TREATMENT OF LIGNOCELLULOSIC MATERIAL

Abstract: A method of treating subdivided or particulate lignocellulosic material with steam at temperature and a pressure high enough and for a time sufficient to effect decomposition and hydrolysis of hemicellulose and/or cellulose into water soluble resin material including pentose and hexose sugars, sugar polymers, furfural, hydroxymethyl furfural, dehydrated carbohydrates and organic acids, characterized in that the steam treatment is effected, at least in part of its duration, in the presence of an acidic catalyst such as sulfuric acid, sulfur dioxide or ammonium sulfate.

Description: I TREATMENT OF LIGNOCELLULOSIC MATERIAL The present invention relates to the treatment of lignocellulosic material . In particular, but not exclusively, the invention relates to the production of composite material and to the production of thermosetting resin adhesive. European patent specifications nos. 0161766 and 0492016 describe the treatment of lignocellulosic material with steam to decompose and hydrolyze hemicellulose into low molecular weight water-soluble resin material including sugars (pentose and hexose), sugar polymers, furfural, dehydrated carbohydrates, organic acids and other decomposition products. The latter European patent specification also describes the treatment of lignocellulosic material, which has been treated with steam to decompose and hydrolyze hemicellulose in the manner referred to above, to decompose and hydrolyze cellulose into low molecular weight water-soluble resin material as referred to above. As described in both of the aforementioned European patent specifications, the lignocellulosic material after decomposition of the hemicellulose, may be formed, optionally together with other particulate or subdivided material, into a mat and the decomposition products thermoset thereby to produce a reconstituted composite product. Similarly as described in European patent specification no. 0429016 the lignocellulosic material after decomposition and hydrolysis of the cellulose, may be formed, optionally together with other particulate or subdivided material, into a mat and the decomposition products thermoset thereby to produce a reconstituted composite product. The decomposition products from the decomposition and hydrolysis of the hemicellulose or cellulose may be separated from the lignocellulosic material, optionally concentrated or dried, and used as a thermosetting resin adhesive, e.g. in the production of composite products. European patent specification nos. 0161766 and 0492016 disclose that the lignin fraction of the lignocellulosic material may also be decomposed and hydrolyzed into low molecular weight lignin and lignin decomposition products. Both of the aforementioned European patent specifications disclose adding acid, as catalyst, to the lignocellulosic material to be treated with steam to decompose and hydrolyze hemicellulose. Specification no. 0492016 also discloses the addition of acid, as catalyst, to lignocellulosic material, wherein the hemicellulose has already been hydrolyzed, prior to treatment of the lignocellulosic material to decompose and hydrolyze cellulose. The lignocellulosic material, at least when hemicellulose is to be decomposed and hydrolysed, remains in contact with the acid prior to the steam treatment for a sufficiently long period of time for the acid to penetrate throughout substantially the entire volume of each particle of lignocellulosic material whereby the material is uniformly decomposed and hydrolysed during the steam treatment. We have now discovered that an excessive amount of acid reduces the mechanical strength of reconstituted composite products prepared from the treated lignocellulosic material. In particular we have now discovered that by use of a controlled amount of acid within a specific range the properties of reconstituted composite products prepared from the lignocellulosic material may be controlled to be within optimum or desirable ranges and the properties of composite products made using thermosetting resin adhesive separated from the lignocellulosic materials may also be controlled to be within optimum or desirable ranges. We have also discovered that the use of acid within a specific range may also affect manufacturing parameters of reconstituted composite products. In particular, the use of a controlled amount of acid within a specific range may also result in increased flexibility with respect to press temperature and time. We have also discovered that by treating the particulate lignocellulosic material with acid but effecting decomposition and hydrolysis of the hemicellulose and/or cellulose of the particulate lignocellulosic material without the acid having penetrated to the core of the particles a composite product of improved strength can be prepared from the treated lignocellulosic material . In a first aspect the present invention provides a method of treating subdivided or particulate lignocellulosic material with steam at a temperature and a pressure high enough and for a time sufficient to effect decomposition and hydrolysis of hemicellulose and/or cellulose into water soluble resin material such as pentose and hexose sugars, sugar polymers, furfural, hydroxymethyl furfural, dehydrated carbohydrates and organic acids, characterized in that the steam treatment is effected, at least during part of its duration, in the presence of an acidic catalyst. The acidic catalyst may be mixed with the lignocellulosic material before and/or during the steam treatment. The acidic catalyst may be a compound, such as sulfuric acid, sulfur dioxide or an acidic salt, which is acidic in aqueous solution. If decomposition and hydrolysis of cellulose is to be effected, then the lignocellulosic material may preferably be lignocellulosic material, the hemicellulose of which has already been hydrolyzed and decomposed, preferably in accordance with the present invention. Reconstituted products having desirable properties may be prepared from the treated lignocellulosic material. It is not