阅读说明：本技术 化学-机械细胞爆破及其制造的固体和液体产物的工艺、方法和系统 (Process, method and system for chemical-mechanical cell blasting and solid and liquid products produced thereby ) 是由 蒂莫西·瓦格勒 丽红·L·迪·安格罗 切斯特·甘恩 于 2019-10-24 设计创作，主要内容包括：本发明公开了一种工艺,其包括：将一种或多种添加剂与原料混合以获得第一混合物,所述原料包含纤维材料和水,所述纤维材料包含木质素、纤维素和半纤维素；以及,调节所述第一混合物以获得液体产物和干浆产物。本发明还公开了调节工艺以及与其配套使用的机器。本发明还公开了通过所公开的工艺制备的液体产物、干浆产物和纤维粒料,以及使用它们的方法。(The invention discloses a process, which comprises the following steps: mixing one or more additives with a feedstock comprising a fibrous material and water, the fibrous material comprising lignin, cellulose and hemicellulose to obtain a first mixture; and adjusting the first mixture to obtain a liquid product and a dry slurry product. The invention also discloses a regulating process and a machine matched with the regulating process for use. Also disclosed are liquid products, dry pulp products, and fiber pellets made by the disclosed processes, and methods of using the same.)

1. A process, comprising:

mixing one or more additives with a raw material to obtain a first mixture, the raw material comprising a fibrous material and water; and

the first mixture is conditioned to obtain a liquid product and a dry slurry product.

2. The process according to claim 1, characterized in that: the fibrous material comprises cellulose.

3. The process according to claim 2, characterized in that: the fibrous material also includes lignin and hemicellulose.

4. The process according to claim 1, characterized in that: the feedstock comprises from about 10 wt% to about 90 wt% water, based on the total weight of the feedstock.

5. The process according to claim 4, characterized in that: the dry pulp product comprises about 35 wt% or less water based on the total weight of the dry pulp product.

6. The process according to claim 4, characterized in that: the liquid product comprises about 50 wt% or more water based on the total weight of the liquid product.

7. The process according to claim 1, characterized in that: the adjusting comprises:

applying a shear force to the first mixture to increase the pressure of the first mixture; and

blasting a plurality of cells of the fibrous material of the first mixture.

8. The process according to claim 7, characterized in that: the adjusting further comprises:

mixing an additive with the fibrous material of the first mixture to form a treated material;

removing a first portion of the water from the treated material;

dissolving the additive with the first portion of water; and

weakening cell walls of a plurality of cells of the fibrous material of the treated material.

9. The process according to claim 8, characterized in that: the weakening comprises reacting the additive with lignin in the cell wall.

10. The process according to claim 8, characterized in that: the adjusting further comprises:

applying a shear force to the treated material to increase the pressure and temperature of the treated material;

evaporating a second portion of the water from the treated material by fractionating the fibrous material of the treated material; and

exposing the treated material to atmospheric pressure to induce bursting of a plurality of cells of the fibrous material.

11. The process according to claim 1, characterized in that: the liquid product comprises at least 75% of the VOCs present in the feedstock.

12. The process according to claim 1, characterized in that: the conditioning occurs at a maximum temperature of about 200 ° f to about 350 ° f.

13. The process according to claim 1, wherein: the additive includes a surfactant.

14. The process according to claim 1, characterized in that: the molecular weight of the additive is from about 30g/mol to about 10,000,000 g/mol.

15. The process according to claim 1, characterized in that: further comprising pelletizing the dried solid product to form pellets.

16. The process according to claim 1, characterized in that: the liquid product comprises one or more biostimulant compounds and water.

17. The process of claim 16, wherein: the one or more biostimulating compounds include one or more of minerals, proteins, amino acids, humic acid, fulvic acid, and one or more organic acids.

18. The process of claim 17, wherein: the minerals comprise one or more of potassium, phosphor, phosphorus, nitrite, calcium, magnesium, sulfur, sulfurous acid, sodium, iron, manganese, zinc, and copper.

19. The process of claim 16, wherein: the liquid product further comprises one or more of cellulose, lignin and hemicellulose.

20. A dry pulp product produced by the process of any one of claims 1 to 19.

21. A liquid product produced by the process of any one of claims 1-19.

22. A chemical-mechanical cell blasting process, comprising:

mixing one or more additives into a fibrous material, the fibrous material comprising water;

removing a first portion of the water from the fibrous material;

dissolving the additive with the first portion of water;

weakening cell walls of a plurality of cells of the fibrous material;

applying a shear force to the fibrous material to increase the pressure and temperature of the fibrous material;

evaporating a second portion of the water in the fibrous material by fractionating the fibrous material; and

exposing the fibrous material to atmospheric pressure to induce a plurality of cells in the fibrous material to explode.

23. The process of claim 22, wherein: when the fibrous material is mixed with one or more additives, the fibrous material comprises from about 5 wt% to about 90 wt% water, based on the total weight of the fibrous material.

24. The process of claim 22, wherein: the fibrous material comprises about 35% or less water by total weight of the fibrous material when exposed to atmospheric pressure to induce bursting of the plurality of cells.

25. The process of claim 22, wherein: the process occurs at a maximum temperature of about 200 ° f to about 350 ° f.

26. The process of claim 22, wherein: the additive includes a surfactant.

27. The process of claim 22, wherein: the molecular weight of the additive is from about 30g/mol to about 10,000,000 g/mol.

28. A fibrous pulp material produced by the process of any one of claims 22 to 27.

29. A liquid produced by the process of any one of claims 22-28, the liquid comprising: solid particles, one or more biostimulant compounds, and water.

30. The liquid of claim 29, wherein: the one or more biostimulant compounds include one or more of minerals, proteins, amino acids, humic acid, fulvic acid, and one or more organic acids.

31. The liquid of claim 30, wherein: the one or more organic acids are present in the liquid in an amount of about 0.001 wt% to about 10 wt%, based on the total weight of the liquid.

32. The liquid of claim 29, wherein: the water is present in the liquid in an amount of about 50 wt% to about 90 wt%, based on the total weight of the liquid.

33. The liquid of claim 29, wherein: further comprising lignin, wherein the amount of lignin in the liquid is from about 0.01 wt% to about 75 wt% based on the total weight of the liquid.

34. The liquid of claim 29, wherein: the minerals include one or more of potassium, phosphorus, nitrite compounds, calcium, magnesium, sulfur, sodium, iron, manganese, zinc and copper.

35. The liquid of claim 29, wherein: the solid particles have a dry matter content of about 0.0001 wt% to about 50 wt% based on the total weight of the liquid.

36. A method of promoting plant growth comprising applying the liquid of any one of claims 29-35 to a plant.

37. A fiber pellet, comprising:

a fibrous material comprising a plurality of exposed cellulosic fibers, each of the plurality of exposed cellulosic fibers being entangled with at least one other exposed cellulosic fiber; and

it further comprises about 35 wt% or less of water based on the total weight of the fiber pellet.

38. A fiber pellet as claimed in claim 37, wherein: the fibrous material further comprises one or more of lignin and hemicellulose.

39. A fiber pellet as claimed in claim 37, wherein: the plurality of exposed cellulosic fibers comprises twisted fibers.

40. A fiber pellet as claimed in claim 37, wherein: the fiber pellets have a Particle Durability Index (PDI) of 75 or more.

41. A fiber pellet as claimed in claim 37, wherein: the fibrous material includes fibers having an average largest cross-sectional dimension of from about 100 nanometers to about 1000 micrometers.

42. A fiber pellet as claimed in claim 37, wherein: the fiber pellets do not contain a binder.

43. A fiber pellet as claimed in claim 37, wherein: the bulk density of the fiber pellets was about 15kg/m³-about 800kg/m³。

44. A fiber pellet as claimed in claim 37, wherein: the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount of about 2 wt% or more based on the total weight of the pellet.

45. A fiber pellet as claimed in claim 44, characterized in that: the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount of about 5 wt% or more based on the total weight of the pellet.

46. A fiber pellet as claimed in claim 45, wherein: the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount from 5 wt% to 80 wt%, based on the total weight of the pellet.

47. A fiber pellet as claimed in claim 46, wherein: the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount from about 5 wt% to 60 wt%, based on the total weight of the pellet.

48. A fiber pellet as claimed in claim 47, wherein: the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount from about 5 wt% to 50 wt%, based on the total weight of the pellet.

49. A fiber pellet as claimed in claim 37, wherein: the amount of fibrous material present in the fibrous pellets is about 99.99% or more by total weight of the pellets.

50. A process for increasing feedstock throughput, the process comprising:

mixing one or more additives with a raw material comprising a fibrous material comprising cellulose and water to obtain a first mixture;

densifying the feedstock to obtain a product;

wherein the process has an increase in throughput of 1-30% over a process without the additive.

51. The process of claim 50, wherein: the water is present in the feedstock in an amount of from about 5 wt% to about 30 wt%, based on the total weight of the feedstock.

52. The process of claim 50, wherein: the fibrous material further comprises lignin.

53. The process of claim 50, wherein: the feedstock comprises one or more of grains, grasses, cellulosic and lignocellulosic materials, bone, food industry processing waste, and combinations thereof.

54. The process of claim 50, wherein: the densification comprises forming the product into one or more of: pellets, briquettes, bales, logs, cubes, and combinations thereof.

