Recyclage des résidus papetiers pour la production de panneaux de fibres

Les résidus solides récupérés au traitement des eaux usées des usines de pâtes et papiers sont appelés boues. La boue primaire (BP) représente une source de fibres pour l'industrie des panneaux de fibres de moyenne densité (MDF) et la boue secondaire (BS) a des propriétés adhésives. L'objectif général de l'étude est d'évaluer la faisabilité de produire des panneaux MDF à partir de BP et de BS issues de différents procédés papetiers, de résine urée-formaldéhyde (UF) et de fibres de bouleau blanc de qualité pâte. Les résidus furent échantillonnés puis caractérisés en termes de composition chimique, de pH, de capacité tampon et de longueur des fibres. Des panneaux de fibres furent fabriqués selon trois dispositifs expérimentaux où les facteurs sont : la proportion de boue, le type de boue (BP, BS), le procédé papetier (PTM, PCTM, kraft) et la teneur en résine UF (0%, 8%, 12%). La BS est riche en protéines et contient plus de lignine et moins de cellulose que la BP. La BP est donc une source de fibres et la BS est une source potentielle d'agent liant. Les boues PTM et PCTM contiennent plus de cellulose et moins de cendre (impuretés) que la boue issue du procédé kraft. Toutefois, les fibres dans les boues kraft sont plus longues. Dans la majorité des cas, le procédé papetier et le type de boue (BP, BS) eurent un effet significatif sur les propriétés des panneaux. Dans les panneaux de boue sans résine, la cohésion interne augmente et le gonflement en épaisseur diminue lorsque la teneur en BS augmente. Ce résultat fut attribué aux propriétés adhésives de la BS. Dans les panneaux MDF (boue, fibres et résine), l'augmentation de la proportion de boue a un effet négatif sur presque toutes les propriétés des panneaux. Toutefois, l'ajout de boues permit de réduire les émissions de HCHO jusqu'à 68% en comparaison avec le panneau témoin, sans effet négatif sur la CI. Les boues ont un pH et une capacité tampon plus élevés que les fibres de bois, ce qui a probablement nuit à la performance (reticulation) de l'adhésif UF

Effect of the Pyro-Gasification Temperature of Wood on the Physical and Mechanical Properties of Biochar-Polymer Biocomposites

The physical and mechanical properties of wood (WPC) and biochar polymer composites (BPC) obtained at different pyro-gasification temperatures and different fiber proportions were investigated. Composite pellets made from wood chips or biochar and thermoplastic polymers (polypropylene or high-density polyethylene) were obtained by twin-screw extrusion, and test specimens were prepared by injection molding. Results showed that BPCs were more dimensionally stable compared to WPCs, but their mechanical properties decreased with increasing pyro-gasification temperatures due to the poor adhesion between the polymer and biochar. Indeed, FTIR investigations revealed the decrease or absence of hydroxyl groups on biochar, which prevents the coupling agent from reacting with the biochar surface. The change in the biochar chemical structure led to an improvement in the dimensional stability and hydrophobicity of the biocomposites. Despite the increased dimensional stability of BPCs compared to WPCs, BPCs still adsorb water. This was explained by the surface roughness and by the biochar agglomerations present in the composite. In conclusion, the thermochemical conversion of black spruce wood chips into biochar makes it brittle but more hydrophobic, thereby reducing the wettability of the BPCs

Medium-Density Fiberboard Produced Using Pulp and Paper Sludge from Different Pulping Processes

Pulp and paper sludge can be recycled in the manufacture of medium-density fiberboard (MDF) because it contains wood fibers. A comparative study was conducted to evaluate the properties of MDF made from virgin fibers mixed with different pulp and paper sludge sources. A factorial design was used in which factors were mill pulping processes, thermal-mechanical pulping (TMP), chemical-thermal-mechanical pulping (CTMP), and kraft pulping, and percentage of sludge mixed with virgin fibers (0, 25, 50, and 75%). Virgin fibers were obtained from paper birch wood, an underutilized species. Chemical composition, physical characteristics, pH, and buffer capacity of sludge were measured. MDF properties decreased mostly linearly with sludge content. Panel properties negatively correlated with the proportion of nonfibrous material such as ash and extractives. TMP and CTMP sludge sources produced panels of similar quality, and kraft sludge produced the lowest quality. It was concluded that the amount of sludge that can be incorporated into MDF without excessive decrease in panel quality depends on the pulping process. At 25% sludge content, all panels met ANSI quality requirements for MDF used for interior applications