suggested that any individual parameter of the composite products are necessarily optimised but merely that the respective values of a number of such parameters are within desirable ranges. Such parameters may be, for example, resistance to swelling in the presence of moisture or liquid water, internal bond strength, bending strength and stiffness, lightness of colour, low odourousness, and machineability. In particular reconstituted composite products of good strength and low odour can be obtained. The decomposition products, i.e. the water soluble resin material, may be used as a thermosetting adhesive, e.g. either in the production of the above- mentioned composite material from the treated lignocellulosic material or in the production of other composite material or for other purposes. Preferably when hemicellulose is to be hydrolysed the amount of sulfuric acid is at least 0.05%, more preferably 0.10%, and preferably is in the range 0.10 to 0.35% . Even more preferably the amount of acid does not exceed 0.30% . The percentage amounts of sulfuric acid and other acidic catalysts given herein are by weight and are based on the dry (oven dry) weight of the lignocellulosic material. The percentage amounts of sulfuric acid are calculated as 100% sulfuric acid. Preferably when cellulose is to be hydrolysed, dilute sulfuric acid is added to lignocellulosic material to give a mixture containing 0.5 to 5% sulfuric acid. Alternatively, instead of sulfuric acid, an equivalent amount of another acid may be used. By an amount of acid equivalent to an amount of sulfuric acid we mean an amount of the first-mentioned acid providing the same number of H + ions as said amount of sulfuric acid, assuming that both the first-mentioned acid and the sulfuric acid fully dissociate. As mentioned above, sulfur dioxide or an acidic salt may be used as the acidic catalyst. Sulphur dioxide reacts with steam to produce sulphurous acid and may react further with components of the lignocellulosic material to produce other acids. The amount of sulfur dioxide used is preferably 0.5 to 5% or 1.0 to 4.0% . The acidic salt may be ammonium sulfate. Preferably ammonium sulfate is used in an amount of 0.10 to 10%, preferably 0.25 to 10%, more preferably 1.0 to 8.0% . In practice, the amount of acid catalyst should be adjusted according to the buffer capacity or ash content of the lignocellulosic material. Certain wood species and agricultural plants are well known for their high content of ash or alkalinity . The natural alkalinity in Hgnocellulose material causes a significant loss of acid that must be considered when calculating the acidic catalyst requirements. Preferably the acidic catalyst is mixed with the lignocellulosic material to provide a pH within the range of 1.0 to 5.0, even more preferably, 2.0 to 4.5 and most preferably 2.5 to 3.5, at the beginning of the steam treatment. Preferably the steam treatment is carried out at a temperature not exceeding 220 degrees C, and preferably not exceeding 210 degrees C. Preferably the steam treatment is carried out for a time not exceeding 90 minutes. Preferably the amount of acid used and the conditions of steam treatment are such that the amount of water solubles produced is greater than 15%, more preferably 20%, of the initial dry weight (before any decomposition and hydrolysis of any hemicellulose) of the lignocellulosic material and preferably the pentosan content of such water solubles exceeds 10% by weight based on the dry weight of the lignocellulosic material. When hemicellulose is to be hydrolyzed, the acidic catalyst reduces undesired hydrolysis of cellulose thereby increasing the strength of composite material made from the treated Hgnocellulose material. Also the acidic catalyst facilitates the extraction and increases the yield of the water soluble resin material. The acidic catalyst unexpectedly results in the treated lignocellulosic material being lighter in colour and less odorous, thus enabling a composite product which is lighter in colour and less odourous to be prepared from the treated lignocelulosic material . These characteristics are desirable qualities for commercial products. When the acidic catalyst is sulfuric acid it is preferably used in aqueous solution at a concentration not exceeding 10% by weight, of H 2 SO 4 , and more preferably at a concentration not exceeding 5.0%. The concentration is mainly determined by the amount of acid to be used and size, shape and initial moisture content of the particles of lignocellulosic material. However, it should be noted that low concentration of acid solution always adds more water to the lignocellulosic material, thereby consuming more thermal energy to be required for the steam treatment. The acid may be added to the whole bulk of the lignocellulosic material to be treated or may be added only to a part of that bulk, that part and the remaining bulk of the lignocellulosic material being mixed together either during the steam treatment or subsequent thereto but prior to formation of composite products from the treated lignocellulosic material or extraction of the water soluble resin material from the lignocellulosic material. It will be appreciated that if the acidic catalyst is added only to a part of the bulk of the lignocellulosic material, then the percentage amounts of acidic catalyst given above relate to that part and not the whole bulk. In accordance with a second aspect of the present invention there is provided a method of treating subdivided or particulate lignocellulosic material with steam at a temperature and a pressure high enough and for a time sufficient to effect decomposition and hydrolysis of hemicellulose and/or cellulose into water soluble resin material such as pentose and hexose sugars, sugar polymers, dehydrated carbohydrates, furfural, hydroxymethyl furfural and organic acids, wherein acid is applied to the lignocellulosic material in subdivided or particulate form prior to and/or during decomposition and hydrolysis and the lignocellulosic material remains in contact with the acid