface of the particles were thus rendered hydrophilic The mixture was then transferred to a Baker Perkins double shafted blade mixer with a water jacket maintained at 80°C and mixed for lmin with the lid closed. 150g of 50% solids aqueous calcium lignosulfonate which had been heated in a water bath at 80°C was then added over a period of 5s to the mixture. The material was then mixed for 2.5 mins with the lid closed and conditioned in the mixer for a 2 mins with the lid open. The conditioned and relatively free flowing material was then transferred to the tumbling fluid bed and exposed to tumbling fluidising action of hot air at 300°C so as to achieve semi-polymerisation of the lignosulfonate over a period of 5 minutes. The semi-polymerised material was then transferred to the Baker Perkins mixer and allowed to equilibrate with the water jacket at a temperature of 80°C. 30g of urea powder was added to the mix incremental over a period of 20 sees and mixed for 1 min with the lid closed; lOg of water at 80°C was then added and further mixed for 2.5 mins with the lid closed. The lid was opened and the material was conditioned for 2 mins. The relatively free flowing conditioned material was then pressed as in example 5 and produced a block with the natural odour of fresh grass that was stronger than that produced by the original long grass. Example 6 40g of autoclave and dried sewage sludge was heated in a hot air oven set at 126°C for 30 mins. 40g of Pitsburg No8 coal was also dried and heated in the same oven at 126°C for 3Omin. The sludge and the coal were then mixed for 1 min with the lid closed. 12g of calcium lignosulfonate (Borresperse Ca approx 50% solids) was added over a time of 5 sees, mixed for 2.5 mins with the lid closed and then the material was conditioned for 2 mins with the lid open. The material was then transferred to a stainless steel hot air oven set at 136-137°C for 2hours. The semi polymerised material was then transferred form the hot air oven to the Beakin mixer with the water jacket at 80°C. 2g of urea powder was added to the mix incremental over a period of 20 sees. The material was then mixed for 1 min with the lid closed; lg of water was then added and the material was mixed for a further 2.5 mins with the lid closed and then conditioned for 2minutes with the lid open. The material was then transferred to a floating ring briquette die which was pre-heated to 60°C. The material in the die waε given an initial compaction using hand presεure and then pressed on a hydraulic press with 60001bs per square inch on a 2^ins diameter ram (21,279lbs load) . A strong green briquette with a smooth surface waε produced with no resilience cracks. The green briquette was placed in a εtainless steel carbonisation pot and carefully surrounded by fine anthracite to minimise the presence of air. The carbonisation pot was placed in the carbonisation oven with both the oven and container at ambient temperature; the oven being set to ramp itε temperature to reach 800°C in 1.25hours. Smoke waε obεerved at 450°C but had virtually finished by the time the temperature had reached 800°C; the carbonisation waε maintained at 800°C for 5 mins. The carbonisation pot was removed from the oven, there was a small flame from the container; the flame was not smoking. The weight of the carbonised briquette was 25.6g producing a weight loss of 45.6%. There was no visible cracks and the briquette was in the form of coke. The appearance of the briquette gave no indication of its component parts. The briquette was crushed on a briquette test rig which had been independently calibrated for the test crushing strength was 153KgF.

