U.S. patent application number 14/997233 was filed with the patent office on 2016-06-30 for resin compositions comprising lignin derivatives.
The applicant listed for this patent is Fibria Innovations Inc.. Invention is credited to Alex Berlin.
Application Number | 20160185810 14/997233 |
Document ID | / |
Family ID | 43222095 |
Filed Date | 2016-06-30 |
United States Patent
Application |
20160185810 |
Kind Code |
A1 |
Berlin; Alex |
June 30, 2016 |
RESIN COMPOSITIONS COMPRISING LIGNIN DERIVATIVES
Abstract
The present invention provides derivatives of native lignin
having a certain ethoxy content. Surprisingly, it has been found
that phenolic resins comprising derivatives of native lignin having
certain ethoxy contents have acceptable performance characteristics
such as bond-strength.
Inventors: |
Berlin; Alex; (Burnaby,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fibria Innovations Inc. |
Vancouver |
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CA |
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|
Family ID: |
43222095 |
Appl. No.: |
14/997233 |
Filed: |
January 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13322890 |
Feb 15, 2012 |
9267027 |
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PCT/CA2010/000800 |
May 27, 2010 |
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14997233 |
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61304745 |
Feb 15, 2010 |
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61233345 |
Aug 12, 2009 |
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61182044 |
May 28, 2009 |
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Current U.S.
Class: |
524/72 ; 162/14;
530/500 |
Current CPC
Class: |
C08H 6/00 20130101; C08H
8/00 20130101; C08L 97/005 20130101; C07G 1/00 20130101; D21C 3/20
20130101; C08L 97/005 20130101; C08K 5/13 20130101; C08L 97/005
20130101; C08L 61/06 20130101; C08L 97/02 20130101; C08L 61/12
20130101; C08L 97/02 20130101; C08L 61/06 20130101; C08L 97/02
20130101; C08L 61/12 20130101; C08L 1/10 20130101; C08L 61/06
20130101; C08K 5/13 20130101; C08K 5/13 20130101 |
International
Class: |
C07G 1/00 20060101
C07G001/00; D21C 3/20 20060101 D21C003/20; C08L 61/06 20060101
C08L061/06 |
Claims
1. A lignin derivative having an ethoxy content of 0.45 mmol/g or
greater.
2. The lignin derivative according to claim 1, wherein the
derivative has an ethoxy content of about 0.5 mmol/g or
greater.
3. The lignin derivative according to claim 1, wherein the
derivative has an ethoxy content of about 0.6 mmol/g or
greater.
4. The lignin derivative according to claim 1, wherein the
derivative has an aliphatic hydroxyl content of from about 0.001
mmol/g to about 8 mmol/g.
5. The lignin derivative according to claim 1, wherein the lignin
is derived from hardwood biomass.
6. The lignin derivative according to claim 1, wherein the lignin
is derived from softwood biomass.
7. The lignin derivative according to claim 1, wherein the lignin
is derived from annual fibre biomass.
8. The lignin derivative according to claim 1, wherein the lignin
is derived from biomass comprising Populus spp, Eucalyptus spp.,
Acacia spp., or combinations/hybrids thereof.
9. The lignin derivative according to claim 1, wherein the biomass
comprises Populus tremuloides, Eucalyptus globulus, Acacia
dealbata, or combinations/hybrids thereof.
10. The lignin derivative according to claim 1, wherein the lignin
is derived from biomass comprising pine; spruce; and
combinations/hybrids thereof
11. The lignin derivative according to claim 1, wherein the lignin
is derived from biomass comprising Pinus radiata, Pinus taeda, BC
spruce, or combinations/hybrids thereof.
12. The lignin derivative according to claim 1, wherein the lignin
is derived from biomass comprising wheat straw, bagasse, corn cobs,
or combinations/hybrids thereof.
13. The lignin derivative according to claim 1, wherein the
derivative has an ethoxy content of about 3.5 mmol/g or less.
14. A hardwood lignin derivative having an ethoxy content of from
0.45 mmol/g to about 1.4 mmol/g.
15. A softwood lignin derivative having an ethoxy content of from
about 0.35 mmol/g to about 1.4 mmol/g.
16. An annual fibre lignin derivative having an ethoxy content of
from about 0.25 mmol/g to about 1.4 mmol/g.
17. A phenol composition comprising the lignin derivative according
to claim 1, wherein the weight ratio of lignin:phenol is from about
1:4 to about 4:1.
18. A phenol-formaldehyde resin composition comprising from about
0.5% to about 20%, by of the lignin derivative according to claim
1.
19. A method of producing a lignin derivative according to claim 1,
said method comprising: a) pulping a fibrous biomass in a vessel
with an organic solvent/water solvent solution to form a liquor,
wherein: i. the solution comprises about 30% or greater, by weight,
of organic solvent; and ii. the pH of the liquor is from about 1 to
about 6; b) heating the liquor to about 100.degree. C. or greater;
c) maintaining the elevated temperature and pressure for 1 minute
or longer; d) separating the cellulosic pulps from the pulping
liquor; and e) recovering derivatives of native lignin.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/322,890, filed Feb. 15, 2012, which is a
National Stage of International Application PCT/CA2010/00800, filed
May 27, 2010, published Dec. 2, 2010, under PCT Article 21(2) in
English; which claims the priority of U.S. Provisional Patent
Application Nos. 61/182,044, filed May 28, 2009; 61/233,345, filed
Aug. 12, 2009; and 61/304,745, filed Feb. 15, 2010; the contents of
the above-identified applications are incorporated herein by
reference in their entirety.
FIELD
[0002] This invention relates to derivatives of native lignin
recovered from lignocellulosic feedstocks, and industrial
applications thereof. More particularly, this invention relates to
compositions, uses, processes and methods utilizing derivatives of
native lignin.
BACKGROUND
[0003] Native lignin is a naturally occurring amorphous complex
cross-linked organic macromolecule that comprises an integral
component of all plant biomass. The chemical structure of lignin is
irregular in the sense that different structural units (e.g.,
phenylpropane units) are not linked to each other in any systematic
order. It is known that native lignin comprises pluralities of two
monolignol monomers that are methoxylated to various degrees
(trans-coniferyl alcohol and trans-sinapyl alcohol) and a third
non-methoxylated monolignol (trans-p-coumaryl alcohol). Various
combinations of these monolignols comprise three building blocks of
phenylpropanoid structures i.e. guaiacyl monolignol, syringyl
monolignol and p-hydroxyphenyl monolignol, respectively, that are
polymerized via specific linkages to form the native lignin
macromolecule.
[0004] Extracting native lignin from lignocellulosic biomass during
pulping generally results in lignin fragmentation into numerous
mixtures of irregular components. Furthermore, the lignin fragments
may react with any chemicals employed in the pulping process.
Consequently, the generated lignin fractions can be referred to as
lignin derivatives and/or technical lignins. As it is difficult to
elucidate and characterize such complex mixture of molecules,
lignin derivatives are usually described in terms of the
lignocellulosic plant material used, and the methods by which they
are generated and recovered from lignocellulosic plant material,
i.e. hardwood lignins, softwood lignins, and annual fibre
lignins.