prior to and/or during decomposition and hydrolysis for a time insufficient to allow the acid to penetrate to the core of the particles of lignocellulosic material before cessation of the decomposition and hydrolysis so that cellulose fibres in the core of the particles are not substantially degraded by the steam treatment. Reconstituted products may be prepared from the treated lignocellulosic material. A stronger composite product can be produced from the treated lignocellulosic material than if the acid had penetrated to the core of the particles resulting in the cellulosic fibres throughout the particles being degraded by the steam treatment. The decomposition products, i.e. the water soluble resin material, may be used as a thermosetting adhesive, e.g. either in the production of the above- mentioned composite material from the treated lignocellulosic material or in the production of other composite materials or for other purposes. The acid may be applied to the lignocellulosic material by soaking the particles in an acid solution or spraying the particles with an acid solution. The steam treatment may be carried out in a pressure vessel (often referred to as a cooker or a digester). The extraction of the treated material from the pressure vessel can be slow and gentle or in an instant release, resulting in an explosive discharge, which renders the treated lignocellulosic material in fibrous and particulate form. After the steam treatment the particles of lignocellulosic material may be broken down into fibres, or fine particles by means of refining or hammermilling, prior to reconstitution as a composite product, so that the "well cooked" exterior parts of the lignocellulosic material (i.e. the parts wherein the cellulose fibres have been degraded or broken down) are well mixed with the "undercooked" core parts of the lignocellulosic material (i.e. the parts wherein the cellulosic fibres have not been broken down due to lack of acid). The well cooked parts of the particles provide resin for binding the composite product together whilst the undercooked parts of the particles provide substantially undamaged cellulose fibres for strengthening the composite product, thus also resulting in a composite product being lighter in colour and less odourous. The second aspect of the invention enables the waste water problem that otherwise arises if the Hgnocellulose particles are impregnated with acid solution to be eliminated since no waste water is produced with the in situ addition of acid solution. Alternatively to obtain differently "cooked" portions of lignocellulosic material would require the separate production and treatment of lignocellulosic material to produce well cooked particles and treatment of lignocellulosic material to produce undercooked particles and this would require extra production steps and/or equipment. In both aspects of the invention, the treatment of the lignocellulosic material may be effected as a continuous process or as a batch process. It will be understood that the first and second aspects of the invention are not mutually exclusive. A preferred process in accordance with the invention is in accordance with both the first and second aspects of the invention. A preferred method in accordance with the present invention comprises the following steps in the order given below: (a) bringing lignocellulosic material in the presence of an acidic catalyst into contact with steam at a pressure and temperature sufficiently high and for a time sufficient to decompose and hydrolyze hemicellulose contained in the lignocellulosic material into low molecular weight water soluble resin material including pentose and hexose sugars, sugar polymers, furfural, hydroxymethyl furfural, dehydrated carbohydrate, organic acids and other decomposition products, with negligible degradation of cellulose and no carbonization of the lignocellulosic material; and (b) separating at least a portion of the water soluble resin material from the lignocellulosic material and optionally concentrating or drying the separated resin material. This preferred method may also comprise, after step (b): (c) bringing the remaining lignocellulosic material in the presence of an acidic catalyst into contact with steam at a pressure and at a temperature sufficiently high and for a time sufficient to decompose and hydrolyze cellulose contained in the lignocellulosic material into low molecular weight water soluble resin material including pentose and hexose sugars, sugar polymers, furfural, hydroxymethyl furfural, dehydrated carbohydrate, organic acid and other decomposition products, with no significant carbonization of the lignocellulosic material; and (d) optionally separating at least a portion of the resin material from the lignocellulosic material and optionally concentrating or drying the separated material. The separated resin material from steps (b) and (d) is suitable for use, separately or in admixture (i.e. together), as a waterproof thermosetting resin adhesive. The lignocellulosic material from steps (a) and (c), optionally after separation of resin material in steps (b) and (d) respectively, may be formed, separately or in admixture, and alone or in combination with other lignocellulosic material into a reconstituted composite material. To form the treated Hgnocellulose material into a composite product it may, together with thermosetting water soluble resin material from the decomposition of the hemicellulose or cellulose be formed into a mat and the mat pressed at temperature not exceeding that at which the mat would char at a pressure and for a time sufficient to thermoset the resin to adhesively bond together the Hgnocellulose material. In both aspects of the invention, lignin of the lignocellulosic material may be decomposed and hydrolysed by the high pressure steam into low molecular weight lignin and lignin decomposition products and the water soluble resin material derived from decomposition and hydrolysis of hemicellulose and/or cellulose may contain such water soluble low molecular weight lignin