Technical Field

The present invention relates generally to chemical-mechanical conditioning processes. In particular, embodiments of the present invention relate to the preparation of solids and liquids by a chemical-mechanical cell blasting process, and systems and methods for making and using the same.

Background

The processing of raw materials into usable value-added products is a continuously developing area of constant innovation for mankind. For example, wood or other lignocellulosic materials can be processed into useful value-added products such as paper, packaging, biofuels, pellets, and the like. As with all processes, the current problem with such processes is the addition of high energy input harsh chemicals to obtain valuable products. In processing lignocellulosic materials, a large amount of shaft work is required to grind the material to the desired size, and a large amount of additional energy (e.g., heat and/or pressure) and chemicals (e.g., strong acids or bases) are required to remove excess moisture content and inhibitory components. In addition, the temperature increase caused by heating may vaporize and/or cause the organic materials to be converted into harmful Volatile Organic Compounds (VOCs) that are then released into the atmosphere. In some cases, additional energy and cost intensive measures must be taken to further treat the VOCs and other hazardous wastes released during the process. It is desirable to produce practical products in an energy efficient manner without the use of harmful and irritating chemicals to expand the design space of many industries, such as buildings/infrastructure, civil construction, energy production, packaging, lawn/garden products, agriculture, food production, pollution resistance, etc. Furthermore, it is desirable to retain the content of organic materials, such as VOCs, nutrients, organic acids, etc., in order to obtain other useful by-products during processing. These by-products provide attractive opportunities for producing value added products and increasing processing profits.

Accordingly, there is a need for processes, methods, and systems that produce solid and liquid products from lignocellulosic (or other) feedstocks in an energy efficient and clean manner (i.e., without the addition of harsh chemicals) without the emission of harmful byproducts, such as VOCs. Embodiments of the present invention address such needs and others which will become apparent upon reading the following description in conjunction with the accompanying drawings.

Disclosure of Invention

The present invention relates generally to chemical-mechanical conditioning processes. In particular, embodiments of the present invention relate to the preparation of solids and liquids by a chemical-mechanical cell blasting process, and systems and methods for making and using the same. An exemplary embodiment of the present invention provides a process, comprising: mixing one or more additives with a raw material to obtain a first mixture, the raw material comprising a fibrous material and water; and conditioning the first mixture to obtain a liquid product and a dry slurry product.

In any of the embodiments disclosed herein, the fibrous material comprises cellulose.

In any of the embodiments disclosed herein, the fibrous material further comprises lignin and hemicellulose.

In any of the embodiments disclosed herein, the feedstock comprises from about 10 wt% to about 90 wt% water, based on the total weight of the feedstock.

In any of the embodiments disclosed herein, the dry pulp product comprises about 35 wt% or less water based on the total weight of the dry pulp product.

In any of the embodiments disclosed herein, the liquid product comprises about 50 wt% or more water based on the total weight of the liquid product.

In any of the embodiments disclosed herein, the adjusting comprises: applying a shear force to the first mixture to increase the pressure of the first mixture; and blasting the plurality of cells of the fibrous material of the first mixture.

In any of the embodiments disclosed herein, the adjusting further comprises: mixing an additive with the fibrous material of the first mixture to form a treated material; removing a first portion of the water from the treated material; dissolving the additive in a first portion of water; and weakening cell walls of a plurality of cells of the fibrous material of the treated material.

In any of the embodiments disclosed herein, the weakening comprises reacting the additive with lignin in the cell wall.

In any of the embodiments disclosed herein, the adjusting further comprises: applying a shear force to the treated material to increase the pressure and temperature of the treated material; fractionating the fibrous material of the treated material to evaporate a second portion of the water in the treated material; and exposing the treated material to atmospheric pressure to induce blasting of a plurality of cells of the fibrous material.

In any of the embodiments disclosed herein, the liquid product comprises at least 75% of the VOCs present in the feedstock.

In any of the embodiments disclosed herein, the conditioning occurs at a maximum temperature of from about 200 ° f to about 350 ° f.

In any of the embodiments disclosed herein, the additive comprises a surfactant.

In any of the embodiments disclosed herein, the molecular weight of the additive is from about 30g/mol to about 10,000,000 g/mol.

In any of the embodiments disclosed herein, the process further comprises pelletizing the dried solid product to form pellets.

In any of the embodiments disclosed herein, the liquid product comprises one or more biostimulant compounds and water.

In any of the embodiments disclosed herein, the one or more biological stimulatory compounds comprise one or more of the following: minerals, proteins, amino acids, humic acid, fulvic acid and one or more organic acids.

In any of the embodiments disclosed herein, the mineral comprises one or more of potassium, phosphor, phosphorus, nitrite, calcium, magnesium, sulfur, sulfurous acid, sodium, iron, manganese, zinc, and copper.

In any of the embodiments disclosed herein, the liquid product further comprises one or more of: cellulose, lignin and hemicellulose.

Exemplary embodiments of the present invention provide a dry pulp product made by any of the processes disclosed herein.

Exemplary embodiments of the present invention provide liquid products prepared by any of the processes disclosed herein.

Another embodiment of the present invention provides a chemical-mechanical cell blasting method, comprising: mixing one or more additives into a fibrous material, the fibrous material comprising water; removing a first portion of the water from the fibrous material; dissolving the additive with a first portion of water; weakening cell walls of a plurality of cells of fibrous material; applying a shear force to the fibrous material to increase the pressure and temperature of the fibrous material; evaporating a second portion of the water from the fibrous material by fractionating the fibrous material; and exposing the fibrous material to atmospheric pressure to induce a plurality of cells in the fibrous material to explode.

In any of the embodiments disclosed herein, the fibrous material comprises from about 5 wt% to about 90 wt% water, based on the total weight of the fibrous material, when mixed with one or more additives.

In any of the embodiments disclosed herein, the fibrous material comprises about 35% or less water by total weight of the fibrous material when exposed to atmospheric pressure to induce bursting of the plurality of cells.

In any of the embodiments disclosed herein, the process occurs at a maximum temperature of about 200F to about 350F.

In any of the embodiments disclosed herein, the additive comprises a surfactant.

In any of the embodiments disclosed herein, the molecular weight of the additive is from about 30g/mol to about 10,000,000 g/mol.

Exemplary embodiments of the present invention provide a fibrous pulp material produced by any of the processes disclosed herein.

An exemplary embodiment of the present invention provides a liquid product produced by any of the methods disclosed herein, the liquid product comprising: solid particles, one or more biostimulant compounds, and water.

In any of the embodiments disclosed herein, the one or more biostimulating compounds comprise one or more of: minerals, proteins, amino acids, humic acid, fulvic acid and one or more organic acids.

In any of the embodiments disclosed herein, the one or more organic acids are present in the liquid in an amount from about 0.001 wt% to about 10 wt%, based on the total weight of the liquid.

In any of the embodiments disclosed herein, the water is present in the liquid in an amount of from about 50 wt% to about 90 wt%, based on the total weight of the liquid.

In any of the embodiments disclosed herein, the liquid further comprises lignin, wherein the amount of lignin in the liquid is from about 0.01 wt% to about 75 wt% based on the total weight of the liquid.

In any of the embodiments disclosed herein, the minerals comprise one or more of: potassium, phosphorus, nitrite compounds, calcium, magnesium, sulfur, sodium, iron, manganese, zinc and copper.

In any of the embodiments disclosed herein, the solid particles have a dry matter weight percent of about 0.0001 wt% to about 50 wt% based on the total weight of the liquid.

Exemplary embodiments of the present invention provide methods of promoting plant growth comprising applying a liquid of any of the processes disclosed herein to a plant.

Another embodiment of the present invention provides a fiber pellet, comprising: a fibrous material comprising a plurality of exposed cellulosic fibers, each of the plurality of exposed cellulosic fibers being entangled with at least one other exposed cellulosic fiber; and further comprising about 35 wt% or less of water, based on the total weight of the fiber pellets.

In any of the embodiments disclosed herein, the fibrous material further comprises one or more of lignin and hemicellulose.

In any of the embodiments disclosed herein, the plurality of exposed cellulosic fibers comprises twisted fibers.

In any of the embodiments disclosed herein, the fiber pellets have a Particle Durability Index (PDI) of 75 or greater.

In any of the embodiments disclosed herein, the fibrous material comprises fibers having an average largest cross-sectional dimension of from about 100 nanometers to about 1000 micrometers.

In any of the embodiments disclosed herein, the fiber pellets do not comprise a binder.

In any of the embodiments disclosed herein, the fiber pellets have a bulk density of about 15kg/m³-about 800kg/m³。

In any of the embodiments disclosed herein, the plurality of exposed cellulosic fibers present in the fiber pellet is about 2 wt% or more based on the total weight of the pellet.

In any of the embodiments disclosed herein, the plurality of exposed cellulosic fibers present in the fiber pellet is about 5 wt% or more based on the total weight of the pellet.

In any of the embodiments disclosed herein, the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount from 5 wt% to 80 wt%, based on the total weight of the pellet.

In any of the embodiments disclosed herein, the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount from about 5 wt% to 60 wt%, based on the total weight of the pellet.

In any of the embodiments disclosed herein, the plurality of exposed cellulosic fibers are present in the fiber pellet in an amount from about 5 wt% to 50 wt%, based on the total weight of the pellet.