[0005] Native lignins are partially depolymerized during the
pulping processes into lignin fragments which are soluble in the
pulping liquors and subsequently separated from the cellulosic
pulps. Post-pulping liquors containing lignin and polysaccharide
fragments, and extractives, are commonly referred to as "black
liquors" or "spent liquors", depending on the pulping process. Such
liquors are generally considered a by-product, and it is common
practice to combust them to recover some energy value in addition
to recovering the cooking chemicals. However, it is also possible
to precipitate and/or recover lignin derivatives from these
liquors. Each type of pulping process used to separate cellulosic
pulps from other lignocellulosic components produces lignin
derivatives that are very different in their physico-chemical,
biochemical, and structural properties.
[0006] Given that lignin derivatives are available from renewable
biomass sources there is an interest in using these derivatives in
certain industrial processes. For example, U.S. Pat. No. 5,173,527
proposes using lignin-cellulosic materials in phenol-formaldehyde
resins. A. Gregorova et al. propose using lignin in blends or
alloys with polypropylene for its radical scavenging properties (A.
Gregorova et al., Radical scavenging capacity of lignin and its
effect on processing stabilization of virgin and recycled
polypropylene, Journal of Applied Polymer Science 106-3 (2007) pp.
1626-1631). However, large-scale commercial application of the
extracted lignin derivatives, particularly those isolated in
traditional pulping processes employed in the manufacture of pulp
and paper, has been limited due to, for example, the inconsistency
of their chemical and functional properties. This inconsistency
may, for example, be due to changes in feedstock supplies and the
particular extraction/generation/recovery conditions. These issues
are further complicated by the complexity of the molecular
structures of lignin derivatives produced by the various extraction
methods and the difficulty in performing reliable routine analyses
of the structural conformity and integrity of recovered lignin
derivatives.
[0007] Formaldehyde-based resins such as phenol formaldehyde (PF),
urea formaldehyde and melamine formaldehyde are extremely common
and used for a variety of purposes such as manufacturing of housing
and furniture panels such as medium density fibreboard (MDF),
oriented strand board (OSB), plywood, and particleboard. Concerns
about the toxicity of formaldehyde have led regulatory authorities
to mandate the reduction of formaldehyde emissions (e.g. California
Environmental Protection Agency Airborne Toxic Control Measure
(ATCM) to Reduce Formaldehyde Emissions from Composite Wood
Products, Apr. 26, 2007).
[0008] The addition of phenol-free and formaldehyde-free
compositions, such as sulphur-free lignin derivatives, represents a
viable alternative to the toxic chemicals. However, past attempts
at adding lignin derivatives, such as Alcell.RTM. lignin, to PF
resins have been largely unsuccessful due to the relatively poor
performance characteristics of the final product. For example, the
normalized Alcell.RTM. lignin-PF resin bond strength at 150.degree.
C. was 3,079 MPa*cm.sup.2/g as tested by the ABES method (Wescott,
J. M., Birkeland, M. J., Traska, A. E., New Method for Rapid
Testing of Bond Strength for Wood Adhesives, Heartland Resource
Technologies Waunakee, Wis., U.S.A. and Frihart, C. R. and Dally,
B. N., USDA Forest Service, Forest Products Laboratory, Madison,
Wis., U.S.A., Proceedings 30.sup.th Annual Meeting of The Adhesion
Society, Inc., Feb. 18-21, 2007, Tampa Bay, Fla., USA). These
values are significantly lower than what is commonly expected for
instance for plywood or OSB PF resins (3,200-3,600
MPecm.sup.2/g).
SUMMARY
[0009] The present invention provides derivatives of native lignin
having a certain ethoxy content. Surprisingly, it has been found
that phenolic resins comprising derivatives of native lignin having
certain ethoxy contents have acceptable performance characteristics
such as bondstrength.
[0010] As used herein, the term "native lignin" refers to lignin in
its natural state, in plant material.
[0011] As used herein, the terms "lignin derivatives" and
"derivatives of native lignin" refer to lignin material extracted
from lignocellulosic biomass. Usually, such material will be a
mixture of chemical compounds that are generated during the
extraction process.
[0012] This summary does not necessarily describe all features of
the invention. Other aspects, features and advantages of the
invention will be apparent to those of ordinary skill in the art
upon review of the following description of specific embodiments of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows the HSQC spectrum of non-acetylated hardwood
lignin derivatives (arrows indicate the signals corresponding to
the ethoxyl groups).
[0014] FIG. 2 shows the quantitative .sup.13C NMR spectrum of
non-acetylated hardwood lignin derivatives.
[0015] FIG. 3 shows the quantitative .sup.13C NMR spectrum of
acetylated hardwood lignin derivatives.
DETAILED DESCRIPTION
[0016] The present invention provides derivatives of native lignin
having certain ethoxy contents. Phenol-formaldehyde (PF) resins
comprising lignin derivatives having higher ethoxy contents have
been found to have acceptable bond-strengths. Thus, selecting for
derivatives of native lignin having a higher ethoxy content results
in a product having better performance characteristics. It has been
found that derivatives of native lignin having an ethoxy content of
0.45 mmol/g or greater result in PF-resins having acceptable
bond-strengths. For example, about 0.5 mmol/g or greater; about 0.6
mmol/g or greater; about 0.7 mmol/g or greater; about 0.8 mmol/g or
greater; about 0.9 mmol/g or greater; about 1 mmol/g or greater;
about 1.1 mmol/g or greater; about 1.2 mmol/g or greater.
[0017] The present lignin derivatives may, for example, have an
ethoxy content of about 3.75 mmol/g or less; 3.5 mmol/g or less;
3.25 mmol/g or less; 3 mmol/g or less; 2.75 mmol/g or less; 2.5
mmol/g or less; 2.25 mmol/g or less; 2 mmol/g or less; 1.9 mmol/g
or less; 1.8 mmol/g or less; 1.7 mmol/g or less; 1.6 mmol/g or
less; 1.5 mmol/g or less; 1.4 mmol/g or less; 1.3 mmol/g or
less.
[0018] The lignin derivatives may comprise other alkoxy groups
apart from ethoxy groups such as C.sub.1-C.sub.6 alkoxy groups;
C.sub.1-C.sub.4 alkoxy groups; C.sub.1-C.sub.3 alkoxy groups;
methoxy and/or propoxy.
[0019] Quantification of the alkoxy groups can be performed using
high resolution .sup.13C NMR spectroscopy. For example,
quantification of ethoxyl groups can be performed by high
resolution .sup.13C NMR spectroscopy. Identification of ethoxyl
groups can be confirmed by 2D NMR HSQC spectroscopy. 2D NMR spectra
may be recorded by a Bruker 700 MHz UltraShield Plus standard bore
magnet spectrometer equipped with a sensitive cryogenically cooled
5 mm TCI gradient probe with inverse geometry. The acquisition
parameters are the following: standard Bruker pulse program
hsqcetgp, temperature of 298 K, a 90.degree. pulse, 1.1 sec pulse
delay (d1), and acquisition time of 60 msec.
[0020] The present invention provides derivatives of native lignin
recovered during or after pulping of lignocellulosic biomass
feedstocks. The pulp may be from any suitable lignocellulosic
feedstock including hardwoods, softwoods, annual fibres, and
combinations thereof.