and lignin decomposition products. The invention is illustrated by the following examples. Examples 1 to 6 relate to the first aspect of the invention. Examples 7 relates to the second aspect of the invention. Abbreviations used in the examples have the following meanings: MOR Modulus of rupture MOE Modulus of elasticity IB Internal bond strength MDF Medium density fibreboard OD Oven dry Example 1 This example demonstrates the use of acidic catalyst to hydrolyze and 11 decompose the hemicellulose portion of Aspen poplar sawdust and extract the water soluble resin material for use as a thermosetting liquid adhesive for bonding waferboard. Fresh poplar sawdust (3.2 mm mesh size) with a moisture content (M.C.) of about 100%, O.D. weight was treated with high pressure steam at 32 bar (470 psi, or 240°C) for 30, 60, 90 and 120 seconds respectively. A second batch of the same Aspen poplar sawdust was impregnated with dilute sulfuric acid to contain 0.2 gram of H 2 SO 4 per 100 grams of oven dry sawdust, stored for 6 hours to ensure the acid reached equilibrium in the sawdust and then treated with high pressure steam at 22 bar (322 psi, 220°C) for 30, 60, 90 and 120 seconds respectively. Eight steam treatments were applied to the acidified and non-acidified poplar sawdust. Pentosan analysis (TAPPI Standard Method: T2230S-71) was performed on each treatment of poplar sawdust along with the mass recovered, water solubles and pH value. The results are recorded in Table 1. Table 1 Water soluble resin material and pentosan content of hydrolyzed Poplar sawdust (percentage based on original O.D. weight of Poplar sawdust) Steam temperature Mass recovered Pentosan in Water solubles Pentosan in pH of water after steaming mass water solubles solubles [seconds] [%] [%] W [%] at 240 oC 30" no acid 95.8 16.1 19.2 8.6 3.57 60" no acid 94.6 15.2 19.6 9.2 3.54 90" no acid 93.2 13.7 18.1 9.7 3.43 120" no acid 90.1 12.2 17.3 7.8 3.34 (93.4) (14.3) (18.6) (8.9) (3.45) at 220 oC 30" + 0.2 % acid 94.6 15.5 24.3 11.6 3.18 60" + 0.2 % acid 93.4 15.2 25.6 12.0 3.05 90" + 0.2 % acid 91.7 14.3 26.5 11.2 2.92 120" + 0.2 % 89.2 13.1 25.1 10.3 2.86 acid (92.2) (14.5) (25.4) (11.4) (3.00) Aspen poplar sawdust contains 19.2 % pentosau by weight of original O.D. weight of sawdust. It can be seen from Table 1 that the pentosan content of the acidified and non- acidified sawdust treated for the same steaming time is very similar. Poplar sawdust treated with H 2 SO 4 at 220°C and with H 2 SO 4 at 240°C showed almost identical degrees of hemicellulose decomposition when treated with identical steaming times. This indicates that about the same degree of hemicellulose decomposition occurred under the acidified and non-acidified steam treatments. However, the average water solubles extracted from the acid catalyzed poplar sawdust was 25.4%, based on the original O.D. weight of sawdust as compared to 18.6% water solubles extracted from non-acidified poplar sawdust; a significant difference in yield of 37.0% . Surprisingly, the average pentosan content in the water solubles extracted from the acid catalyzed poplar sawdust was 11.4% as compared to 8.9% for the non-acidified poplar sawdust. This difference in pentosan content between the acidified and non-acidified sawdust was about 28.0% . These higher percentages exemplify the advantages of using acid catalyst in that a higher yield of pentosan can be obtained from the same poplar sawdust. In this present invention, pentosan is one of the essential bonding components of the thermosetting resin adhesive. It may be noted that the water soluble resin material also contains a small portion of low molecular weight lignin and lignin decomposition products which are soluble in acidic aqueous. The effects of lignin products in the water soluble resin material are not known. Water soluble resin material, extracted from poplar sawdust treated with and without acid catalyst and steamed for various times, was concentrated under vacuum to liquid resin adhesive, with a solids content of about 55.0% for bonding waferboard. Commercial poplar wafers were sprayed with 10.0% (solids basis) of the liquid resin adhesive, and 1.0% (solids basis) emulsified paraffin wax, based on O.D. weight of poplar wafers. The resinated wafers were dried to a M.C. of about 3 - 4% for making waferboards. One panelboard (600 x 600 x 11.1 mm) was made from each of the liquid resin adhesives with a target density of 670 Kg/M 3 (42 pcf) density. One press temperature of 230°C, combined with a press time of 10 minutes and an initial pressure of 34 kg/cm 2 (500 psi) was used to manufacture eight waferboards. The waferboards were conditioned for 3 days and tested in accordance with CAN3-0188.3-78 method. Their physical properties are listed in Table 2. Table 2 Physical propeities of 11.1 nini poplar waferboard bonded with 10 % liquid resin adhesive derived from poplar sawdust Resin Board MOR MOE IB Thickness swelling treatment density dry boil soak boil [°C/secondsJ [kg/M'l [MPa] [MPa] [MPa] [kPa] {%] [%] Resin adhesive catalyzed with 0.2 % acid 220/30" 672 24.2 7.5 5470 550 9.2 17.8 220/60" 669 23.7 10.3 5620 620 7.8 14.3 220/90" 677 25.4 11.7 5780 670 6.2 12.6 220/120" 667 23.8 13.6 5820 680 5.9 12.2 (671) (24.3) (10.8) (5670) (640) (7.3) (14.2) Resin adhesive non-acid catalyzed 240/30" 668 21.6 5.1 4830 480 14.3 25.6 240/60" 672 23.2 8.8 5280 560 11.4 21.2 240/90" 675 24.3 9.7 5330 630 9.7 17.5 240/120" 676 24.8 11.6 5470 640 7.2 14.7 (672) (23.4) (9.0) (5210) (580) (10.7) (19.8) CSA standard 17.2 8.6 3100 345 25 CAN 3-0437.0M86 As can be seen from Table 2, the physical properties of poplar waferboards bonded with acid catalyzed resin adhesive are better than those of waferboards bonded with non-acidified resin adhesive. Of particular interest is the 12 relatively higher wet bending strength (MOR), and stiffness (MOE) and lower thickness swelling of the waferboard bonded with acid catalyzed resin adhesive derived from the hemicellulose hydrolysis. These superior physical properties also indicate that the acid catalyzed resin adhesive