Claims: Claims : 1. A method of producing a chemically bonded medium, which method compriseε: (a) providing a reεilient organic macromolecular material, in which said organic macromolecular material is in cut elongate or finely divided form; (b) at least partly thermally drying said cut elongate or finely divided material, under conditions permitting escape of water vapour therefrom, such that said dried material has a predominantly hydrophobic surface and a water content of not more than 10% by weight, said drying optionally comprising flashing at least the surface of said material; (c) subjecting at leaεt εome of εaid dried material to vapour preεsure equilibration, under conditions inhibiting escape of water vapour and other volatiles, such that said predominantly hydrophobic surface is rendered hydrophilic; and (d) mixing the product of step (c) with a lignosulfonate, with sufficient heat being applied to maintain the lignosulfonate in fluid form, εuch that the lignosulfonate forms a coating film on said hydrophilic εurface; and (e) cauεing partial polymerisation of said lignosulfonate on εaid εurface to produce a flowable, εubεtantially non-reεilient, chemically bonded medium. 2. A method according to claim 1, wherein εaid water content at εtep (b) iε not more than 5%. 3. A method according to claim 2, wherein εaid water content at step (b) is not more than 3%. 4. A method according to any of claims 1 to 3 , wherein said coating film in step (d) is a monolayer or the like. 5. A method according to any of claims 1 to 4, wherein said chemically bonded medium is stored before being further processed. 6. A method according to any of claims l to 5, wherein said chemically bonded medium from step (e) is further processed to render said chemically bonded medium pressure sensitive. 7. A method according to any of claims 1 to 6, wherein said chemically bonded medium from step (e) is treated with water or steam and/or urea. 8. A method according to claim 7, wherein εaid chemically bonded medium is cured after said treatment with water or steam and/or urea. 9. A method according to any of claims 1 to 8, wherein said chemically bonded medium is further processed in a step comprising compacting and compression of said chemically bonded medium. 10. A method according to any of claims 1 to 9, wherein said lignosulfonate, in an aqueous form is preεent in an amount not more than 15% by weight, relative to the hydrophilic surfaced product 11. A method according to any of claimε 1 to 10, wherein the lignosulfonate is used in an aqueous form containing 40-60% dry weight of said lignosulfonate. 12. A method according to any of claims 1 to 11, wherein the lignosulfonate is an ammonium, εodium, calcium or magnesium salt. 13. A method according to claim 12, wherein the salt is calcium lignosulfonate. 14. A method according to any of claims 1 to 13 , wherein the lignosulfonate is substantially sugar-free. 15. A method according to any of claims 1 to 14, wherein the resilient material compriseε comminuted peat or sewage sludge. 16. A method according to claim 15, wherein said peat or sewage sludge is in the form of flakes, powder or granules. 17. A method according to claim 15 or 16, wherein said peat or sewage sludge have a particle size of not more than 2 millimetres. 18. A method according to any of claims 1 to 14, wherein the resilient material comprises cut grass. 19. A method according to any of claims 1 to 18, wherein said partial polymerisation is achieved in a hot air oven, a vacuum oven or by means of oil or steam heated hollow mixing screws or a tumble action fluid bed system. 20. A method according to any of claims 1 to 19, wherein said chemically bonded medium is εhaped under preεsure to form agglomerates. 21. A method according to claim 20, wherein said agglomerates are briquettes. 22. A method according to claim 21, wherein said briquettes are pillow shaped. 23. A method of producing a chemically bonded medium, which method comprises: (a) providing a resilient organic macromolecular material, in which said organic macromolecular material is in cut, elongate or finely divided form; (b) heating and/or drying said organic macromolecular material; (c) mixing the organic macromolecular material from step (b) with a lignosulfonate, with sufficient heat being applied to maintain the lignosulfonate in fluid form, such that the lignosulfonate forms a coating film on the surface of said organic macromolecular material; and (d) causing partial polymerisation of said lignosulfonate on said surface to produce a flowable, substantially non-resilient, chemically bonded medium. 24. A method according to claim 23, wherein the organic macromolecular material is mixed with a further material. 25. A method according to claim 24, wherein the organic macromolecular material is mixed with the further material prior to step (c) . 26. A method according to claim 24 or claim 25, wherein said further material comprises a particulate organic material such as a carbonaceous fuel. 27. A method according to any preceding claim, wherein the partial polymerisation step compriseε elevating the temperature of the lignosulfonate on the surface of the organic macromolecular material to a level in the region of but below the temperature at which irreversible polymerisation would occur. 28. A method according to claim 27, wherein the temperature of the lignosulfonate on the surface of the organic macromolecular material is elevated to a temperature substantially in the range 110°C and 150°C in the partial polymerisation step. 29. A method according to claim 28, wherein the temperature of the lignosulfonate on the surface of the organic macromolecular material is elevated to a temperature substantially in the range 120°C to 140°C in the partial polymerisation step. 30. A method according to any preceding claim, wherein the organic macromolecular material comprises peat.

Inventors: REES WILLIAM GERAINT, REES, WILLIAM, GERAINT
Applicants: REES WILLIAM GERAINT, REES, WILLIAM, GERAINT
Application year: 1996
Main classification: C10L5
IPC codes: A23K1, B09B3, C02F11, C08L97, C10L5