[0021] Hardwood feedstocks include Acacia; Afzelia; Synsepalum
duloificum; Albizia; Alder (e.g. Alnus glutinosa, Alnus rubra);
Applewood; Arbutus; Ash (e.g. F. nigra, F. quadrangulata, F.
excelsior, F. pennsylvanica lanceolata, F. latifolia, F. profunda,
F. americana); Aspen (e.g. P. grandidentata, P. tremula, P.
tremuloides); Australian Red Cedar (Toona ciliata); Ayna
(Distemonanthus benthamianus); Balsa (Ochroma pyramidale); Basswood
(e.g. T. americana, T. heterophylla); Beech (e.g. F. sylvatica, F.
grandifolia); Birch; (e.g. Betula populifolia, B. nigra, B.
papyrifera, B. lenta, B. alleghaniensis/B. lutea, B. pendula, B.
pubescens); Blackbean; Blackwood; Bocote; Boxelder; Boxwood;
Brazilwood; Bubinga; Buckeye (e.g. Aesculus hippocastanum, Aesculus
glabra, Aesculus flava/Aesculus octandra); Butternut; Catalpa;
Cherry (e.g. Prunus serotina, Prunus pennsylvanica, Prunus avium);
Crabwood; Chestnut; Coachwood; Cocobolo; Corkwood; Cottonwood (e.g.
Populus balsamifera, Populus deltoides, Populus sargentii, Populus
heterophylla); Cucumbertree; Dogwood (e.g. Cornus florida, Cornus
nuttallii); Ebony (e.g. Diospyros kurzii, Diospyros melanida,
Diospyros crassiflora); Elm (e.g. Ulmus americana, Ulmus procera,
Ulmus thomasii, Ulmus rubra, Ulmus glabra); Eucalyptus; Greenheart;
Grenadilla; Gum (e.g. Nyssa sylvatica, Eucalyptus globulus,
Liquidambar styraciflua, Nyssa aquatica); Hickory (e.g. Carya alba,
Carya glabra, Carya ovata, Carya laciniosa); Hornbeam; Hophornbeam;
Ip ; Iroko; Ironwood (e.g. Bangkirai, Carpinus caroliniana,
Casuarina equisetifolia, Choricbangarpia subargentea, Copaifera
spp., Eusideroxylon zwageri, Guajacum officinale, Guajacum sanctum,
Hopea odorata, Ipe, Krugiodendron ferreum, Lyonothamnus lyonii (L.
floribundus), Mesua ferrea, Olea spp., Olneya tesota, Ostrya
virginiana, Parrotia persica, Tabebuia serratifolia); Jacaranda;
Jotoba; Lacewood; Laurel; Limba; Lignum vitae; Locust (e.g. Robinia
pseudacacia, Gleditsia triacanthos); Mahogany; Maple (e.g. Acer
saccharum, Acer nigrum, Acer negundo, Acer rubrum, Acer
saccharinum, Acer pseudoplatanus); Meranti; Mpingo; Oak (e.g.
Quercus macrocarpa, Quercus alba, Quercus stellata, Quercus
bicolor, Quercus virginiana, Quercus michauxii, Quercus prinus,
Quercus muhlenbergii, Quercus chysolepis, Quercus lyrata, Quercus
robur, Quercus petraea, Quercus rubra, Quercus velutina, Quercus
laurifolia, Quercus falcata, Quercus nigra, Quercus phellos,
Quercus texana); Obeche; Okoume; Oregon Myrtle; California Bay
Laurel; Pear; Poplar (e.g. P. balsamifera, P. nigra, Hybrid Poplar
(Populus.times.canadensis)); Ramin; Red cedar; Rosewood; Sal;
Sandalwood; Sassafras; Satinwood; Silky Oak; Silver Wattle;
Snakewood; Sourwood; Spanish cedar; American sycamore; Teak; Walnut
(e.g. Juglans nigra, Juglans regia); Willow (e.g. Salix nigra,
Salix alba); Yellow poplar (Liriodendron tulipifera); Bamboo;
Palmwood; and combinations/hybrids thereof.
[0022] For example, hardwood feedstocks for the present invention
may be selected from acacia, aspen, beech, eucalyptus, maple,
birch, gum, oak, poplar, and combinations/hybrids thereof. The
hardwood feedstocks for the present invention may be selected from
Populus spp. (e.g. Populus tremuloides), Eucalyptus spp. (e.g.
Eucalyptus globulus), Acacia spp. (e.g. Acacia dealbata), and
combinations/hybrids thereof.
[0023] The present invention provides lignin derivatives from
hardwood biomass wherein the derivatives have an ethoxy content, of
from 0.45 mmol/g to about 1.4 mmol/g; about 0.5 mmol/g to about 1.3
mmol/g; about 0.6 mmol/g to about 1.2 mmol/g.
[0024] Softwood feedstocks include Araucaria (e.g. A. cunninghamii,
A. angustifolia, A. araucana); softwood Cedar (e.g. Juniperus
virginiana, Thuja plicata, Thuja occidentalis, Chamaecyparis
thyoides Callitropsis nootkatensis); Cypress (e.g. Chamaecyparis,
Cupressus Taxodium, Cupressus arionica, Taxodium distichum,
Chamaecyparis obtusa, Chamaecyparis lawsoniana, Cupressus
semperviren); Rocky Mountain Douglas fir; European Yew; Fir (e.g.
Abies balsamea, Abies alba, Abies procera, Abies amabilis); Hemlock
(e.g. Tsuga canadensis, Tsuga mertensiana, Tsuga heterophylla);
Kauri; Kaya; Larch (e.g. Larix decidua, Larix kaempferi, Larix
laricina, Larix occidentalis); Pine (e.g. Pinus nigra, Pinus
banksiana, Pinus contorta, Pinus radiata, Pinus ponderosa, Pinus
resinosa, Pinus sylvestris, Pinus strobus, Pinus monticola, Pinus
lambertiana, Pinus taeda, Pinus palustris, Pinus rigida, Pinus
echinata); Redwood; Rimu; Spruce (e.g. Picea abies, Picea mariana,
Picea rubens, Picea sitchensis, Picea glauca); Sugi; and
combinations/hybrids thereof.
[0025] For example, softwood feedstocks which may be used herein
include cedar; fir; pine; spruce; and combinations thereof. The
softwood feedstocks for the present invention may be selected from
loblolly pine (Pinus taeda), radiata pine, jack pine, spruce (e.g.,
white, interior, black), Douglas fir, Pinus silvestris, Picea
abies, and combinations/hybrids thereof. The softwood feedstocks
for the present invention may be selected from pine (e.g. Pinus
radiata, Pinus taeda); spruce; and combinations/hybrids
thereof.
[0026] The present invention provides lignin derivatives from
softwood biomass wherein the derivatives have an ethoxy content, of
from about 0.35 mmol/g to about 1.4 mmol/g; about 0.45 mmol/g to
about 1.3 mmol/g; about 0.5 mmol/g to about 1.2 mmol/g; about 0.6
mmol/g to about 1.1 mmol/g.
[0027] Annual fibre feedstocks include biomass derived from annual
plants, plants which complete their growth in one growing season
and therefore must be planted yearly. Examples of annual fibres
include: flax, cereal straw (wheat, barley, oats), sugarcane
bagasse, rice straw, corn stover, corn cobs, hemp, fruit pulp, alfa
grass, switchgrass, and combinations/hybrids thereof. Industrial
residues like corn cobs, corn fibre, distillers' dried grains
(DDGs), fruit peals, seeds, etc. may also be considered annual
fibres since they are commonly derived from annual fibre biomass
such as edible crops and fruits. For example, the annual fibre
feedstock may be selected from wheat straw, corn stover, corn cobs,
sugar cane bagasse, and combinations/hybrids thereof.