is more reactive, than non- acidified adhesive, with a faster curing rate. In terms of economic efficiency, acid catalyzed poplar saw dust yielded 37% more resin adhesives in comparison to non acidified poplar sawdust. Example 2 This example illustrates the effect of acid catalyst on the physical properties of MDF made with a mixture of Western red Cedar and Hemlock mill residue. Fresh Western red Cedar shavings (60 % O.D. weight), and Hemlock planer shavings (40 %, O.D. weight), with a M.C. of about 35 % to 50 %, were mixed to provide fibre furnish for the MDF. The mixtures were divided into seven equal groups for steam treatment under varying conditions, using different steam temperatures and times. The first three groups were control groups, the first group of which were steamed at a steam temperature of 240 °C (32 bar or 470 psi) for 45 seconds. The second and third control groups were steamed at 184 °C (10 bar or 145 psi) for 6 and 12 minutes respectively. The remaining four groups were sprayed with dilute H 2 SO 4 to contain 0.1, 0.2, 0.3 and 0.4% H 2 SO 4 based on O.D . weight of the mixture. After spraying, the M.C. of the mixed planer shavings was increased to about 55 % to 70 %. Acid would quickly and easily penetrate throughout planar shavings because they are very thin. All four groups treated with the dilute H 2 SO 4 solution were immediately steamed in separate batches at 184 °C (10 bar or 145 psi) for 6 minutes. All seven groups of steamed shavings were refined in a 36 inch Bauer disc refiner, to convert the material into fibres. The refining was performed under atmospheric pressure and 1.5 % emulsified paraffin wax was added to the fibre during refining. After refining, the fibre furnish was dried to about 3 - 5 % M.C. for fabrication of MDF. One panelboard (600 x 600 x 12.5 mm) was made from each group of fibre furnish with a target density of 800 kg/M 3 . One set of press conditions, consisting of 230 °C platen temperature, 10 minute pressing time and an initial pressure of 22 kg/cm 2 was used for all seven panelboards. Test results from seven individual MDF are recorded in Table 3. Table 3 Physical Properties of 12.5 mm MDF made with Cedar and Hemlock fiber with and without acid catalyst (press temperature 230 °C, press time 10 minutes) oard Steam Board MOR MOE IB Thickness swelling ID condition density dry wet soak boil [°C & time] [kg/M J ] [MPa] [MPa] [MPa] [kPa] [%] [%] No aci d catalyst with different steam temperatures and times 1 240 824 24.5 12.2 3670 810 10.9 19.2 °C/45" 2 184 °C/12' 811 22.5 11.7 3140 790 11.6 24.6 3 184 °C/6' 802 16.7 DEL 1860 220 93.2 DEL Acid catalyst with < Jteam 1 e perature of 184 ° C for 6 minutes 184 °C/6' % of acid 4 0.1 817 19.7 5.6 2740 350 22.3 98.2 5 0.2 808 23.8 12.4 3420 870 10.2 21.7 6 0.3 804 21.2 13.3 3560 830 8.4 17.2 7 0.4 812 14.7 9.2 2670 840 6.2 14.5 The physical properties of MDF made with acidified and non-acidified fibres, except for boards ID # 3 and 7, in general, were very comparable. However, the colour and odour of the acidified MDF were much lighter in comparison to the non-acidified MDF. It appears that the intensity of colour and odour is closely related to the degree of acidification. The highly acidified fibre resulted in MDF with lighter colour and far less odour, which is more commercially desirable. There was a similar correlation between acid content and thickness swelling; the higher the acid content, the lower the thickness swelling. It is believed that the residual acid in the steam treated lignocellulosic contributed greatly to the low swelling of the MDF and fast cure of the resin bond. Among the four MDF panels made with fibres catalyzed with different levels of H 2 SO 4 , the 0.4% acid catalyzed (the highest amount), produced MDF with the lightest colour and the least odour. These findings are surprising because one would expect more intense odour and darker colour with the increased hydrolysis of the acidified material. The usual faint sweet odour was not detected; however, the bending strength of this highly acidified panel was relatively weak in comparison to MDF made with less acidified fibres. The low bending strength seems to result from excessive hydrolysis promoted by the high content of sulfuric acid that causes random scission of the crystalline chain in the cellulose fibre, or reduces the degree of polymerization (DP) of the cellulose crystalline. It was also found that the MDF made with higher content of acid catalyst possess better machinability, i.e. , cutting, sawing, and routing characteristics. Good machinability is an important requirement for MDF used in furniture manufacturing. By controlling the amount of acid catalyst, it is possible to produce a panelboard with specifically desired characteristics to suit the end use. Example 3 This example demonstrates the use of gaseous sulfur dioxide (SO 2 ) as an acid catalyst for hydrolysis of Poplar sawdust (3.2 mm mesh size) and the use of short press time to make MDF. SO 2 impregnation was performed by passing anhydrous S0 2 gas into a plastic bag containing fresh Poplar sawdust. The absorption of SO 2 (about 1.8% SO 2 based on O. D. weight Poplar sawdust) was determined by the weight of the bag of Poplar sawdust before and after addition of SO 2 . The absorption was rapid and uniform. The acid impregnated sawdust was immediately steam treated at 220 °C for 2 minutes. For purposes of comparison, identical Poplar sawdust, without the addition of SO, was also steamed at 220 °C for 2 minutes. The acidified and non-acidified saw dust were refined into fibre in separate batches and dried to a M.C. of about 5 % . The dried fibres were ready for fabrication of 8 mm MDF. The fibres were formed into mats and hot pressed at 190 °C for 2 minutes and the hot board followed by oven heated at 180 C C for 2 hours. When compared with sulfuric acid, SO 2 may act as a weak acid by simply dissolving in the water, contained in the fresh Poplar sawdust to form sulphurous acid, or it may react with oxygen of any air present, to produce sulfuric acid. It may