In any of the embodiments disclosed herein, the amount of fibrous material present in the fibrous pellets is about 99.99% or greater, based on the total weight of the pellets.

Another embodiment of the present invention provides a method for increasing feedstock throughput, comprising: mixing one or more additives with a raw material to obtain a first mixture, the raw material comprising a fibrous material and water, the fibrous material comprising cellulose; densifying the feedstock to obtain a product; wherein the process has a 1-30% increase in throughput relative to the process without the additive.

In any of the embodiments disclosed herein, the water is present in the feedstock in an amount of from about 5 wt% to about 30 wt%, based on the total weight of the feedstock.

In any of the embodiments disclosed herein, the fibrous material further comprises lignin.

In any of the embodiments disclosed herein, the starting material comprises one or more of: grains, grasses, cellulosic and lignocellulosic materials, bones, food industry processing waste, and combinations thereof.

In any of the embodiments disclosed herein, the densifying comprises forming the product into one or more of: pellets, briquettes, bales, logs, cubes, and combinations thereof.

These and other aspects of the invention are illustrated in the following detailed description and drawings. Other aspects and features of embodiments of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific exemplary embodiments of the invention in conjunction with the accompanying figures. While features of the invention may be discussed with respect to certain embodiments and figures, all embodiments of the invention may include one or more of the features discussed herein. Furthermore, although one or more embodiments may be discussed as having certain advantageous features, one or more such features may also be used with the various embodiments of the invention discussed herein. In a similar manner, although exemplary embodiments may be discussed below as device, system, or method embodiments, it should be understood that such exemplary embodiments may be implemented in various devices, systems, and methods of the present invention.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the inventive subject matter and, together with the description, serve to explain the principles of the presently disclosed inventive subject matter. The drawings are not intended to limit the scope of the presently disclosed subject matter in any way.

FIG. 1 illustrates an exemplary process, according to some embodiments of the invention;

FIG. 2 illustrates a conventional method for treating fibrous material for comparison with the process of the present invention;

FIG. 3A illustrates an exemplary adjustment process, according to some embodiments of the invention;

FIG. 3B illustrates an exemplary adjustment process, according to some embodiments of the invention;

FIG. 4A shows a photograph of fiber pellets produced by a conventional process;

FIG. 4B shows a photograph of fiber pellets produced by the process of some embodiments of the present invention;

FIG. 5A shows a Scanning Electron Microscope (SEM) image of a fiber pellet produced by a conventional process;

fig. 5B shows an SEM image of fiber pellets produced by the process of some embodiments of the present invention;

FIG. 6 illustrates a machine for certain processes, according to some embodiments of the invention.

Detailed Description

The present invention discloses a comprehensive solution based on a compression blasting process that simultaneously dehydrates, dries, fractionates, extracts and separates cell-based (bio) materials, especially those (a) refractory materials that are considered difficult to process industrially; and (b) liquid by-products of commercial value. The disclosed technology may be independent of the state of the biomaterial. For example, in addition to processing green lignocellulosic feedstocks, the disclosed technology may be well applied to processing cellulosic waste materials, such as coffee grounds, waste paper, wood construction waste, poultry residues such as feathers, biosolids, compost production, and the like.

As another example, when a liquid extract of orchard grass was applied to the test lawn, the dandelion was removed and the grass rapidly grew. This result would allow the municipality or lawn services to process the cut grass and then reapply the extract back to the lawn. Saving water and avoiding the use of harsh fertilizers would be widely attractive. Grass extracts also have other potential. In another experiment, orchard grass extracts were treated by heating. Protein coagulation, thereby making the process suitable for applications in which extremely high leaf protein concentrates are sought, and is a very viable alternative to the Pro-Xan process. This advancement can greatly expand the design space of, for example, the "meat protein free" market.

The disclosed technology not only simultaneously dehydrates, dries, fractionates, extracts and separates plant material, but also fundamentally transforms the fully exposed fibers of plant cells. All of these make the material useful for subsequent processing in many industrial applications, such as bioenergy feedstock, advanced material production, sorbent manufacture, soil improvement agents, water filtration systems, fortifiers for the construction industry, biopharmaceuticals, investment of fungal and yeast substrates, etc., some examples of which are outlined below.

The disclosed technology can adjust the wood fiber to a degree that makes it suitable for use in an input of an industry utilizing pulp, such as paper industry, fiberboard manufacturing, and the like. The extremely small particle size allows for faster conversion. Many products are now available, the best known being carbonized products, such as graphene and the like. In the case of graphene, the process allows for low cost production, adding it to fabrics for better aesthetics and performance, such as moisture wicking and insect pest (e.g., mosquito) shielding. Graphene is also well suited for use as a resource for degradable electronic products, renewable carbon materials for electrochemical energy storage, and circuit substrates, thereby replacing millions of tons of hazardous substances in landfill sites worldwide every year.

In addition, advanced processes are being developed that utilize organic phenolic chemicals, such as humic acid, as a base material for advanced materials used in green energy systems, such as supercapacitors. The liquid extract produced by the process of the invention may be rich in humic and fulvic acids, as well as other organic acids.

The environmental challenges presented by the world's supply and demand of plastics necessitate recycling solutions. By using the product of the invention, less plastic can be used. Such materials are commonly referred to as wood-plastic composites. The combination of the product of the invention can lead the plastic raw material to generate better cross linking. Such improvements can improve consumer products, such as composite panels. Furthermore, the products disclosed herein provide the small particle size needed to simulate the appearance of real wood and achieve improved material properties.

Research into producing sustainable polymers made from carboxylic acids to prevent the atomization of jet fuels in the event of an accident is also being pursued. Certain products of the invention are rich in organic carboxylic acids.

Nowadays, 3D printing has become the mainstream, but the materials used are mainly synthetic. Due to the improved form factor and smaller particle size, the product of the invention can be used as a filament for 3D printing.

Cellulose nanomaterials, such as nanocrystals and nanofibers, are very small cylindrical particles produced from lignocellulosic materials. The techniques of the present invention can speed up their production and reduce their associated costs. Cellulose nano-materials are currently in widespread use in many industries, fields and disciplines worldwide, in various applications such as chemical manufacturing, pulp and paper making, composites, food packaging and cosmetics.

Cellulose nanocrystals are a unique nanomaterial derived from the most abundant and almost inexhaustible natural polymers such as cellulose. This material has a wide and exciting potential in many industries. Exposed cellulose, once considered expensive to obtain from trees and similar plants, can now be converted into nanocrystals for use in the medical, material science and electronics fields. The disclosed technology can condition the wood fibers by consolidating the lignin into exposed "droplets" on the surface of the cellulose, making the cellulose stronger. This effect allows the development of an industrial process for the production of cellulose nanocrystals by removing lignin in a more cost-effective and more environmentally friendly manner.

The process and product of the present invention can be used as a feedstock to allow the production of sustainable polymers from aroma molecules typically contained in aroma materials such as pine, witch hazel, eucalyptus, and the like. In view of the disputes that exist in the world today between polymers and plastics produced from traditional petroleum feedstocks, such processes of the present invention can improve the production of polymers.

Recent advances in electrochemistry have occurred that simplify the generation of valuable, desirous molecules for use in pharmaceuticals, electronics, and the like. The process of the present invention can generate important reactive intermediate molecules, which are believed to be the carbenium ions required for the synthesis of diethyl ether from inexpensive carboxylic acids. The product of the invention is rich in carboxylic acids, providing an even cheaper feedstock for this key process.

The unique and economical way of conditioning raw green lignocellulosic feedstock according to the present technology has many applications in horticulture. These applications range from the replacement of non-sustainable substrates such as peat and other non-recyclables, to the production of very efficient organic soil amendments, to the use of liquid extracts as organic fertilizers.

It has been found that the products of the present invention resulting from the chemical mechanical cell blasting of lignocellulosic material can preserve freshly cut plants such as industrial hemp, tomato stems and/or succulent plants for extended periods of time before they can root into the soil. Applying the product to vegetables can also preserve them to extend their shelf life.

Typical greenhouse substrates consist of peat and perlite. Peat is a hydrocarbon and is not renewable. The process of the present invention can produce a wood feedstock that is favorable to the form factor of the growth medium. A portion of the product of the invention may replace a portion of the peat, thereby reducing the dependence on hydrocarbons. In addition, the product of the invention may be used inherently as an inoculated mushroom growth medium. Due to its expanded form factor, the product can also be compressed into growth and erosion control pads, and the cost of doing so is significantly reduced.

The spray-seeding covering is a mixture of fibre/grass seed/fertiliser, suitable for steep slopes where erosion may occur. At present, mechanically treated wood fibers are used as base materials. In contrast, the product of the present invention may provide a superior product that can be produced at a lower price, and with less energy and emissions. The result is reduced surface soil erosion and cleaner waterways. The hydraulic seeding is a mixture of grass seeds, fertilizer and wood fiber. The product of the invention may provide greater hygroscopicity and thus help to accelerate seed germination.

The demand for natural and organic food products is rapidly increasing. Instead, continued cultivation uses up the vitality of the soil. Because of their nature produced by organic acids, sugars, humic/fulvic acids and various amino acids, the products of the present invention can form a soil environment that attracts microbial activity that is critical to the fixation of nitrogen and other nutrients in the soil.