[0028] The present invention provides lignin derivatives from
annual fibre biomass wherein the derivatives have an ethoxy
content, of from about 0.25 mmol/g to about 1.4 mmol/g; about 0.35
mmol/g to about 1.3 mmol/g; about 0.45 mmol/g to about 1.2 mmol/g;
about 0.5 mmol/g to about 1.1 mmol/g.
[0029] The derivatives of native lignin will vary with the type of
process used to separate native lignins from cellulose and other
biomass constituents. Any suitable process may be used herein but
it should be noted that kraft pulping, sulphite pulping, and ASAM
organosolv pulping will generate derivatives of native lignin
containing significant amounts of organically-bound sulphur which
may make them unsuitable for certain uses.
[0030] Organosolv processes, particularly the Alcell.RTM. process,
tend to be less aggressive and can be used to separate highly
purified lignin derivatives and other useful materials from biomass
without excessively altering or damaging the native lignin building
blocks. Such processes can therefore be used to maximize the value
from all the components making up the biomass.
[0031] A description of the Alcell.RTM. process can be found in
U.S. Pat. No. 4,764,596 (herein incorporated by reference). The
process generally comprises pulping or pre-treating a fibrous
biomass feedstock with primarily an ethanol/water solvent solution
under conditions that include: (a) 60% ethanol/40% water, (b)
temperature of about 180.degree. C. to about 210.degree. C., (c)
pressure of about 20 atm to about 35 atm, and (d) a processing time
of 5-120 minutes. Derivatives of native lignin are fractionated
from the native lignins into the pulping liquor which also receives
solubilised hemicelluloses, other carbohydrates and other
extractives such as resins, organic acids, phenols, and tannins.
Organosolv pulping liquors comprising the fractionated derivatives
of native lignin and other extractives from the fibrous biomass
feedstocks, are often called "black liquors". The organic acid and
extractives released by organosolv pulping significantly acidify
the black liquors to pH levels of about 5 and lower. After
separation from the cellulosic pulps produced during the pulping
process, the derivatives of native lignin are recovered from the
black liquors by flashing (depressurization) followed by addition
of the flashed black liquor to cold water which will cause the
fractionated derivatives of native lignin to precipitate thereby
enabling their recovery by standard solids/liquids separation
processes. Various disclosures exemplified by U.S. Pat. No.
7,465,791 and PCT Patent Application Publication No. WO
2007/129921, describe modifications to the Alcell organosolv
process for the purpose of increasing the yields of fractionated
derivatives of native lignin recovered from fibrous biomass
feedstocks during biorefining. Modifications to the Alcell
organosolv process conditions included adjusting: (a) ethanol
concentration in the pulping liquor to a value selected from a
range of 35%-85% (w/w) ethanol, (b) temperature to a value selected
from a range of 100.degree. C. to 350.degree. C., (c) pressure to a
value selected from a range of 5 atm to 35 atm, and (d) processing
time to a duration from a range of 20 minutes to about 2 hours or
longer, (e) liquor-to-wood ratio of 3:1 to 15:1 or higher, (f) pH
of the cooking liquor from a range of 1 to 6.5 or higher if a basic
catalyst is used.
[0032] The present invention provides a process for producing
derivatives of native lignin, said process comprising:
[0033] (a) pulping a fibrous biomass feedstock with an organic
solvent/water solution,
[0034] (b) separating the cellulosic pulps or pre-treated
substrates from the pulping liquor or pre-treatment solution,
[0035] (c) recovering derivatives of native lignin.
[0036] The organic solvent may be selected from short chain primary
and secondary alcohols, such as such as methanol, ethanol,
propanol, and combinations thereof. For example, the solvent may be
ethanol. The liquor solution may comprise about 20%, by weight, or
greater, about 30% or greater, about 50% or greater, about 60% or
greater, about 70% or greater, of ethanol.
[0037] Step (a) of the process may be carried out at a temperature
of from about 100.degree. C. and greater, or about 120.degree. C.
and greater, or about 140.degree. C. and greater, or about
160.degree. C. and greater, or about 170.degree. C. and greater, or
about 180.degree. C. and greater. The process may be carried out at
a temperature of from about 300.degree. C. and less, or about
280.degree. C. and less, or about 260.degree. C. and less, or about
240.degree. C. and less, or about 220.degree. C. and less, or about
210.degree. C. and less, or about 205.degree. C. and less, or about
200.degree. C. and less.
[0038] Step (a) of the process may be carried out at a pressure of
about 5 atm and greater, or about 10 atm and greater, or about 15
atm and greater, or about 20 atm and greater, or about 25 atm and
greater, or about 30 atm and greater. The process may be carried
out at a pressure of about 150 atm and less, or about 125 atm and
less, or about 115 atm and less, or about 100 atm and less, or
about 90 atm and less, or about 80 atm and less.
[0039] The fibrous biomass may be treated with the solvent solution
of step (a) for about 1 minute or more, about 5 minutes or more,
about 10 minutes or more, about 15 minutes or more, about 30
minutes or more. The fibrous biomass may be treated with the
solvent solution of step (a) at its operating temperature for about
360 minutes or less, about 300 minutes or less, about 240 minutes
or less, about 180 minutes or less, about 120 minutes or less.
[0040] The pH of the pulp liquor may, for example, be from about 1
to about 6, or from about 1.5 to about 5.5.
[0041] The weight ratio of liquor to biomass may be any suitable
ratio. For example, from about 5:1 to about 15:1, from about 5.5:1
to about 10:1; from about 6:1 to about 8:1.
[0042] The present lignin derivatives may have any suitable
phenolic hydroxyl content such as from about 2 mmol/g to about 8
mmol/g. For example, the phenolic hydroxyl content may be from
about 2.5 mmol/g to about 7 mmol/g; about 3 mmol/g to about 6
mmol/g.
[0043] The present lignin derivatives may have any suitable number
average molecular weight (Mn). For example, the Mn may be from
about 200 g/mol to about 3000 g/mol; about 350 g/mol to about 2000
g/mol; about 500 g/mol to about 1500 g/mol.
[0044] The present lignin derivatives may have any suitable weight
average molecular weight (Mw). For example, the Mw may be from
about 500 g/mol to about 5000 g/mol; about 750 g/mol to about 4000
g/mol; about 900 g/mol to about 3500 g/mol.
[0045] The present lignin derivatives may have any suitable
polydispersity (D). For example, the D may be from about 1 to about
5; from about 1.2 to about 4; from about 1.3 to about 3.5; from
about 1.4 to about 3.
[0046] The present lignin derivatives are preferably hydrophobic.
Hydrophobicity may be assessed using standard contact angle
measurements. For example, a lignin pellet may be formed using a
FTIR KBr pellet press. Then a water droplet is added onto the
pellet surface and the contact angle between the water droplet and
the lignin pellet is measured using a contact angle goniometer. As
the hydrophobicity of lignins increases the contact angle also
increases. Preferably the lignins herein will have a contact angle
of about 90.degree. or greater.
[0047] The lignin derivatives herein may, for example, have an
aliphatic hydroxyl content of from about 0.001 mmol/g to about 8
mmol/g; about 0.1 mmol/g to about 7 mmol/g; about 0.2 mmol/g to
about 6.5 mmol/g; about 0.4 mmol/g to about 6 mmol/g.