react with the lignin decomposition prodcuts to form lignosulphonates which are very strong acids, or it may act in both these ways to promote hydrolysis. The formation of lignosulphonates may enhance the bonding capabilities of the fibres as lignosulphonates are known to have adhesive qualities. The ease by which gaseous SO 2 can be added to wood and the quick penetration and even distribution of the gas makes this very practical for industrial application. In contrast, sulfuric acid impregnation is a difficult procedure, as sulfuric acid is a more corrosive chemical to handle and results in wetter wood substrates. Water in the sawdust consumes a large portion of the thermal energy required for the hydrolysis. By using SO 2 , higher water content in the sawdust can be avoided, thus reducing energy consumption. Test results for the 8.0 mm MDF are listed in table 4, showing a significant difference in physical properties between the MDF made from the acidified and non-acidified fibres. Table 4 Physical properties of 8.0 mm MDF made with Poplar fiber with and without SO, catalyst (press temperature 190 °C, press time 3 minutes and post oven heating at 180 °C for two hours) Steam Board MOR MOE IB Thickness swelling condition density dry wet soak boil [minute] [kg/M'l [MPa MPa] [MPa] [kPa] [*] [%] o acid 220 °C/2 miu 804 18.2 0.0 2460 410 67.4 DEL 1.8 % 220 °C/2 miu 810 26.2 10.7 3820 860 14.2 31.6 S0 2 The physical properties of MDF made with acidified fibre, are better than those of the MDF made with non-acidified fibre, particularly with regard to internal bond strength, wet bending strength and thickness swelling. It should be appreciated that the SO 2 catalyzed board required much shorter press time when followed with a shorter post-oven heat treatment to achieve a boil resistant bond. In commercial production shorter press time, in combination with a post-heat treatment, represents a significant reduction in production cost. Example 4 This example demonstrates a method to further lighten the colour and eliminate the odour of MDF by selective acidification of raw material prior to steam hydrolysis and refining. A mixture of Western red cedar and Hemlock planer shavings, used in Example 2, was treated with 0.3% H 2 SO 4 in a dilute solution. The acidified material was mixed thoroughly with non-acidified material of Western red Cedar and Hemlock planer shaving at three different ratios of 70:30, 60:40 and 50:50 with the major portion being the acidified material in each case. The mixed material was steam treated at 184 °C for 6 minutes and refined to fibres. The fibres were dried to 3 - 5 % M.C. and processed into MDF panels according to the procedure described in Example 2. One panel was made from each of the three fibre mixtures. Test results, including one panel made from 100 % acidified material (0.3 % H 2 SO 4 ) from Example 2, are summarized in the Table 5. Table 5 Physical properties of 12.5 mm MDF made from mixed acidified fiber consisting of a mixture of acidified and non-acidified Cedar and Hemlock shavings and sawdust Board ID Board MOR MOE IB Thickness Odoui density dry wet swelling [acid/non- [kg/M 5 ] [MPa] [MPa] [MPa] [kPa] [%] acid] 0.3 % acid 100:0 804 21.2 13.3 3860 680 8.4 faint 70:30 812 22.6 14.2 3940 660 9.1 none 60:40 807 23.1 13.5 3860 620 10.6 none 50:50 815 23.8 12.2 3620 620 13.3 none It can be seen from Table 5 that the physical properties of MDF made from a mixture of acidified and non-acidified fibre are very similar to those made with the acidified fibre alone, except for some variations in thickness swelling. Of particular interest, the usual faintly sweet odour appears to be virtually nonexistent in the MDF that contains a mixture of non-acidified and acidified fibre. Example 5 This example describes a method of producing both liquid and powder thermosetting resin adhesives from the acid catalyzed and hydrolyzed hemicellulose portion of Hgnocellulose. Dry cotton stalks with rind were chopped and hammer milled to pass 1/4" (6.4mm) screen. The first batch of the cotton stalks was treated with dilute solution to contain 4% (NH 4 ) 2 SO 4 and second batch was untreated. Both batches of cotton stalks were steamed at 220 °C for 90 seconds and instantly released from the pressure vessel with an explosive discharge. The explosive discharge rendered cotton stalk into fibrous and particulate form. The hydrolyzed cotton stalks, which contained about 18 - 24 % water solubles, and a M.C. of more than 100 %, were eluted with hot water to extract about 6.0% water solubles. The water solubles thus obtained were evaporated under vacuum to a concentration of about 50% solids and used for bonding foundry sands. Two 60 gram samples of the liquid adhesive, acidified and non-acidified, with a solids content of 50 % were mixed, respectively, with 2 kg of AFS GEN 60 sand (1.5 % resin content). The resin coated sand was then used to produce 6.3 mm thick tensile specimens (dog bones) by heating hand rammed sand between a pair of hot plates at 250 °C for various times to cure and thermoset the resin. All heated solids turned dark brown or black in colour. Edge retention and surface definition appeared normal. Test results of tensile strength, curing time, and resin types, including a commercial resin, are summarised in Table 6. Table 6 Curing time and tensile strength of foundry sand composite using acidified and non-acidified liquid resin from cotton stalks Curing time at 250 °C Tensile strength [minutes] [kPa] Control Acid catalyzed 2 656 693 4 682 728 6 705 755 Commercial resin 700 These test results indicate the potential of using the liquid resin adhesive extracted from the hydrolyzed cotton stalks for bonding foundry sand. The residue of the acid and non-acid catalyzed and hydrolyzed cotton stalks, from which about 6 % water soluble resin material from hemicellulose hydrolysis had been extracted, was dried to less than 4 % M.C , then ground and pulverized to fine particles to pass a 100 mesh screen. This fine powdery material consists of water soluble resin material and solid residue