The techniques of the present invention allow for the extraction of biological stimulants found in willow and other aqueous materials that were once considered ineffective for processing due to the costs involved. In addition, the properties of the products of the invention may provide very specialized gene expression and control that was once thought impossible to achieve with organic matter. The pure nature and quantity of organic chemicals contained, such as the various glutamine concentrations found in different species, provide a very powerful horticultural approach. For example, the liquid extract produced from the method of the present invention using hardwood material can be used as a cloning agent for pecan nuts. The pecan tree can start from seeds or can be cloned from the stem of a live tree. The process of cloning presents challenges to the survival of the clones. The faster the cloning can increase healthy roots, the more chance it has to survive. Many of the organic acids found in the products of the present invention are the basis for the production of growth hormones that stimulate health and accelerate root growth.

In another example, the technique of the present invention can extract large amounts of tannins for certain kinds of raw materials, particularly for bark components. Studies have shown that after regular application of tannic acid and related phenolic compounds, there is a significant change in soluble nitrogen in the soil. These tannins are used as substrates by soil microorganisms, increasing their nitrogen demand and are immobilized in the microbial biomass. This increase translates into more nitrogen being fixed by the microorganisms, thereby making more nitrogen available to the plant.

The products of the present invention may also provide pest control and defense mechanisms for horticultural markets that were once considered monopolies of synthetic chemicals. Allergenicity which may be produced by the products of the invention may be mentioned as an example: the liquid extract can achieve a new but sustainable herbicidal effect. Liquid extracted from hardwood can also control nematodes very effectively, which is critical for keeping millions of dollars of product. The overuse of various combinations of phenolic compounds and other biological stimulants and amino acids is a very effective growth control option, not synthetic chemicals

The techniques of the present invention, such as fiber and liquid extracts produced therefrom, provide an unprecedented investment for the construction market. The availability of fibers may facilitate the development of new engineered wood, concrete and asphalt formulations, resins and preservatives.

Wood fiber is a good sound insulation material. This product is popular in europe and is also becoming more and more popular in the united states. The product of the invention can provide better insulation due to improved density of smaller particle sizes. Such products of the invention may also improve fibre-based or particle-based boards, such as Medium Density Fibres (MDF). For applications such as fiber cement siding, an expanded form of the product of the invention can provide additional support for concrete-based siding. The disclosed technology also allows for the use of alternative sheet materials, such as giant reeds and the like, thereby improving the carbon cycle of the environment. The form of the product of the present invention may also allow for the use of less adhesive in the panel structure, thereby imparting another environmental advantage.

The product of the invention can also be used in the research of engineering boards and wall boards. Lignin is the main component of wood fiber and consists of various phenolic groups. By utilizing the phenolic groups contained in the extract, it is now possible to build a sustainable foam board. By the ability of the present technology it is possible to produce part of the lignin contained in the wood fibres dissolved in the liquid extract. These extracted phenolics may then be used in the formulation of foam boards.

The product of the invention may also contribute to the reinforcement of concrete. In order for the concrete to be able to withstand high loads, it must be reinforced. Generally, reinforcing steel is used to reinforce concrete. The product of the invention may be a very good reinforcement mechanism for concrete.

The techniques of the present invention may be used to manufacture engineered bamboo articles, such as flooring. Before bamboo is converted into value-added products, it must be decomposed. The method of the present invention can decompose bamboo fibers into materials that can be easily converted into valuable products, such as bamboo composite boards and bamboo flooring.

The technique of the present invention allows partial removal of lignin from lignocellulosic fibers. The lignin can be collected in the liquid extract. From this extract, lignin can be separated and then used as a component of natural asphalt.

Certain types of wood, such as teak, red oak, and the like, are produced as natural wood preservatives by the disclosed technology. This process is commonly denoted as acetylation. The acetic acid contained in the extract creates an environment in which the mold cannot grow. Once thought not to be scalable to a sufficient and cost-effective scale, the presently disclosed technology makes acetylation possible.

The technology disclosed by the invention can make a great contribution to the environment and the repair market. The product of the invention can produce various adsorbents and filter media, as well as accelerate composting of biosolids. The adsorbent can be used in almost all industrial applications where leaks can occur. The products disclosed herein show higher absorption rates than commonly used materials, such as clay or sawdust.

Filtration is part of many industrial processes. Wood fibers are used in many applications. Filtration efficiency is directly related to the surface area of the filter media. The products of the present invention can provide significantly greater surface area than typical machined wood fibers. The process disclosed in the present invention is also very scalable, allowing large problems to be solved, such as controlling red tides and algae problems caused by fertilizer loss.

Biosolids are becoming a very big problem in the world. The mechanism of disposal by land use has proven unsatisfactory due to the inclusion of metals and other materials. Composting is rapidly becoming the method of disposal of choice. The products produced by the present invention may contain sugars and other molecules that can rapidly accelerate the growth of the desired bacteria. Subsequently, metabolites of these bacteria are based on the already abundant nutrient concentrations in the compost biosolids.

In addition, the products produced by the techniques of the present invention are rich in amino acids that have proven to be very valuable as a botanical drug input for combating cancer and other diseases. The ether extract and alkaloid can be used as anticancer drugs for treating breast cancer and diseases causing dysfunction to human health. In addition, it has been found that a quantitative reduction in short chain fatty acids, particularly butyrate, contributes to the progression of chronic kidney and stomach disease problems. The products disclosed in this invention are rich in such short chain fatty acids during fermentation processing. The product may also contain berberine, depending on the type of raw material, which helps to reduce sugar and maintain healthy cholesterol levels; this is a powerful tool for treating diabetes.

In addition, a variety of plant-based and non-plant based raw materials can be extracted for specific medical purposes. The technology of the present invention is very effective in hemp and hemp processing. The liquid extract can provide valuable cannabinoids and other nutrients which provide a novel therapeutic approach. Our technology also achieves a variety of antibacterial properties of flavonoids in eucalyptus gellan gum (sap).

The technology of the invention can make a great contribution to the application of human health. The various components of the product of the invention are useful in the production of insecticides and pesticides from recalcitrant (obstinate) exotic materials such as oak and sanguinea. The technology also makes possible the extremely low cost production of aromatherapy products and other terpenes for aroma into cannabis and special/transgenic wines.

Experiments were also underway to produce insoluble dietary fibers using the techniques of the present invention and use them as food additives. Numerous studies have shown that physiological and psychological improvements are enhanced when beneficial bacteria are used as substrates during gastric metastases in vivo.

In addition to benefits in terms of gastrointestinal disorders, the short and medium chain fatty acids obtained by the products of the invention may exhibit antibacterial activity against oral microorganisms. This type of treatment will help prevent dental and gum disease.

For decades, mold and mildew have been increasingly serious problems in homes. Irritant chemicals and sprays are conventional methods of eliminating this problem. However, by using the disclosed production of products from hardwoods and other phenolic rich feedstocks, the present technology can make possible the control of organic mold in mold infected basements and the like.

The technology disclosed in the present invention can be immediately and directly applied to the agricultural market. The disclosed products can enhance litter (litter) and bedding applications, as well as improve animal health when added to feed and drinking water. The disclosed products can also be used directly for the prevention and treatment of certain animal diseases. In addition, the technology of the present invention can also contribute to forestry when applied to specially planted wood fibers, thereby participating in recycling economy.

The disclosed products, such as fibrous materials, can produce an extremely absorbent animal bedding due to their very large surface area. This property enables the management of harmful moisture and outgassing (e.g. ammonia gas). The product can also be used very effectively for drying and warming certain kinds of livestock. For example, when pigs are born, they are covered with moisture and their skin sensitivity is usually high. By applying this fibrous material to the skin of pigs after birth, moisture can be rapidly absorbed and the skin dried, thereby causing their body temperature to rise more rapidly.

The large surface area also allows the biochar to be produced more efficiently than current conventional processes. Biochar is also a very effective adsorbent, especially in sequestering ammonia. Mixing biochar with the product of the invention can provide a healthier environment for livestock, particularly poultry with problems with moisture and ammonia.

In the context of animal feed, the technology of the present invention can promote the growth and feeding of many species, including fish. The organic acids in the products of the invention can be used as a substitute for antibiotics. Research shows that the average daily feed consumption and average daily weight gain of the pigs fed with the organic acid are improved. Some products of the invention comprise tryptophan and a substrate of very small particle size fibers having a form factor similar to that of a digested product. Tryptophan is an essential amino acid in the pig diet and is important for stimulating feed intake and subsequent growth performance. Monogastric organisms, such as pigs, do not produce tryptophan and must therefore be included as part of a dietary supplement.

The products of the invention can also be used as very efficient substrates for protein-forming yeasts, such as Candida Utilis (Candida Utilis). These proteins have the potential to replace fish feed. In addition, for some exotic fish species having a ruminant-like digestive system, the exposed cellulose provided in the product of the present invention can be more rapidly digested as a food source. Finally, for example, seaweed material and other high protein herbaceous material may also be processed by the techniques of the present invention to replace plant-based proteins. Replacing traditional fish meal with vegetable proteins would bring considerable environmental benefits.

For ruminants, such as cattle, sheep and goats, the techniques of the present invention may provide a number of advantages. If the lignin contained is sufficiently adjusted to expose the cellulose, it is possible for the ruminant's digestive system to digest the lignocellulosic material. The technology disclosed in the present invention can aggregate lignin into the form of "droplets", thereby making cellulose more readily available to cellulase enzymes in the intestinal tract of animals, thereby improving digestion and nutrition. Certain species of wood (e.g., larch) have also been shown to promote liver health in cattle because they are rich in arabinogalactans, lignin, flavonoids, and diterpenes. Providing ruminants with these types of feeds, particularly those materials that were once considered too recalcitrant, has a global impact on human nutrition and well-being.