[0048] The present invention provides a process for producing a
lignin derivative having an ethoxy content of 0.45 mmol/g or
greater result, said process comprising: [0049] a) pulping or
pre-treating a fibrous biomass feedstock in a vessel with an
organic solvent/water solvent solution to form a liquor, wherein:
[0050] i. the solution comprises about 30% or greater, by weight,
of organic solvent; and [0051] ii. the pH of the liquor is from
about 1 to about 6; [0052] b) heating the liquor to about
100.degree. C. or greater; [0053] c) maintaining the elevated
temperature for 1 minute or longer; [0054] d) separating the
cellulosic pulps from the pulp liquor [0055] e) recovering
derivatives of native lignin.
[0056] The present invention provides a process for producing a
hardwood lignin derivative having an ethoxy content of 0.45 mmol/g
or greater result, said process comprising: [0057] a) pulping or
pre-treating a fibrous feedstock comprising hardwood biomass in a
vessel with an organic solvent/water solvent solution to form a
liquor, wherein: [0058] i. the solution comprises about 30% or
greater, by weight, of organic solvent; and [0059] ii. the pH of
the liquor is from about 1 to about 6; [0060] b) heating the liquor
to about 100.degree. C. or greater; [0061] c) maintaining the
elevated temperature for 1 minute or longer; [0062] d) separating
the cellulosic pulps from the pulp liquor [0063] e) recovering
derivatives of native lignin.
[0064] The present invention provides a process for producing a
softwood lignin derivative having an ethoxy content of 0.35 mmol/g
or greater result, said process comprising: [0065] a) pulping or
pre-treating a fibrous feedstock comprising softwood biomass in a
vessel with an organic solvent/water solvent solution to form a
liquor, wherein: [0066] i. the solution comprises about 30% or
greater, by weight, of organic solvent; and [0067] ii. the pH of
the liquor is from about 1 to about 6; [0068] b) heating the liquor
to about 100.degree. C. or greater; [0069] c) maintaining the
elevated temperature for 1 minute or longer; [0070] d) separating
the cellulosic pulps from the pulp liquor [0071] e) recovering
derivatives of native lignin.
[0072] The present invention provides a process for producing a
annual fibre lignin derivative having an ethoxy content of 0.25
mmol/g or greater result, said process comprising: [0073] a)
pulping or pre-treating a fibrous feedstock comprising annual fibre
biomass in a vessel with an organic solvent/water solvent solution
to form a liquor, wherein: [0074] i. the solution comprises about
30% or greater, by weight, of organic solvent; and [0075] ii. the
pH of the liquor is from about 1 to about 5.5; [0076] b) heating
the liquor to about 100.degree. C. or greater; [0077] c)
maintaining the elevated temperature and pressure for 1 minute or
longer; [0078] d) separating the cellulosic pulps from the pulp
liquor [0079] e) recovering derivatives of native lignin.
[0080] The derivatives of native lignin herein may be incorporated
into resin compositions as epoxy resins, urea-formaldehyde resins,
phenol-formaldehyde resins, polyimides, isocyanate resins, and the
like. The lignin derivatives herein are particularly useful in
phenolic resins.
[0081] Phenol-formaldehyde resins can be produced by reacting a
molar excess of phenol with formaldehyde in the presence of an acid
catalyst, such as sulfuric acid, hydrochloric acid or, oxalic acid
(usually in an amount of 0.2 to 2% by weight based on the phenol)
or a basic catalyst such as sodium hydroxide. To prepare the
so-called "high ortho" novolac resins, the strong acid catalyst is
typically replaced by a divalent metal oxide (e.g. MgO and ZnO) or
an organic acid salt of a divalent metal (e.g. zinc acetate or
magnesium acetate) catalyst system. The resins so-produced are
thermoplastic, i.e., they are not self-crosslinkable. Such novolac
resins are converted to cured resins by, for example, reacting them
under heat with a crosslinking agent, such as hexamine (also called
hexa or hexamethylenetetramine), or for example, by mixing them
with a solid acid catalyst and paraformaldehyde and reacting them
under heat. Novolac resins also may be cured with other cross
linkers such as resoles and epoxies.
[0082] The lignin derivative may be mixed with phenol at any
suitable ratio. For example, a lignin:phenol weight ratio of about
1:10 to about 10:1, about 1:8 to about 8:1, about 1:6 to about 6:1,
about 1:5 to about 5:1, about 1:4 to about 4:1, about 1:3 to about
3:1, about 1:2 to about 2:1, about 1:1.
[0083] The lignin derivative may comprise any suitable amount of
the total resin composition. For example, from about 0.1%, by
weight, or greater, about 0.5% or greater, about 1% or greater, of
the total resin composition. The lignin derivative may comprise
from about 80%, by weight, or less, about 60% or less, about 40% or
less, about 20% or less, about 10% or less, of the total resin
composition.
[0084] The compositions may comprise a variety of other optional
ingredients such as adhesion promoters; biocides (e.g.
bactericides, fungicides, and moldicides), anti-fogging agents;
anti-static agents; bonding, blowing and foaming agents;
dispersants; fillers and extenders; fire and flame retardants and
smoke suppressants; impact modifiers; initiators; lubricants;
micas; pigments, colorants and dyes; plasticizers; processing aids;
release agents; silanes, titanates and zirconates; slip and
anti-blocking agents; stabilizers; stearates; ultraviolet light
absorbers; foaming agents; defoamers; hardeners; odorants;
deodorants; antifouling agents; viscosity regulators; waxes; and
combinations thereof.
[0085] The present derivatives may be used for other purposes such
as, for example, laminates, stains, pigments, inks, adhesives,
coatings, rubbers, elastomers, plastics, films, paints, carbon
fibre composites, panel boards, print-circuit boards, lubricants,
surfactants, oils, animal feed, food and beverages, and the
like.
[0086] All citations are herein incorporated by reference, as if
each individual publication was specifically and individually
indicated to be incorporated by reference herein and as though it
were fully set forth herein. Citation of references herein is not
to be construed nor considered as an admission that such references
are prior art to the present invention.
[0087] One or more currently preferred embodiments of the invention
have been described by way of example. The invention includes all
embodiments, modifications and variations substantially as
hereinbefore described and with reference to the examples and
figures. It will be apparent to persons skilled in the art that a
number of variations and modifications can be made without
departing from the scope of the invention as defined in the claims.
Examples of such modifications include the substitution of known
equivalents for any aspect of the invention in order to achieve the
same result in substantially the same way.
[0088] The following examples are intended to be exemplary of the
invention and are not intended to be limiting.
EXAMPLES
Example 1
Recovery of Lignin Derivatives from Hardwood Feedstocks
[0089] Hardwood feedstock chips were prepared from: (1) aspen (P.
tremuloides) grown in British Columbia, Canada; (2) acacia (A.
dealbata) grown in Chile; and (3) eucalyptus (E. nitens) grown in
Chile. Three samples of each feedstock where were individually
pulped using an acid-catalyzed ethanol organosolv pulping process
wherein a different set of pulping conditions was used for each
sample (Tables 1, 2 and 3).