Binderless Fiberboard Made from Primary and Secondary Pulp and Paper Sludge

Pulp and paper sludge is valuable in fiberboard manufacturing because primary sludge (PS) contains fibers and secondary sludge (SS) has adhesive properties. We evaluated properties of binderless fiberboard made from conventional pulp and paper mill sludge sources using a factorial design in which the factors were SS:PS ratio (1:9, 2:8, and 3:7) and pulping process (thermomechanical [TMP], chemical-thermomechanical [CTMP], and kraft). Sludge was collected, refined, dried, and characterized for chemical composition and fiber length. Internal bond strength of CTMP panels increased 90% and thickness swell of TMP panels improved 92% with increasing SS content from 10-30%. IR Fourier transform and X-ray photoelectron spectroscopy analyses were conducted to better understand these results. Increased bonding was attributed to presence of proteins and lignin on the sludge fiber surface, which enhanced adhesion during hot pressing, whereas surface contamination decreased bonding efficiency. The TMP formulation at SS:PS ratio 3:7 met the ANSI requirement for basic hardboard. All other formulations were not dimensionally stable enough to meet the standard. The CTMP source resulted in the highest mechanical properties, and thickness swell was similar for the TMP and CTMP pulping processes. The kraft source produced low-integrity and dimensionally unstable panels

Effects of wood fiber surface chemistry on strength of wood–plastic composites

International audienceBecause wood–plastic composites (WPC) strength relies on fiber-matrix interaction at fiber surface, it is likely that fiber surface chemistry plays an important role in WPC strength development. The objective of the present study is to investigate the relationships between fiber surface chemical characteristics and WPC mechanical properties. Different fibers were selected and characterized for surface chemical characteristics using X-ray photoelectron spectroscopy (XPS) and infrared spectroscopy (FTIR). WPC samples were manufactured at 40% fiber content and with six different fibers. High density polyethylene was used as matrix and maleated polyethylene (MAPE) was used as compatibility agent. WPC samples were tested for mechanical properties and fiber-matrix interface was observed with scanning electron microscope. It was found WPC strength decreases as the amount of unoxidized carbon (assigned to lignin and extractives) measured with XPS on fiber surface increases. In the opposite case, WPC strength increases with increasing level of oxidized carbon (assigned to carbohydrates) on fiber surface. The same conclusions were found with FTIR where WPC strength decreases as lignin peaks intensity increases. Esterification reaction of fibers with MAPE occurs on polar sites of carbohydrates, such as hydroxyls (Osingle bondH). Thus, fibers with carbohydrates-rich surface, such as cellulose pulp, produced stronger WPC samples. Other factors such as mechanical interlocking and fiber morphology interfered with the effects of fiber surface chemistry

Physical and Mechanical Properties of Polypropylene-Wood-Carbon Fiber Hybrid Composites

Effects of the addition of short carbon fibers (CFs) on the mechanical, physical, and morphological properties of polypropylene (PP) and wood-polypropylene composites (WPCs) were investigated. Hybrid composites (mix of wood and CFs) were manufactured in a two-stage process, pellet extrusion and samples mold injection with varying amounts of poplar wood fiber (0%, 20%, 30%, and 40%) and CFs (0%, 3%, 6%, and 9%), with and without maleic anhydride grafted PP (MAPP) as a coupling agent. The composites were prepared with extrusion blending followed by injection molding. The samples where then tested for mechanical and physical properties, and fractured surfaces where observed with scanning electron microscopy. The results indicated that the addition of CFs to WPCs improved the tensile and flexural strength and the modulus of elasticity but had only a small influence on elongation at break and impact strength. The density of hybrid composites slightly increased with CFs proportion but their water absorption was not affected. Scanning electron micrographs of the tensile fractured specimens showed improved adhesion of CFs and poplar with the PP matrix in the presence of a coupling agent

Effects of Coating on the Dimensional Stability of Wood-Polymer Composites

Wood polymer composites (WPC) are sensitive to moisture because of the hydrophilic nature of the wood fibers. The main objective of this study was to improve the dimensional stability of WPCs by coating. Polypropylene and polylactic acid were reinforced by three pulp fibers (kraft, thermomechanical (TMP), and chemothermomechanical (CTMP)) at three fiber contents (50, 60, and 70% w/w). The resulting WPCs were coated using two commercial coatings, epoxy and acrylic. Kraft fiber WPCs were less sensitive to moisture than TMP and CTMP WPCs. These differences were explained by the crystallinity of the kraft fibers and their better interfacial adhesion to the polymers. The epoxy coating proved to be more effective than the acrylic coating and significantly reduced the water absorption and the thickness swell for all formulations. Negative relationships between the contact angle and water absorption were obtained. These relationships depend on the fiber content and type, the matrix nature, and the coating

Numerical and experimental assessment of water absorption of wood-polymer composites

International audienceThis article focuses on the evaluation of the water immersion properties of wood-plastic composite (WPC) made with industrial wood residues. The effects of fiber type and proportion on the dimensional stability of WPC were studied. The water absorption of WPC samples was studied using modeling techniques. Samples were prepared according to a process in two steps: (i) extrusion compounding and (ii) injection molding. The results showed that the water absorption and swelling varied with fiber source and increased proportionally with fiber proportion. The variations of the water absorption and swelling have been represented following the theoretical model of the Fick's law of diffusion. The parameters of this diffusion process such as diffusion and Fick's coefficients are subsequently identified and modeled by both numerical and experimental approaches. The novel modeling includes short term diffusion and long term diffusion parameters for a better representation of the complex sorption behavior of WPC