Certain sizes of lignocellulosic fibers and specially designed shape factors can achieve targeted activation of organic acids, such as butyrate-2, to produce specific microbiota in the animal gut. The ability of the present technology to handle different fiber form factors for different species is critical to the commercialization of the process. Beneficial regulation of the gut microbiome is also "modified" into a number of metabolic changes and interdependent pathways that produce short chain fatty acids. These types of probiotic products are essential for the animal husbandry to meet the demand for natural food.

The disclosed technology may also benefit poultry. Current consumers are avoiding poultry fed antibiotics. Since antibiotics do improve the health and viability of poultry, there is a possibility that these antibiotics will remain in the poultry after slaughter. Tannic acid, due to its antibacterial properties and fatty acids, has been shown to be resistant to pathogen growth in poultry farming. The products disclosed herein, such as liquid extracts, can contain and produce valuable fatty acids and tannins. As such, the products of the present invention can be included in poultry feed and water systems to improve poultry health without the addition of synthetic antibiotics.

In a recent study, it has been demonstrated that butyric acid produced by fermentation of certain products of the invention, when mixed with zinc, can reduce the appearance of woody broast in commercial broilers in the poultry industry. The woody meat describes the quality problems caused by muscle abnormalities of a small portion of chicken meat. While this does not pose a health risk to the consumer, it can result in meat that is undesirable.

The techniques of the present invention may also be used in agriculture and forestry, commonly referred to as tree planting. Agriculture and forestry is an agriculture involving the planting, care and maintenance of trees or other woody plants. Since the products of the present invention may be originally derived from the xylem and phloem of trees, once extracted and processed, they can provide the industry with a formulation of nutrients and care products. Prior to the present technology, the liquid in the trees evaporated from the fibers and converted to volatile organic compounds, which presented a challenge to emission control.

The technology disclosed in the present invention can directly contribute to the production of sustainable and clean energy. Applications include biofuels and biorefineries, wood pellets, and even the hydraulic fracturing industry for traditional fuels.

The technology of the present invention can utilize green (wet) feedstock to produce conditioned and fractionated fibers that can be used directly to produce highly durable, low moisture and high energy wood pellets. It can be used without the use of conventional slasher, such as a hammer mill, and without the need for a very expensive indirect drying system. Avoiding the use of these systems, and the consequent capital and recurring costs, brings the wood pellet industry a revolutionary paradigm shift that will eliminate the reliance on subsidies, create a worldwide alternative to industrial processing, and raw materials that were once considered too humid to process, such as forestry and farm residues, bamboo, aqueous biomass (e.g., algae, seaweed, kelp, etc.), and other high humidity species.

The techniques disclosed herein may also contribute to the value of conventional granulation processes. Producing good quality wood pellets by conventional methods is a difficult challenge. Manufacturers have extensively sought effective binders to improve the durability of the pellets with the goal of improving their durability. When the product of the invention, such as a dry pulp product, is mixed with traditionally dried wood fibres, it allows for a higher densification of the pellets and a better utilization of the lignin for bonding.

The cellulosic component of lignocellulosic fibers has been considered as a potential base feedstock for cellulosic ethanol production. However, in order to be a viable feedstock, the lignin must be removed to some extent by biorefinery in order to adequately expose the cellulose to specific cellulases. The method of the invention allows the lignin to be exposed and partially removed. Further processing can easily remove the remaining lignin. In addition, the use of low operating temperatures prevents the formation of inhibitors which can negatively affect the efficacy of the cellulase. The method provides higher cellulose exposure and improves the effectiveness of the enzyme. Such products may also be used to produce bio-butanol and other bio-energy products. Certain product forms made by the presently disclosed technology may now also be suitable for making cleaner biorefinery processes effective. These include, but are not limited to, organic solvents and Simultaneous Saccharification and Fermentation (SSF) processes.

The techniques of the present invention may also be applied in the drilling industry, such as gas, oil, etc. For example, lost circulation materials are widely used in the drilling industry. Which helps to prevent mud loss to fractures or high permeability areas. The smaller particle size produced by the disclosed technology allows for better flow and permeability of the product to seal the cracks and crevices inherent in oil drilling. In another example, tannic acid of the product of the invention has proven to be a very good, environmentally safe drilling fluid.

The technology disclosed by the invention can also directly make a contribution to the food and beverage market. The products of the invention can be used to better improve some of the relevant senses including, but not limited to, flavor enhancement, taste perception and olfactory enhancement. The product can also be used for the upgrading of nutrients and for the production of sweeteners, and as an auxiliary ingredient in flour-containing food products.

With the tannins in the product of the invention, and in particular the ellagitannins contained therein, wine producers can design the "dryness" of their products and simulate the traditional effects of transit time during oxidation of oak barrels.

Similarly, some of the phenolic compounds found in the products of the invention may be added to food as a nutritional value; anthocyanins in certain lignocelluloses have been shown to improve cognitive function.

In another example, the acetoin produced may be used as a food flavoring in baked goods using an SSF process after pulping. The technology of the invention can also actively participate in torula yeast, and scientifically become the production of candida utilis. The product of the invention can be used as a substrate for its growth. It is widely used as a flavoring agent in processed foods and pet foods. The form factor of other products disclosed herein can also accelerate the production of food grade cellulose. The products are commonly used as thickeners and bulking agents for tomato paste, salad dressings, ice cream, energy bars, pasta, bread and many other products.

The technology of the present invention is also very effective in facilitating the production of xylitol, a naturally occurring alcohol found in certain lignocellulosic feedstocks. It is widely used as a replacement for sugar and in "sugarless" chewing gum, mints and other confections. The process disclosed in the present invention allows for more cost effective conditioning of raw materials such as birch wood, thereby reducing overall costs. It also allows the pulp and paper and bio-refinery markets to build byproduct streams that traditionally lose opportunity.

Pulp is a fibrous material produced chemically or mechanically (or by some combination of chemical and mechanical means) from wood or other cellulosic raw materials. Lignocelluloses have inanimate cell walls made of cellulose fiber, hemicellulose and lignin, which provide strength and support to the cell wall. Lignin holds the cellulose fibers in the cell wall. Thus, the lignin must be removed to separate out the individual cellulose fibers, ultimately into paper.

Conventional pulping processes pose very difficult environmental problems. In fact, the industry has traditionally been one of the largest sources of industrial air, water and land emissions in the world, primarily due to the use of harsh chemicals. Thousands of tons of pollutants are discharged each year. This industry is also one of the largest energy and water consumptions in the world, using more water to produce a ton of product than any other industry.

The industry is facing tremendous pressures from society to address these challenges. Research is being conducted to develop sustainable pulping mechanisms including mechanical conditioning of feedstocks using environmentally friendly chemicals and lower energy consumption methods.

Steam explosion is a promising process for the whole industry. However, in the traditional form, it shows many economic problems, including insufficient destruction of lignin-carbohydrate complexes, and, for biorefinery and papermaking applications, possible production of fermentation inhibitors. In addition, for engineered wood segments, the fibers also need to be dried for further processing.

The techniques disclosed herein may provide substantial advantages to both conventional processes and steam explosion processes. Compared with the traditional process, no irritant chemical substance is used, and monosaccharide degradation hardly occurs. The energy requirements are much less and no environmental problems arise. In contrast, the disclosed products, such as liquid products, can capture soil nutrients and tree biologics for application. The resulting fibers are also susceptible to the action of cellulase enzymes.

In biorefineries and papermaking, due to the effectiveness of the process of the present invention, a cost-effective pulping process, such as organic solvent pulping, is now feasible. The method uses organic solvents to break down lignin and hemicellulose. This method is considered to be the cleanest modern method in use today.

In terms of products, the technology of the present invention can also significantly reduce the costs required for producing paperboard, molded pulp and fluff pulp. Today, most of the raw materials required to make these products come from the recycling industry. The raw material requires extensive handling to make it clean and useful again, causing other environmental problems.

Engineered wood includes manufactured wood products produced by bonding fibers together with a binder or forming a composite by other fixation methods. The technology of the present invention may be directly helpful in the production of high density wood, Medium Density Fiberboard (MDF) and particle board. The technology of the present invention can also directly promote the development of the market for transparent wood.

All of the above engineered wood products are formed by compression molding of wood chips, wood shavings or even sawdust, and synthetic resin or other suitable binder. Traditionally, the raw materials required for the production must be dried, and the disclosed technology can inherently dry the raw materials and avoid this expensive step in the process. Emissions are also avoided and the fractionation form factor of the fibers produced by the disclosed process may help produce a robust product. Products produced by conventional methods also require binders, most of which are not sustainable, which can present additional environmental challenges in both production and disposal/recycling. The disclosed technology may require less adhesive. Additionally, the liquid extracts produced by the presently disclosed technology can be developed into sustainable adhesive products to meet other market benefits discussed previously.

Effective utilization of the waste stream often requires dewatering, drying, and conditioning of the feedstock. Typically, this is accomplished by various belt presses, extruders, and cyclone processes. The waste is then reduced in size by other mechanical treatments. The disclosed technology can combine all of these processes into one and condition the feedstock to a degree not previously possible.