TABLE-US-00001 TABLE 1 Pulping conditions for aspen wood chip
samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 1 3.27 100 166 65
0.56 2 2.29 46 169 73 1.17 3 1.97 89 172 79 0.62
TABLE-US-00002 TABLE 2 Pulping conditions for acacia wood chip
samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 4 2.27 101 180 48
0.73 5 2.93 56 176 60 0.55 6 2.75 82 191 41 0.56
TABLE-US-00003 TABLE 3 Pulping conditions for eucalyptus wood chip
samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 7 2.33 94 177 47
0.67 8 2.66 82 191 41 0.48 9 2.00 21 166 46 0.67
[0090] For each wood chips sample, the ethanol pulping solvent was
prepared to the specified concentration by first, partially
diluting the ethanol with water after which, a suitable amount of
sulphuric acid was added to achieve the target final acidity.
Finally, the ethanol solution was further diluted with water to
achieve the target ethanol concentration.
[0091] The original lignin content of each fibrous biomass
subsample was determined using the methods described in National
Renewable Energy Laboratory (NREL) Technical Report entitled
"Determination of Structural Carbohydrates and Lignin in
Biomass"--Laboratory Analytical Procedure (TP-510-42618 (25 Apr.
2008)). Then, after adding the fibrous biomass sample to a pressure
vessel (2 L or 7 L Parr reactor (Parr Instrument Company, Moline,
Ill., USA)) (100-700 g odw chips), the pH-adjusted ethanol-based
pulping solvent was added to the vessel at a 6:1 liquor:wood ratio
& the pH recorded. The vessel was then pressurized and brought
up to the target temperature listed in Tables 1-3 (aspen, acacia,
eucalyptus, respectively). The biomass sample was then "cooked" for
the specified period of time, after which, the pulping process was
stopped. After pulping, the contents of the pressure vessel were
transferred to a hydraulic 20 ton manual shop press (Airco, China).
The liquor was separated from the solids by first squeezing the
pulped materials in the press to express the liquor. The expressed
liquor was then filtered through a coarse silk screen to separate
expressed chip residues from liquor stream. Next, fine particles
were separated out from the liquor stream by filtration through
fine filter paper (Whatman No 1). The recovered fine particles
represent lignin derivatives that were extracted and
self-precipitated out from the liquor during cooling of the pulped
biomass. The particulate lignin is herein referred to as
self-precipitated lignin derivatives (i.e., "SPL"). The solubilized
lignin derivatives still remaining in the filtered liquor were
precipitated from by dilution with cold water. The lignin
derivatives precipitated by dilution with cold water are referred
to as precipitated lignin or "PL". After determination of the dry
weights of SPL and PL lignin derivatives, the relative yield of
each lignin derivative was determined in reference to total native
lignin (sum of the acid-insoluble lignin and acid-soluble lignin)
value determined for the original biomass sample before pulping.
The yield of PL lignin derivatives for each sample is shown in
Tables 1-3 on a weight % basis relative to their original lignin
(acid-insoluble lignin plus acid-soluble lignin values).
[0092] The ethoxyl groups content can be measured by quantitative
.sup.13C high resolution NMR spectroscopy of acetylated and
non-acetylated lignin derivatives, using, for instance,
1,3,5-trioxane and tetramethyl silane (TMS) as internal references.
For the data analysis "BASEOPT" (DIGMOD set to baseopt) routine in
the software package TopSpin 2.1.4 was used to predict the first
FID data point back at the mid-point of .sup.13C r.f. pulse in the
digitally filtered data was used. For the NMR spectra recording a
Bruker AVANCE II digital NMR spectrometer running TopSpin 2.1 was
used. The spectrometer used a Bruker 54 mm bore Ultrashield magnet
operating at 14.1 Tesla (600.13 MHz for .sup.1H, 150.90 MHz for
.sup.13C). The spectrometer was coupled with a Bruker QNP cryoprobe
(5 mm NMR samples, .sup.13C direct observe on inner coil, .sup.1H
outer coil) that had both coils cooled by helium gas to 20K and all
preamplifiers cooled to 77K for maximum sensitivity. Sample
temperature was maintained at 300 K.+-.0.1 K using a Bruker BVT
3000 temperature unit and a Bruker BCU05 cooler with ca. 95%
nitrogen gas flowing over the sample tube at a rate of 800 L/h.
Resonance of ethoxyl groups is seen at 16.0-14.5 ppm both in the
acetylated and non-acetylated lignin spectra.
[0093] Identification of ethoxyl groups was confirmed by 2D NMR
HSQC spectroscopy. 2D NMR spectra were recorded by a Bruker 700 MHz
UltraShield Plus standard bore magnet spectrometer equipped with a
sensitive cryogenically cooled 5 mm TCI gradient probe with inverse
geometry. The acquisition parameters were as follow: standard
Bruker pulse program hsqcetgp, temperature of 298 K, a 90.degree.
pulse, 1.1 sec pulse delay (d1), and acquisition time of 60
msec.
Example 2
Recovery of Lignin Derivatives from Softwood Feedstocks
[0094] Softwood feedstock chips were prepared from: (1) hybrid
spruce trees grown in British Columbia, (2) radiata pine grown in
Chile, and (3) loblolly pine grown in south eastern USA. Three
samples from each feedstock were individually pulped using an
acid-catalyzed ethanol pulping process wherein a different set of
pulping conditions was used for each sample (Tables 8, 9 and
10).
TABLE-US-00004 TABLE 8 Pulping conditions for hybrid spruce wood
chip samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 10 2.11 34 172 79
0.90 11 2.43 49 179 45 0.73 12 1.89 31 167 52 0.66
TABLE-US-00005 TABLE 9 Pulping conditions for radiata pine wood
chip samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 13 1.72 32 182 50
0.59 14 3.01 60 182 62 1.01 15 2.04 34 172 79 1.02
TABLE-US-00006 TABLE 10 Pulping conditions for loblolly pine wood
chip samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 16 2.15 59 171 42
0.52 17 2.58 51 176 65 0.77 18 2.65 84 184 76 0.97
[0095] For each wood chips sample, the ethanol pulping solvent was
prepared to the specified concentration by first, partially
diluting the ethanol with water after which, a suitable amount of
sulphuric acid was added to achieve the target final acidity.
Finally, the ethanol solution was further diluted with water to
achieve the target ethanol concentration.
[0096] The lignin content of each original fibrous biomass
subsample was determined using the NREL method (NREL/TP-510-42618
(April 2008)). Then, after adding the fibrous biomass sample to a
pressure vessel (2 L or 7 L Parr reactor (Parr Instrument Company,
Moline, Ill., USA) (100-700 g odw chips), the pH-adjusted
ethanol-based pulping solvent was added to the vessel at a 6:1
liquor:wood ratio & the pH recorded.
[0097] The vessel was then pressurized and brought up to the target
temperature listed in Tables 8-10 (spruce, radiata pine, loblolly
pine, respectively). The biomass sample was then "cooked" for the
specified period of time, after which, the pulping process was
stopped. After pulping, the contents of pressure vessel were
transferred to a hydraulic 20 ton manual shop press (Airco, China).
The liquor was separated from the solids by first squeezing the
pulped materials in the press to express the liquor.
[0098] The expressed liquor was then filtered through a coarse silk
screen to separate expressed chip residues from liquor stream.
