Method for producing wood fibre pellets

• US 10,150,227 B2
• Filed: 11/30/2016
• Issued: 12/11/2018
• Est. Priority Date: 06/23/2004
• Status: Active Grant

• Current Assignee: New Zealand Forest Research Institute Limited
• Original Assignee: New Zealand Forest Research Institute Limited
• Inventors: Warnes, Jeremy Martin, Fernyhough, Alan, Anderson, Charles Ross, Lee, Brendan James, Witt, Michael Ralph Juergen
• Primary Examiner(s): Thrower, Larry W
• Application Number:
  US15/364,447
• Publication Number:
  US 20170080597A1
• Time in Patent Office: 741 Days
• CPC Class Codes: B27N 1/00 Pretreatment of moulding material
• CPC Class Codes: B27N 1/02 Mixing the material with binding agent mixing in general B01F
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B29B 7/905 with means for pretreatment of the charges or fibres
• CPC Class Codes: B29B 7/92 Wood chips or wood fibres
• CPC Class Codes: B29B 9/04 in the form of plates or sheets
• CPC Class Codes: B29B 9/14 fibre-reinforced
• CPC Class Codes: B29B 9/16 Auxiliary treatment of granules

Abstract

A process for producing pellets or granules comprising fibres of a lignocellulousic material, for use as a feedstock in plastics manufacture, conveying in a dry or wet air stream and applying to the fibres a liquid formulation comprising one or more polymers, monomers, or oligomers, forming the fibres into a solid product, and breaking down the solid product to produce said pellets or granules. Typically the conduit conveys the fibres in a plant for manufacture of fibre board.

Claims

1. A process for producing pellets or granules comprising wood fibres, for use as a feedstock in plastics manufacture, which comprises

applying to wood, wood fibres or fibre bundles prior to a blowline, the wood fibres or fibre bundles being produced by mechanically or thermomechanically or chemo-thermomechanically or chemo-mechanically breaking down the wood in a refiner, a liquid formulation comprising one or more thermoplastic polymers, monomers, or oligomers to coat or partially coat the fibres,

pressing the fibres into a solid product, and

breaking down the solid product into wood fibre-containing pellets or granules,

the pellets or granules comprising 0.3 to 25 parts per 100 parts of fibre by dried weight of one or more thermoplastic polymers or thermoplastic oligomers.

2. The process of claim 1, comprising applying the liquid formulation to the fibres in the refiner.

3. The process of claim 1, further comprising applying to the fibres while conveying the fibres in an air stream a formaldehyde or isocyanate resin, or a further liquid formulation comprising one or more thermoplastic polymers, monomers, or oligomers.

4. The process of claim 2, further comprising applying to the fibres while conveying the fibres in an air stream a formaldehyde or isocyanate resin, or a further liquid formulation comprising one or more thermoplastic polymers, monomers, or oligomers.

5. The process according to claim 3 including conveying the fibres along a conduit in a dry or wet stream and introducing the formaldehyde or isocyanate resin or liquid formulation into the interior of the conduit to apply the formaldehyde or isocyanate resin or liquid formulation to the fibres while the fibres are moving through the conduit, or introducing the formaldehyde or isocyanate resin or liquid formulation into the conduit by spraying the formaldehyde or isocyanate resin or liquid formulation into the interior of the conduit as the fibres move through the conduit, to coat or partially coat the fibres.

6. The process according to claim 4 including conveying the fibres along a conduit in a dry or wet stream and introducing the formaldehyde or isocyanate resin or liquid formulation into the interior of the conduit to apply the formaldehyde or isocyanate resin or liquid formulation to the fibres while the fibres are moving through the conduit, or introducing the formaldehyde or isocyanate resin or liquid formulation into the conduit by spraying the formaldehyde or isocyanate resin or liquid formulation into the interior of the conduit as the fibres move through the conduit, to coat or partially coat the fibres.

7. The process according to claim 1 including conveying the fibres along a conduit in a dry or wet stream wherein the conduit conveys the fibres from the refiner in a plant for manufacture of fibre board.

8. The process according to claim 2 including conveying the fibres along a conduit in a dry or wet stream wherein the conduit conveys the fibres from the refiner in a plant for manufacture of fibre board.

9. The process according to claim 5 wherein the conduit conveys the fibres from the refiner in a plant for manufacture of fibre board.

10. The process according to claim 6 wherein the conduit conveys the fibres from the refiner in a plant for manufacture of fibre board.

11. The process according to claim 1 including conveying the fibres along a conduit in a dry or wet stream wherein the conduit conveys the fibres to or from a drying stage or drier.

12. The process according to claim 2 including conveying the fibres along a conduit in a dry or wet stream wherein the conduit conveys the fibres to or from a drying stage or drier.

13. The process according to claim 5 wherein the conduit conveys the fibres to or from a drying stage or drier.

14. The process according to claim 6 wherein the conduit conveys the fibres to or from a drying stage or drier.

15. The process according to claim 1 including pressing the fibres into a solid product by pressing the fibres to a solid product in planar form.

16. The process according to claim 15 including pressing the fibres between heated plattens.

17. The process according to claim 1 wherein the wood fibres or fibre bundles are MDF fibre.

18. The process according to claim 15 including pressing the fibres into a sheet of up to about 2 cm in thickness.

19. The process according to claim 1, wherein the fibres have an average fibre length or fibre-bundle length of at least about 0.8 mm.

20. The process according to claim 1, wherein a major fraction of the fibres have an aspect ratio of at least 10:

1.

21. The process according to claim 1, including breaking down the solid product to produce pellets which are longer than the average fibre length of the fibres within the pellets.

22. A process for manufacture of plastics products or intermediates which includes introducing pellets or granules produced by the process of claim 1 as a feedstock into a plastics extrusion or moulding machine.

24. The process according to claim 1, wherein the pellets or granules comprise 0.3 to 8 parts per 100 parts of fibre by dried weight of the one or more thermoplastic polymers or thermoplastic oligomers.

23. A process for producing pellets or granules comprising wood fibres, for use as a feedstock in plastics manufacture, which comprises

applying to wood, wood fibres or fibre bundles prior to a blowline, the wood fibres or fibre bundles being produced by mechanically or thermomechanically or chemo-thermomechanically or chemo-mechanically breaking down the wood in a refiner, a liquid formulation comprising one or more thermoplastic polymers, monomers, or oligomers to coat or partially coat the fibres,

conveying the fibres along a conduit in a dry or wet stream and introducing a formaldehyde or isocyanate resin or a further liquid formulation comprising one or more thermoplastic polymers, monomers, or oligomers into the interior of the conduit to apply the formaldehyde or isocyanate resin or liquid formulation to the fibres while the fibres are moving through the conduit, the conduit conveying the fibres from the refiner or to or from a drying stage or drier in a plant for manufacture of fibre board,

pressing the fibres into a solid product, and

breaking down the solid product into wood fibre-containing pellets or granules, the pellets or granules comprising 0.3 to 25 parts per 100 parts of fibre by dried weight of one or more thermoplastic polymers or thermoplastic oligomers.

25. The process according to claim 23, wherein the pellets or granules comprise 0.3 to 8 parts per 100 parts of fibre by dried weight of the one or more thermoplastic polymers or thermoplastic oligomers.