For example, the disclosed technology can very efficiently process used coffee grounds and make them useful for pellet production. These pellets can then be incinerated as a solid fuel to generate heat or electricity, or used as a flavored tobacco product in the rapidly developing barbecue industry. In another example, the techniques of the present invention can be used to process poultry feathers to produce keratin, which provides a form factor never available for film applications, as well as many other applications. In another example, the present technology can process citrus peel into a very unique form, making it more effective for many industrial applications. The liquids extracted from the process disclosed by the present invention also have great potential, particularly in pursuit of organic chemical synthesis.

While certain embodiments of the invention have been described in detail, it is to be understood that other embodiments are also contemplated. Thus, no limitations are intended to the details of construction or arrangement of parts illustrated in the drawings or described below. Other embodiments of the invention can be practiced or carried out in various ways. Furthermore, in describing these embodiments, specific terminology will be resorted to for the sake of clarity. It is intended that each term encompass the broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

In the present invention, the use of terms such as "having," "including," or "including" is open-ended and is intended to have the same meaning as terms such as "comprising" or "including," and does not exclude the presence of other structure, material, or acts. Similarly, although the use of terms such as "may" or "may" is intended to be open-ended in that it reflects that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. Structures, materials, or acts are considered necessary if they are presently considered to be essential.

"comprising" or "comprises" or "comprising" means that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if other such compounds, materials, particles, method steps have the same function as what is named.

It should also be understood that the mention of one or more method steps does not preclude the presence of other method steps or intermediate method steps between those steps expressly identified.

The components making up the various elements of the present invention in the following description are intended to be illustrative, and not restrictive. Many suitable components that perform the same or similar functions as the components described herein are intended to be within the scope of the present invention. Such other components not described in the present disclosure may include, but are not limited to, similar components developed, for example, after disclosure of the presently disclosed subject matter.

As used herein, the term "pulp" is understood to include lignocellulosic materials having different moisture contents, physical characteristics, bulk densities, or materials that have been dewatered, dried, fractionated, and expanded.

As used herein, the term "exposed cellulose fibers" is understood to mean cellulose fibers or fibrils that are not bound within the cell wall. For example, cellulose fibers may be exposed via the cell blasting process of the present invention.

As used herein, the term "entangled" is understood to mean when at least a portion of each fiber is interwoven with at least a portion of a second fiber and at least two fibers are not parallel entangled.

The process disclosed by the invention comprises the following steps: mixing an additive with a raw material to obtain a first mixture, the raw material comprising a fibrous material and water, the fibrous material comprising lignin, cellulose and hemicellulose; and conditioning the first mixture to obtain a liquid product and a dry pulp product.

The invention also discloses a conditioning process, a machine and a method for use in conjunction with the above process.

The invention also discloses a liquid product prepared by the process, a dry pulp product and/or a fiber pulp material prepared by the process, and fiber granules prepared by the process.

Processes, systems, and methods for treating and/or producing materials including fibrous materials are disclosed. The fibrous material may comprise natural fibres, such as cellulose fibres. For example, the fibrous material may comprise wood fibers. The wood fibers may be provided in the form of wood pulp or other lignocellulosic fiber sources. For example, the wood fibers may be provided in the form of southern bleached softwood kraft pulp. Suitable examples of fiber sources may include, but are not limited to, fluff pulp, dissolving pulp, mechanical pulp, chemical pulp, chemimechanical pulp, recycled pulp, semi-mechanical pulp, semi-chemical pulp, soft-cooked all-chemical pulp, consumer waste products such as clothing, viscose, rayon, lyocell, or any combination thereof. Additionally, the fibrous material may be any material comprising lignin and hemicellulose.

The fibrous material may also be in the form of wood chips, wood fibers, or other wood sources. Other suitable examples of wood sources include hardwood, softwood, aspen, balsa, beech, birch, mahogany, hickory, maple, oak, teak, eucalyptus, pine, cedar, juniper, spruce, redwood, or any combination thereof. It is to be understood that any other known sources of wood fiber and lignocellulosic materials may be used. Alternatively, the fibrous material may be provided in the form of natural non-wood or replacement fibers. Suitable examples of natural non-wood substitute fibers that may comprise the fibrous material include, for example, barley, bagasse, bamboo, wheat and wheat straw, flax, hemp, kenaf, arundo, corn stover, jute, ramie, cotton, wool, rye, rice, papyrus, esparto grass, sisal, grass, abaca, shrubs, miscanthus, giant reed, alfalfa, woody vines, flowers, wisteria, honeysuckle, clematis, kudzu, coffee and other beans/legumes, stevia and other functional plants, other lignocellulosic species, fast-growing grasses, or any combination thereof. It should be understood that the fibrous material may include any other natural fiber or any combination of natural fibers from any source. In some embodiments, the fibrous material may be provided by cellulosic fibers, which may be prepared from wood pulp or a fiber source provided by mechanical methods such as hammer milling or other comminution methods.

The fibrous material may comprise fibers having an average length of about 0.01mm to 12 mm. For example, the fibrous material may comprise an average length of 0.01mm or more (e.g., 0.05mm or more, 0.10mm or more, 0.15mm or more, 0.20mm or more, 0.25mm or more, 0.30mm or more, 0.35mm or more, 0.40mm or more, 0.45mm or more, 0.50mm or more, 0.55mm or more, 0.60mm or more, 0.65mm or more, 0.70mm or more, 0.75mm or more, 0.80mm or more, 0.85mm or more, 0.90mm or more, 0.95mm or more, 1.0mm or more, 1.1mm or more, 1.2mm or more, 1.3mm or more, 1.4mm or more, 1.5mm or more, 1.6mm or more, 1.7mm or more, 1.8mm or more, 1.9mm or more, 2.3mm or more, 1.4mm or more, 1.5mm or more, 2mm or more, 2.6mm or more, 2mm or more, 3.0mm or longer, 3.5mm or longer, 4.0mm or longer, 4.5mm or longer, 5.0mm or longer, 5.5mm or longer, 6.0mm or longer, 6.5mm or longer, 7.0mm or longer, 7.5mm or longer, 8.0mm or longer, 8.5mm or longer, 9.0mm or longer, 9.5mm or longer, 10mm or longer, 10.5mm or longer, 11mm or longer, or 11.5mm or longer).

In some embodiments, the fibrous material can comprise an average length of 12mm or less (e.g., 11.5mm or less, 11mm or less, 10.5mm or less, 10mm or less, 9.5mm or less, 9.0mm or less, 8.5mm or less, 8.0mm or less, 7.5mm or less, 7.0mm or less, 6.5mm or less, 6.0mm or less, 5.5mm or less, 5.0mm or less, 4.5mm or less, 4.0mm or less, 3.5mm or less, 3.0mm or less, 2.9mm or less, 2.8mm or less, 2.7mm or less, 2.6mm or less, 2.5mm or less, 2.4mm or less, 2.3mm or less, 2.2mm or less, 2.1mm or less, 2.0mm or less, 1.9mm or less, 1.8mm or less, 1.1.5 mm or less, 1.1mm or less, 1.5mm or less, 0.95mm or less, 0.90mm or less, 0.85mm or less, 0.80mm or less, 0.75mm or less, 0.70mm or less, 0.65mm or less, 0.60mm or less, 0.55mm or less, 0.50mm or less, 0.45mm or less, 0.40mm or less, 0.35mm or less, 0.30mm or less, 0.25mm or less, 0.20mm or less, 0.15mm or less, 0.10mm or less, 0.05mm or less.

In some embodiments, the fibrous material has a length of 0.01mm to 12mm (e.g., 0.3mm to 7mm, 0.5mm to 5mm, 0.7mm to 2.8mm, 2.9mm to 8mm, 8mm to 12mm, 0.01mm to 1 mm). In some embodiments, the fibrous material comprises a mixture of one or more fibers having different average fiber lengths. In other words, in some embodiments, the fibrous material has a bimodal (or trimodal, etc.) average fiber length. In some embodiments, the fibrous material can have an average fiber length of about 1 angstrom to about 5000 microns.

The fibrous material can include fibers having various cross-sectional shapes (e.g., round, scalloped oval, cruciform, six-channel, etc.). The fibrous material may have a cross-sectional dimension based on a cross-sectional shape. As used herein, the term "cross-sectional dimension" is to be understood as the largest dimension of a plane perpendicular to the length of the fiber (i.e., the diameter in a cylindrical fiber, the diagonal in a rectangular fiber). In some embodiments, the fibers in the fibrous material have an average largest cross-sectional dimension (i.e., the average diameter of the round fibers) of from 100 nanometers to 1000 micrometers. In some embodiments, the fibrous material can have a fiber diameter of 100 nanometers or greater (e.g., 150 nanometers or greater, 250 nanometers or greater, 350 nanometers or greater, 450 nanometers or greater, 650 nanometers or greater, 750 nanometers or greater, 850 nanometers or greater, 950 nanometers or greater, 1 micron or greater, 5 microns or greater, 10 microns or greater, 15 microns or greater, 20 microns or greater, 25 microns or greater, 30 microns or greater, 35 microns or greater, 40 microns or greater, 45 microns or greater, 50 microns or greater, 55 microns or greater, 60 microns or greater, 65 microns or greater, 70 microns or greater, 75 microns or greater, 80 microns or greater, 85 microns or greater, 90 microns or greater, 95 microns or greater, 100 microns or greater, 200 microns or greater, 300 microns or greater, 400 microns or greater, 500 microns or more, 600 microns or more, 700 microns or more, 800 microns or more, or 900 microns or more).