Next, fine particles were separated out from the liquor stream by
filtration through fine filter paper (Whatman No 1). The recovered
fine particles represent lignin derivatives that were extracted and
self-precipitated out from the liquor during cooling of the pulped
biomass. The particulate lignin is herein referred to as
self-precipitated lignin derivatives (i.e., "SPL"). The solubilized
lignin derivatives still remaining in the filtered liquor were
precipitated from by dilution with cold water. The lignin
derivatives precipitated by dilution with cold water are referred
to as precipitated lignin or "PL". After determination of the dry
weights of SPL and PL lignin derivatives, the relative yield of
each lignin derivative was determined in reference to the total
lignin content (acid-insoluble plus the acid-soluble lignin)
determined for the original biomass sample before pulping. The
yield of PL lignin derivatives for each sample is shown in Tables
8-10 on a weight % basis relative to total lignin in the original
biomass.
[0099] The ethoxyl groups content can be measured by quantitative
.sup.13C high resolution NMR spectroscopy of acetylated and
non-acetylated lignin derivatives, using, for instance,
1,3,5-trioxane and tetramethyl silane (TMS) as internal references.
For the data analysis "BASEOPT" (DIGMOD set to baseopt) routine in
the software package TopSpin 2.1.4 was used to predict the first
FID data point back at the mid-point of .sup.13C r.f. pulse in the
digitally filtered data was used.
[0100] For the NMR spectra recording a Bruker AVANCE II digital NMR
spectrometer running TopSpin 2.1 was used. The spectrometer used a
Bruker 54 mm bore Ultrashield magnet operating at 14.1 Tesla
(600.13 MHz for .sup.1H, 150.90 MHz for .sup.13C). The spectrometer
was coupled with a Bruker QNP cryoprobe (5 mm NMR samples, .sup.13C
direct observe on inner coil, .sup.1H outer coil) that had both
coils cooled by helium gas to 20K and all preamplifiers cooled to
77K for maximum sensitivity. Sample temperature was maintained at
300 K.+-.0.1 K using a Bruker BVT 3000 temperature unit and a
Bruker BCU05 cooler with ca. 95% nitrogen gas flowing over the
sample tube at a rate of 800 L/h. Resonance of ethoxyl groups is
seen at 16.0-14.5 ppm both in the acetylated and non-acetylated
lignin spectra.
[0101] Identification of ethoxyl groups was confirmed by 2D NMR
HSQC spectroscopy. 2D NMR spectra were recorded by a Bruker 700 MHz
UltraShield Plus standard bore magnet spectrometer equipped with a
sensitive cryogenically cooled 5 mm TCI gradient probe with inverse
geometry. The acquisition parameters were as follow: standard
Bruker pulse program hsqcetgp, temperature of 298 K, a 90.degree.
pulse, 1.1 sec pulse delay (d1), and acquisition time of 60
msec.
Example 3
Recovery of Lignin Derivatives from Annual Fibre Feedstocks
[0102] Two sets of annual fibre feedstock materials were prepared
from: (1) corn cobs produced in Europe, (2) bagasse produced from
sugarcane grown and processed in Brazil, and (3) wheat straw
produced in Alberta, Canada. Three samples of the each feedstock
were individually pulped using an acid-catalyzed ethanol pulping
process based wherein a different set of pulping conditions was
used for each sample (Table 14, 15 and 16).
TABLE-US-00007 TABLE 14 Pulping conditions for corn cob samples at
6:1 liquor-to-wood ratio. Time Temperature Ethanol Ethoxy Sample #
pH min .degree. C. % wt. mmol/g 19 2.11 106 176 38 0.35 20 2.33 49
192 37 0.32 21 2.19 39 189 50 0.40
TABLE-US-00008 TABLE 15 Pulping conditions for sugarcane bagasse
samples at 6:1 liquor-to-wood ratio. Time Temperature Ethanol
Ethoxy Sample # pH min .degree. C. % wt. mmol/g 22 3.26 32 197 51
0.50 23 3.19 81 181 57 0.47 24 2.06 47 176 38 0.54
TABLE-US-00009 TABLE 16 Pulping conditions for wheat straw samples
at 6:1 liquor-to-wood ratio. Time Temperature Ethanol Ethoxy Sample
# pH min .degree. C. % wt. mmol/g 25 1.97 93 165 40 0.56 26 2.23
100 190 67 0.62 27 2.49 53 185 72 0.55
[0103] For each biomass sample, the ethanol pulping solvent was
prepared to the specified concentration by first, partially
diluting the ethanol with water after which, a suitable amount of
sulphuric acid was added to achieve the target final acidity.
Finally, the ethanol solution was further diluted with water to
achieve the target ethanol concentration.
[0104] The original lignin content of each fibrous biomass
subsample was determined using the NREL method (NREL/TP-510-42618
(April 2008)). Then, after adding the fibrous biomass sample to a
pressure vessel (2 L or 7 L Parr reactor (Parr Instrument Company,
Moline, Ill., USA) (100-700 g odw chips), the pH-adjusted
ethanol-based pulping solvent was added to the vessel at a 6:1
liquor:biomass ratio & the pH recorded. The vessel was then
pressurized and brought up to the target temperature listed in
Tables 14-16 (bagasse, corncobs, wheat straw respectively). The
biomass sample was then "cooked" for the specified period of time,
after which, the pulping process was stopped. After pulping, the
contents of pressure vessel were transferred to a hydraulic 20 ton
manual shop press (Aicro, China). The liquor was separated from the
solids by first squeezing the pulped materials in the press to
express the liquor. The expressed liquor was then filtered through
a coarse silk screen to separate expressed chip residues from
liquor stream. Next, fine particles were separated out from the
liquor stream by filtration through fine filter paper (Whatman No
1). The recovered fine particles represent lignin derivatives that
were extracted and self-precipitated out from the liquor during
cooling of the pulped biomass. The particulate lignin is herein
referred to as self-precipitated lignin derivatives (i.e., "SPL").
The solubilized lignin derivatives still remaining in the filtered
liquor were precipitated from by dilution with cold water. The
lignin derivatives precipitated by dilution with cold water are
referred to as precipitated lignin or "PL". After determination of
the dry weights of SPL and PL lignin derivatives, the relative
yield of each lignin derivative was determined in reference to the
total lignin (sum of acid-insoluble lignin plus acid-soluble
lignin) value determined for the original biomass sample before
pulping. The yield of PL lignin derivatives for each sample is
shown in Tables 14-16 on a weight % basis relative to their
original total lignin values.
[0105] The ethoxyl groups content can be measured by quantitative
.sup.13C high resolution NMR spectroscopy of acetylated and
non-acetylated lignin derivatives, using, for instance,
1,3,5-trioxane and tetramethyl silane (TMS) as internal references.
For the data analysis "BASEOPT" (DIGMOD set to baseopt) routine in
the software package TopSpin 2.1.4 was used to predict the first
FID data point back at the mid-point of .sup.13C r.f. pulse in the
digitally filtered data was used. For the NMR spectra recording a
Bruker AVANCE II digital NMR spectrometer running TopSpin 2.1 was
used. The spectrometer used a Bruker 54 mm bore Ultrashield magnet
operating at 14.1 Tesla (600.13 MHz for .sup.1H, 150.90 MHz for
.sup.13C). The spectrometer was coupled with a Bruker QNP cryoprobe
(5 mm NMR samples, .sup.13C direct observe on inner coil, .sup.1H
outer coil) that had both coils cooled by helium gas to 20K and all
preamplifiers cooled to 77K for maximum sensitivity. Sample
temperature was maintained at 300 K.+-.0.1 K using a Bruker BVT
3000 temperature unit and a Bruker BCU05 cooler with ca. 95%
nitrogen gas flowing over the sample tube at a rate of 800 L/h.