of the hydrolyzed Hgnocellulose. It has unique dual characteristics as it provides both bonding and filling functions in the production of composite products. This powdery resin material can be used alone or mixed with other base filler material in the production of composite products. The resin particles in powder form derived from both acid and non-acid catalyzed cotton stalks were mixed respectively with dry, pine wood flour of 40 mesh size at a 50:50 ratio by O.D. weight basis. These mixtures were compressed and moulded separately into a donut shape frame at a temperature of 215 °C. The moulded frame made with acid catalyzed cotton stalks had a density of 1120 kg/M 3 with very tight smooth surfaces and edges. The tension perpendicular to surface strength or internal bond was 1230 kPa and it was resistant to boiling water, with less than 12 % thickness swelling after 24 hour cold water soaking. The moulded frame made with non-acid catalyzed and hydrolyzed cotton stalk disintegrated in boiling water. Example 6 This example demonstrates a method of converting the cellulose fraction of lignocellulosic material, preferably with lignocellulosic material from which the hemicellulose fraction has been removed, into thermosetting adhesive in both liquid and solid form, thus achieving full utilization of the lignocellulosic material. The hydrolyzed Aspen poplar sawdust residue, which was impregnated with 0.2 % H 2 SO 4 and steamed at 220 °C for 90 seconds and from which the water solubles derived from hemicellulose hydrolysis had been removed, was used as base material. This previously hydrolyzed residue, which consisted mainly of cellulose (about two thirds), insoluble lignin (one third) and a very minor portion of hemicellulose residue, was impregnated with dilute sulfuric acid to contain 1 gram of H 2 SO 4 in 100 grams of oven-dry sawdust and steamed at 180 °C for 90 minutes. The treatment rendered about 50 % of the residue material solubilized. If a high yield of water soluble resin material from cellulose hydrolysis is desired, a multi-stage acid hydrolysis should be used. About 50 % of the water soluble resin material was extracted and concentrated as liquid thermosetting resin adhesive. This resin material was of a very similar adhesive quality to that derived from hemicellulose hydrolysis and can be used alone or mixed with resin material derived from hemicellulose hydrolysis as thermosetting adhesive. The remaining residue, which consisted mainly of lignin decomposition products, cellulose residues and water solubles, was dried to 3 - 4 % M.C. and then pulverized and ground to fine powder ( < 100 mesh). The dried residue was friable and therefore easily pulverized. These powdered resin particles have similar bonding and filling capabilities to the powdered resin particles derived from hemicellulose hydrolysis, as described in Example 6, that are particularly well suited for the production of moulded products. The conversion of the major portion of the previously hydrolyzed Aspen poplar sawdust into fine powder resin particles is essential in achieving the full utilization of lignocellulosic material. Especially from an environmental point of view, the remaining lignin and cellulose residue, if not incorporated into the production of resin adhesive particles, would certainly create a disposal problem. This would also require a secondary treatment to the lignin and cellulose residue prior to discharge. Example 7 This example demonstrates a simple and effective method of selectively applying acidic catalyst to poplar and pine chips, resulting in a stronger MDF. A mixture of fresh poplar (80 %) and pine (20 %) chips were divided into two groups. The first group of mixed chips was impregnated under vacuum with dilute sulfuric acid to contain 0.2 % of H 2 SO 4 , by O.D. weight of chips. The impregnation was for 24 hours to ensure that the acid uniformly and thoroughly penetrated the chips. After 24 hours impregnation the chips were fed into a digester and cooked at a steam temperature of 10 bar (184 °C) for approximately 10 minutes and refined into fibres. The second group of chips were continuously sprayed with dilute H 2 SO 4 as the chips entered the digester. Steam pressure was maintained at 10 bars (184 °C) and the retention time of the chips in the digester was approximately 10 minutes. After cooking the chips passed through a pressurized refiner with the addition of 1.0 % , solids basis, molten paraffin wax and converted into fibres. The two groups of fibres produced with different methods of acid applications were dried and processed into 12.5 mm MDF using identical press conditions. Board results are summarized in Table 7. Table 7 Physical properties of 12.5 mm MDF made from two distinct methods of application of acid Fiber Board MOR MOE IB H Haarrddnneessss S Sccrreeww Swell Treatment density Holding [kg/M J ] [MPa] [MPa] [kPa] [ [kkPPaa]] [ [kkPPaa]] [% 0.2 % H 2 S0 4 812 24.6 3640 810 3890 1180 impregnation 0.2 % H 2 S0 4 803 27.2 4820 790 4720 1370 9.1 'in situ spray" As can be seen from Table 7, the mechanical properties of the 12.5 mm MDF made with "in situ" acid application are considerably higher than the MDF made with the acid impregnation method. Although approximately 0.2 % H 2 SO 4 was added to both fibers and they received the same degree of steam treatment, and processed into MDF with identical pressing conditions, the differences in the mechanical strength are remarkable. Additionally, the MDF made with "in situ" catalyst fiber appeared to be lighter in colour and less odourous. It is understood that "in situ" application of acid under steam pressure allows the acid to penetrate into the chip in a manner by which it can form a gradient with more acid in the surface and less acid in the core of the chips. The inner part or core part of the chip has less acid which would decrease the degree of hydrolysis, or cause less damage to the cellulose portion of the fibers. When the chips are processed into fiber by refining and mixing, the less cooked fibers result in a stronger MDF.