In some embodiments, the fibrous material can have a fiber diameter of 1000 microns or less (e.g., 900 microns or less, 800 microns or less, 700 microns or less, 600 microns or less, 500 microns or less, 400 microns or less, 300 microns or less, 200 microns or less, 100 microns or less, 95 microns or less, 90 microns or less, 85 microns or less, 80 microns or less, 75 microns or less, 70 microns or less, 65 microns or less, 60 microns or less, 55 microns or less, 50 microns or less, 45 microns or less, 40 microns or less, 35 microns or less, 30 microns or less, 25 microns or less, 20 microns or less, 15 microns or less, 10 microns or less, 5 microns or less, 1 micron or less, 900 nanometers or less, 800 nanometers or less, 700 nanometers or less, 600 nanometers or less, 500 nm or less, 400 nm or less, 300 nm or less, 200 nm or less).

In some embodiments, the fibrous material can have an average maximum cross-sectional dimension of about 100 nanometers to about 1000 micrometers (e.g., 100 nanometers to 1 micrometer, 1 micrometer to 10 micrometers, 10 micrometers to 25 micrometers, 25 micrometers to 50 micrometers, 50 micrometers to 75 micrometers, 75 micrometers to 100 micrometers, 25 micrometers to 75 micrometers, 25 micrometers to 100 micrometers, 100 nanometers to 10 micrometers, 100 nanometers to 25 micrometers, 1 micrometer to 25 micrometers, 10 micrometers to 75 micrometers, 1 micrometer to 1000 micrometers, 1 micrometer to 900 micrometers, 1 micrometer to 800 micrometers, 1 micrometer to 700 micrometers, 1 micrometer to 600 micrometers, 1 micrometer to 500 micrometers, 100 micrometers to 1000 micrometers, 100 micrometers to 900 micrometers, 100 micrometers to 800 micrometers, 100 micrometers to 700 micrometers, 100 micrometers to 600 micrometers, or 100 micrometers to 500 micrometers). In some embodiments, the fibrous material may comprise a mixture of one or more fibers having different average maximum cross-sectional dimensions. In other words, in some embodiments, the fibrous material has a bimodal (or trimodal, etc.) average maximum cross-sectional dimension. In some embodiments, the fibers of the fibrous material may be present on a nanoscale, having an average cross-sectional dimension of from 1 nanometer to 100 nanometers or from 1 nanometer to 1000 micrometers.

The invention also discloses an additive material. The additive material may include, for example, a small molecule material, a surfactant, or a polymer. Without wishing to be bound by any particular scientific theory, the additive material may interact with lignin in the fibrous material to weaken the microporous structure of the fibrous material. The additive material may also act catalytically and/or as a drag reducer during processing.

The additive may be a water soluble material capable of interacting with lignin. For example, the additive may be a surfactant. In the present invention, various surfactants may be included to interact with the fibrous material (e.g., to weaken the lignin), to catalyze, and to act as drag reducing agents or dewatering agents during processing. The surfactant used in the present invention may comprise a lipophilic non-polar hydrocarbon group and a polar or ionic (e.g., cationic, anionic, zwitterionic, etc.) functional hydrophilic group. The anionic or polar functional group can be a carboxylate, ester, amine, amide, imide, hydroxyl, ether, nitrile, phosphate, sulfate, or sulfonate. The cationic functional group may be a primary, secondary, tertiary or quaternary amine. The surfactants useful in the present invention may be used alone or in combination. Thus, any combination of surfactants can include anionic, cationic, nonionic, zwitterionic, amphoteric, and amphoteric surfactants.

Thus, the surfactants useful in the present invention may be anionic, including but not limited to sulfonates such as alkyl sulfonates, alkyl benzene sulfonates, alpha-olefin sulfonates, paraffin sulfonates, and alkyl ester sulfonates; sulfates such as alkyl sulfates, alkyl alkoxy sulfates, and alkyl alkoxylated sulfates; phosphates such as monoalkyl phosphates and dialkyl phosphates; a phosphonate ester; carboxylates, for example fatty acids, alkyl alkoxy carboxylates, sarcosinates, isethionates and taurates. Specific examples of carboxylates are sodium cocoyl isethionate, sodium methyl oleoyl taurate, sodium stearate, sodium laureth carboxylate, sodium polyacrylate, sodium trideceth carboxylate, sodium lauryl sarcosinate, sodium carboxymethylcellulose, lauryl sarcosine, and cocoyl sarcosine. Specific examples of the sulfate include Sodium Dodecyl Sulfate (SDS), sodium lauryl sulfate, sodium lauryl ether sulfate, cationic sodium lauryl ether sulfate, sodium trideceth sulfate, sodium cocoyl sulfate, and sodium monolaurin sulfate.

Suitable sulfonate surfactants include, but are not limited to, alkyl sulfonates, aryl sulfonates, lignosulfonates, linear alkyl benzene sulfonates, mono-and dialkyl sulfosuccinates, and mono-and dialkyl sulfosuccinates. Each alkyl group independently contains from about 2 to 20 carbons, and each alkyl group is ethoxylated with an average of up to about 8 units, preferably up to about 6 units, such as an average of 2, 3, or 4 units of ethylene oxide. Illustrative examples of alkyl and aryl sulfonates are Sodium Tridecylbenzenesulfonate (STBS) and Sodium Dodecylbenzenesulfonate (SDBS).

Illustrative examples of sulfosuccinates include, but are not limited to, dimethicone copolymer polyol sulfosuccinate, dipentyl sulfosuccinate, dioctyl sulfosuccinate, dicyclohexyl sulfosuccinate, diheptyl sulfosuccinate, dihexyl sulfosuccinate, diisobutyl sulfosuccinate, dioctyl sulfosuccinate, diisooctyl sulfosuccinate (DOSS), C12-15 alkanol polyether sulfosuccinate, cetearyl sulfosuccinate, polydextrose sulfosuccinate, coco butyl glucose polyether-10 sulfosuccinate, decyl alcohol polyether-5 sulfosuccinate, decyl alcohol polyether-6 sulfosuccinate, dihydroxyethyl sulfosuccinate undecylenate, hydrogenated cottonseed glyceride sulfosuccinate, isodecyl sulfosuccinate, isostearyl sulfosuccinate, distearyl sulfosuccinate, Lanolin polyether-5 sulfosuccinate, laureth-12 sulfosuccinate, laureth-6 sulfosuccinate, laureth-9 sulfosuccinate, lauryl sulfosuccinate, nonoxynol-10 sulfosuccinate, oleyl polyether-3 sulfosuccinate, oleyl sulfosuccinate, PEG-10 lauryl citrate sulfosuccinate, sitoseeth-14 sulfosuccinate, stearyl sulfosuccinate, tallow, tridecyl sulfosuccinate, ditridecyl sulfosuccinate, diethylene glycol castor sulfosuccinate, di (1, 3-dimethylbutyl) sulfosuccinate, and silicone copolyol sulfosuccinate.

Illustrative examples of sulfosuccinamates include, but are not limited to, lauramido-MEA sulfosuccinate, oleamido PEG-2 sulfosuccinate, cocamide MIPA-sulfosuccinate, cocamide PEG-3 sulfosuccinate, isostearamide MEA-sulfosuccinate, isostearamide MIPA-sulfosuccinate, lauramido-MEA sulfosuccinate, lauramido PEG-2 sulfosuccinate, lauramido PEG-5 sulfosuccinate, myristamide MEA-sulfosuccinate, oleamido PIPA-sulfosuccinate, oleamido PEG-2 sulfosuccinate, palmamido PEG-2 sulfosuccinate, palmitamido PEG-2 sulfosuccinate, and mixtures thereof, PEG-4 cocamide MIPA-sulfosuccinate, castor oil amido MEA-sulfosuccinate, stearamido MEA-sulfosuccinate, stearyl sulfosuccinate, tall oil amide (talamido) MEA-sulfosuccinate, undecylenamido PEG-2 sulfosuccinate, wheat germ amide MEA-sulfosuccinate, and wheat germ amide PEG-2 sulfosuccinate.

For anionic surfactants, the counterion is typically sodium, but can also be potassium, lithium, calcium, magnesium, ammonium, (primary, secondary, tertiary or quaternary) amines or other organic bases. Exemplary amines include isopropylamine, ethanolamine, diethanolamine, and triethanolamine. Mixtures of the above cations may also be used.

In some embodiments, the surfactants used in the present invention may also be cationic, so long as at least one surfactant having a net positive charge is also included. Such cationic surfactants include, but are not limited to, organic amines that are primarily primary, secondary, tertiary, or quaternary amines. For cationic surfactants, the counter ion can be chloride, bromide, methylsulfate, ethylsulfate, lactate, saccharinate, phosphate, acetate, and other organic acid anions. Examples of cationic amines include polyethoxylated oleyl/stearylamine, ethoxylated tallow amine, coco alkylamine, oleyl amine and tallow alkylamine.