Resonance of ethoxyl groups is seen at 16.0-14.5 ppm both in the
acetylated and non-acetylated lignin spectra.
[0106] Identification of ethoxyl groups was confirmed by 2D NMR
HSQC spectroscopy. 2D NMR spectra were recorded by a Bruker 700 MHz
UltraShield Plus standard bore magnet spectrometer equipped with a
sensitive cryogenically cooled 5 mm TCI gradient probe with inverse
geometry. The acquisition parameters were as follow: standard
Bruker pulse program hsqcetgp, temperature of 298 K, a 90.degree.
pulse, 1.1 sec pulse delay (d1), and acquisition time of 60
msec.
Example 4
Synthesis of Lignin-Phenol-Formaldehyde (LPF) Resins for Wood
Composites
[0107] LPF Resins were synthesized from a 40/60 Lignin/Phenol
mixture, and at a Phenol:Formaldehyde molar ratio of 1:2.55.
Reagents & equipment used for the synthesis method:
[0108] 12.76 g 50% NaOH solution (Fisher Scientific, CAS 1310-73-2,
Cat# SS410-4)
[0109] 42.4 g 37% Formaldehyde solution (Fisher Scientific, CAS
50-00-0, Cat# F79-4)
[0110] 19.28 g Phenol (Fisher Scientific, CAS 108-95-2, Cat#
A91I-212)
[0111] 32.71 g Nanopure water (18.2 M.OMEGA.*cm or better)
[0112] 12.85 g Lignin derivatives produced by Lignol Innovations,
Ltd., Burnaby, BC, Canada
[0113] 250 ml 3-neck round bottom flasks
[0114] Small condenser
[0115] Corning brand thermocouple
[0116] Rubber stoppers
[0117] Rubber stoppers with a hole punched in center to accept a
thermocouple
[0118] Teflon covered magnetic stir bar
[0119] Hot-stirring plates
[0120] Medium crystallizing dish that fit the 250 ml round bottom
flask
[0121] 1 big crystallizing dish
[0122] Small plastic funnel
[0123] 100 ml beaker
[0124] 1 small glass funnel
[0125] 3-50 ml volumetric flasks with glass stoppers
[0126] 2 pieces of connecting tubing for the condensers
[0127] 2 clamps for the flasks and condensers
[0128] Metal stand
[0129] Weighing dish
[0130] Portable Viscolite viscometer from Hydramotion Ltd. (York,
England)
[0131] The reagents were weighed and synthesis resin reactors were
set-up by connecting the condensers with the tubing in series,
clamping the round bottom flask on top of the crystallizing dish,
sitting on a hot-stirring plate. Thermocouples were inserted
through rubber stoppers and placed in the centre joint of the
flask. The clamped condenser was placed in one of the side joints
of the flask. A magnetic stir bar was placed in the flask. On
another hot-stirring plate a big crystallizing dish was placed
containing the jar with solid phenol. Sufficient hot water was
added to the crystallizing dish to cover the level of solid phenol
in the jar. The water was heated to approximately 70-80.degree. C.
in order to melt the phenol.
[0132] While the phenol was melting, 100 mL beaker and a small
glass funnel was heated in a 105.degree. C. oven. Hot water was
added in the crystallizing dishes containing the flasks, and the
hotplate temperature set to 55.degree. C. When the phenol was
molten and the hotplate had achieved 55.degree. C., the phenol was
removed from the hot water bath. 19.3 g of molten phenol was added
to the hot, 100 mL beaker. Liquid phenol was poured through the hot
glass funnel into the round bottom flask.
[0133] Over 10-15 minutes 12.85 g of lignin derivative was added in
small amounts to the flasks through a small plastic funnel.
Stirring speed was 300 rpm and as the mixture viscosity increased
the stirring speed was gradually be increased to 340 rpm.
[0134] The stirring speed was reduced to 300 rpm. 32.71 g of
deionized water and 12.76 g 50% NaOH solution was poured into the
flask. The temperature may increase due to the exothermic nature of
the reaction. Once the reaction temperature was stabilized at
55.degree. C. the mixture was left to stand for 10 additional
minutes then 42.4 g 37% formaldehyde solution was slowly added. The
temperature was increased to 70.degree. C. and left for it to
stabilize (approx. 10 mins). Once the temperature had stabilized,
the hotplate was set to 75.degree. C. After the reaction achieved
75.degree. C. it was held for 3 hours. The hotplate maintained the
reaction temperature throughout the experiment. The water level was
monitored and hot water added as necessary. The level was kept
above the resin level within the flask.
[0135] After 3 h at 75.degree. C., the reaction temperature was
increased to 80.degree. C. and, after stabilization, maintained for
2.5 hours. The level of water in crystallizing dishes was monitored
to ensure it did not drop below that of the resin in the
flasks.
[0136] A few minutes before the 2 h 30 minutes are done, prepare 2
big crystallizing dishes with cold water. After 2 h30 min at
80.degree. C., the hotplate was adjusted to 35.degree. C., and the
flask with the condenser raised above the crystallizing dish. The
dish with hot water was removed and poured away. A big
crystallizing dish with cold water was placed on the hot plate and
the flask with the condenser lowered in the cold water bath. More
cold water was poured in until the flask is immersed up to the
joints' level in cold water. The flask was kept immersed, under
continuous stirring and in cold water, until the temperature in the
reaction mixture stabilized at 35.degree. C. The reaction was then
removed from the cold water bath.
[0137] The bond strength (also called "shear strength") of LPF
resins was tested by the ABES method (Wescott, J. M., Birkeland, M.
J., Traska, A. E., New Method for Rapid Testing of Bond Strength
for Wood Adhesives, Heartland Resource Technologies Waunakee, Wis.,
U.S.A. and Frihart, C. R. and Dally, B. N., USDA Forest Service,
Forest Products Laboratory, Madison, Wis., U.S.A., Proceedings
30.sup.th Annual Meeting of The Adhesion Society, Inc., Feb. 18-21,
2007, Tampa Bay, Fla., USA) under the following conditions: sliced
aspen strands: 117 mm.times.20 mm.times.0.8 mm (conditioned at 50%
HR & 20.degree. C.), bonding area: 20 mm.times.5 mm, press
temperature: 150.degree. C., press pressure: 2 MPa, press time: 90
seconds. Ten replicates for each resin sample were run. The average
bond strength in MPa of ten replicates was then normalized dividing
by the grams loaded resin per square centimeter of bonding area to
yield the Normalized Bond Strength (NBS) or normalized shear
strength
[0138] The results of the bond strength testing are shown in Table
17:
TABLE-US-00010 TABLE 17 Normalized Bond Strength (NBS) at
150.degree. C. (MPa * cm.sup.2/g) SAMPLE NBS 1 3,379 2 3,485 3
3,706 4 3,258 5 3,462 6 3,655 7 3,553 8 3,549 9 3,504 10 3,707 11
3,692 12 3,604 13 3,552 14 3,607 15 3,345 16 3,634 17 3,546 18
3,563 19 3,537 20 3,576 21 3,490 22 3,685 23 3,506 24 3,452 25
3,504 26 3,541 27 3,511
* * * * *