Claims: CLAIMS 1. A method of treating subdivided or particulate lignocellulosic material with steam at temperature and a pressure high enough and for a time sufficient to effect decomposition and hydrolysis of hemicellulose and/or cellulose into water soluble resin material including pentose and hexose sugars, sugar polymers, furfural, hydroxymethyl furfural, dehydrated carbohydrates and organic acids, characterized in that the steam treatment is effected, at least in part of its duration, in the presence of an acidic catalyst. 2. A method according to claim 1, wherein the acidic catalyst is sulfuric acid. 3. A method according to claim 2, wherein the amount of sulfuric acid is at least 0.10% by weight based on the dry weight of the lignocellulosic material. 4. A method according to claim 3, wherein the amount of sulfuric acid is 0.10 to 0.35% by weight based on the dry weight of the lignocellulosic material. 5. A method according to any of claims 2 to 4, wherein the amount of sulfuric acid is up to 0.30% by weight based on the dry weight of the lignocellulosic material. 6. A method according to claim 1, wherein the acidic catalyst is sulfur dioxide. 7. A method according to claim 6, wherein the amount of sulfur dioxide is 1.0 to 4.0% by weight based on the dry weight of the lignocellulosic material. 8. A method according to claim 1, wherein the acidic catalyst is an acidic salt. 9. A method according to claim 8, wherein the acidic salt is ammonium sulfate. 10. A method according to claim 9, wherein the acidic salt is ammonium sulfate and is used in an amount of 0.25 to 10% by weight based on the dry weight of the lignocellulosic material. 11. A method according to claim 9, wherein the amount of ammonium sulfate is 1.0 to 8.0% by weight based on the dry weight of the lignocellulosic material. 12. A method according to any preceding claim, wherein the acid catalyst is mixed in such an amount as to provide a pH within the range of 1.5 to 5.0 at the beginning of the steam treatment. 13. A method according to any preceding claim, wherein the steam treatment is carried out at a temperature not exceeding 220°C. 14. A method according to any preceding claim, wherein the steam treatment is carried out for a time not exceeding 90 minutes. 15. A method according to any preceding claim, wherein cellulose is to be hydrolyzed and decomposed and the hemicellulose of the lignocellulosic material has already been hydrolyzed and decomposed. 16. A method according to any preceding claim, wherein the treatment of the lignocellulosic material is effected as a continuous process or as a batch process. 3Q 17. A method according to any preceding claim, wherein the treated lignocellulosic material is used in the production of a composite material. 18. A method according to any preceding claim, wherein the decomposition products are used as a thermosetting adhesive. 19. A method according to any of claims 1 to 18, wherein lignin of the lignocellulosic material is decomposed and hydrolyzed by the high pressure steam into low molecular weight lignin and lignin decomposition products. 20. A method according to any preceding claim, wherein the water soluble resin material derived from decomposition and hydrolysis of hemicellulose and/or cellulose contains water soluble low molecular weight lignin and lignin decomposition products. 21. A method of treating subdivided or particulate lignocellulosic material with steam at a temperature and a pressure high enough and for a time sufficient to effect decomposition and hydrolysis of hemicellulose and/or cellulose into water soluble resin material such as pentose and hexose sugars, sugar polymers, dehydrated carbohydrates, furfural, hydroxymethyl furfural and organic acids wherein acid is applied to the lignocellulosic material in subdivided or particulate form prior to and/or during decomposition and hydrolysis and the lignocellulosic material remains in contact with the acid prior to and/or during decomposition and hydrolysis for a time insufficient to allow the acid to penetrate to the core of the particles of lignocellulosic material before cessation of the decomposition and hydrolysis so that cellulose fibres in the core of the particles are not substantially degraded by the steam treatment. 22. A method according to claim 21, wherein the acid is applied to the lignocellulosic material by soaking the particles in solution of the acid or spraying the particles with a solution of the acid. 23. A method according to claim 21 or 22 wherein the steam treatment is carried out in a pressure vessel. 24. A method according to any of claims 21 to 23, wherein after the steam treatment the particles of lignocellulosic material are broken down into fibres, or fine particles by means of refining or hammermilling, prior to reconstitution as a composite product. 25. A method according to any of claims 21 to 24, wherein the treated lignocellulosic material is used in the production of a composite material and/or the decomposition products are used as a thermosetting adhesive. 26. A method according to any preceding claim, wherein the treatment of the lignocellulosic material is effected as a continuous process or as a batch process.

Inventors: SHEN KUO CHENG, SHEN, KUO, CHENG
Applicants: K C SHEN INTERNATIONAL LIMITED, KRONOSPAN GMBH, SHEN KUO CHENG, K.C. SHEN INTERNATIONAL LIMITED, SHEN, KUO, CHENG
Application year: 1997
Main classification: C08L97
IPC codes: B27N1, C08H5, C08L97