Examples of quaternary amines having a single long alkyl group are cetyltrimethylammonium bromide (CETAB), cetyltrimethylammonium chloride (CETAC), dodecyltrimethylammonium bromide, myristyltrimethylammonium bromide, stearyldimethylbenzylammonium chloride, oleyldimethylammonium chloride, lauryl trimethylammonium methyl sulfate (cocoyltrimethylammonium methosulfate), cetyldimethylhydroxyethylammonium dihydrogen phosphate, batusamidopropyl potassium chloride, cocoyltrimethylammonium chloride, distearyldimethylammonium chloride, wheat germ-amidopropyl ammonium chloride, benzalkonium chloride, methylstearyldimethylammonium sulfate, isostearyl aminopropionic acid ammonium chloride, dihydroxypropyl PEG-5 linolic acid ammonium chloride, PEG-2 stearylmethylammonium chloride, behenyltrimethylammonium chloride, dimethyldicetylammonium chloride, dimethyldicetyl ammonium chloride, Tallow trimethyl ammonium chloride and behenamide propyl ethyl dimethyl ammonium ethyl sulfate.

Examples of quaternary amines having two long alkyl groups are distearyldimethylammonium chloride, dicetyl-ammonium dichloride, benzethonium chloride, stearyl octyl dimethyl ammonium methylsulfate, dihydropalmityl hydroxyethyl methosulfate, dipalmitoyl ethyl hydroxyethyl ammonium methosulfate, dioleoyl ethyl hydroxyethyl ammonium methosulfate, and hydroxypropyl distearyldimethylammonium chloride.

Quaternary ammonium compounds of imidazoline derivatives include, for example, isostearyl benzyl azolium chloride, cocoyl benzyl hydroxyethyl imidazolinium chloride, cocoyl hydroxyethyl imidazoline PG-chloride phosphate, and stearyl hydroxyethyl imidazolium chloride. Other heterocyclic quaternary ammonium compounds, such as dodecyl pyridinium chloride and cetyl pyridinium chloride, can also be used.

Surfactants useful in the present invention can be nonionic, including but not limited to polyalkylene oxide carboxylates, fatty acid esters, fatty alcohols, ethoxylated fatty alcohols, poloxamers, polyalkylene oxide alkanolamides, alkoxylated alkanolamides, polyethylene glycol monoalkyl ethers, and alkyl polysaccharides. The polyalkylene oxide carboxylic acid esters have one or two carboxylate groups each having from about 8 to 20 carbons and a polyalkylene oxide moiety containing from about 5 to 200 alkylene oxide units. The ethoxylated fatty alcohols comprise an ethylene oxide moiety containing from about 5 to about 150 ethylene oxide units and a fatty alcohol moiety having from about 6 to about 30 carbons. The fatty alcohol moiety may be cyclic, linear or branched, and may be saturated or unsaturated. Some examples of ethoxylated fatty alcohols include the glycol ethers of oleyl alcohol, stearyl alcohol, lauryl alcohol, and isocetyl alcohol. Poloxamers are block copolymers of ethylene oxide and propylene oxide having from about 15 to 100 moles of ethylene oxide. Alkyl polysaccharide ("APS") surfactants (e.g., alkyl polyglycosides) comprise a hydrophobic group having from about 6 to about 30 carbons and a polysaccharide (e.g., polyglycoside) as a hydrophilic group.

Specific examples of suitable nonionic surfactants include alkanolamides such as cocamide diethanolamide ("DEA"), cocamide monoethanolamide ("MEA"), cocamide monoisopropanolamide ("MIPA"), PEG-5 cocamide MEA, lauramide DEA, and lauramide MEA; alkylamine oxides such as laurylamine oxide, poly-N-vinylformamide, cocoamine oxide, cocamidopropyl amine oxide and lauramidopropylamine oxide; polyalkylene oxides such as polyethylene oxide (PEO), polypropylene oxide, and polybutylene oxide; polyethylene glycol (PEG) and polypropylene glycol and block copolymers thereof; polysorbates or tweens, such as polysorbate 20, polysorbate 40, polysorbate 60, and polysorbate 80; polyacrylamide-co-sodium acrylate (PAAM-co-NaA); polyacrylamide-co- (2- (sodium acrylamido) -2-methylpropanesulfonate) (PAAM-co-NaAMPS); polyacrylamide-co- (3- (acrylamido) -3-methylbutyrate sodium) (PAAM-co-NaAMB); polyacrylamide-co-diacetone acrylamide (PAAM-coDAAM); polyampholytes based on Acrylamide (AM), sodium 2-acrylamido-2-methylpropanesulfonate (NaAMPS), (2-acrylamido-2-methylpropyl) trimethylammonium chloride (AMPTAC), sodium 3-acrylamido-3-methylbutyrate (NaAMB), and sodium 3- ((2-acrylamido-2-methylpropyl) dimethylammonium) -1-propanesulfonate (AMPDAPS) (containing both negative and positive charges in the same polymer chain); guar gum, xanthan gum, Lucas gum, gellan gum, gum arabic, and the like; sorbitan laurate, sorbitan distearate, fatty acids or fatty acid esters, such as lauric acid, isostearic acid and PEG-150 distearate, fatty alcohols or ethoxylated fatty alcohols, such as lauryl alcohol, alkylpolyglucosides, such as alkylpolyglucoside glycerol, lauryl glucoside and cocoglucoside.

The surfactant used in the present invention may be of the zwitterionic type having positive and negative charges on the same molecule. The positively charged groups can be quaternary ammonium, phosphonium or sulfonium, and the negatively charged groups can be carboxylate, sulfonate, sulfate, phosphate or phosphonate. Like other types of surfactants, the hydrophobic moiety may comprise one or more long, straight, cyclic, or branched aliphatic chains of about 8 to 18 carbon atoms. Specific examples of the zwitterionic surfactants include alkyl betaines such as coco dimethyl carboxymethyl betaine, coco betaine, lauryl dimethyl carboxymethyl betaine, lauryl dimethyl α -carboxyethyl betaine, cetyl dimethyl carboxymethyl betaine, lauryl bis- (2-hydroxyethyl) carboxymethyl betaine, stearyl bis- (2-hydroxypropyl) carboxymethyl betaine, oleyl dimethyl γ -carboxypropyl betaine, and lauryl bis (2-hydroxypropyl) α -carboxyethyl betaine, amidopropyl betaine; lecithin (phosphatidylcholine), such as soybean lecithin; alkyl sulphobetaines, for example coco dimethyl sulphopropyl betaine, stearyl dimethyl sulphopropyl betaine, lauryl dimethyl sulphoethyl betaine, lauryl bis (2-hydroxyethyl) sulphopropyl betaine and alkylamidopropyl hydroxysulphobetaine.

The surfactants used in the present invention may be amphoteric. Examples of suitable amphoteric surfactants include ammonium or substituted ammonium salts of alkyl amphocarboxyglycine and alkyl amphocarboxypropionate, alkyl amphodipropionate, alkyl amphodiacetate, alkyl amphoglycinate and alkyl amphopropionate, as well as alkyl imino propionate, alkyl imino dipropionate and alkyl amphopropyl propionate. Specific examples are cocoamphoacetate, cocoamphopropionate, cocoamphodiacetate, lauroamphoacetate, lauroamphodiacetate, lauroamphodipropionate, lauroamphodiacetate, cocoamphopropyl sulfonate, decanoamphodiacetate, decanoamphoacetate, decanoamphodipropionate and stearoamphoacetate.

The surfactants useful in the present invention may also be polymers such as N-substituted polyisobutenyl succinimides and succinates, alkyl methacrylate vinyl pyrrolidone copolymers, polyvinylpyrrolidone, alkyl methacrylate-dialkylaminoethyl methacrylate copolymers, alkyl methacrylate-polyethylene glycol methacrylate copolymers, and polystearamides.

Alternatively, the surfactant may be an oil-based dispersant including alkyl succinimides, succinates, high molecular weight amines, and mannich bases and phosphoric acid derivatives. Some specific examples are polyisobutenyl succinimide-polyethylene polyamine, polyisobutenyl succinate, polyisobutenyl hydroxybenzyl-polyethylene polyamine and dihydroxypropyl phosphate.

The surfactant used in the present invention may also be a combination of two or more selected from anionic, cationic, nonionic, zwitterionic, amphoteric and amphoteric surfactants. Suitable examples of combinations of two or more surfactants of the same type include, but are not limited to, mixtures of two anionic surfactants, mixtures of three anionic surfactants, mixtures of four anionic surfactants, mixtures of two cationic surfactants, mixtures of three cationic surfactants, mixtures of four cationic surfactants, mixtures of two nonionic surfactants, mixtures of three nonionic surfactants, mixtures of four nonionic surfactants, mixtures of two zwitterionic surfactants, mixtures of three zwitterionic surfactants, mixtures of two zwitterionic surfactants, mixtures of three amphoteric surfactants, mixtures of four amphoteric surfactants, mixtures of two amphoteric surfactants, mixtures of three amphoteric surfactants, mixtures of two mixtures of amphoteric surfactants, mixtures of two mixtures of surfactants, mixtures of two mixtures of surfactants, mixtures of two mixtures of surfactants, mixtures of two mixtures of surfactants, and mixtures of two mixtures of surfactants, and mixtures of two mixtures of surfactants, A mixture of three amphoteric surfactants and a mixture of four amphoteric surfactants.

Suitable examples of combinations of two different types of surfactants include, but are not limited to: a mixture of an anionic and a cationic surfactant, a mixture of an anionic and a nonionic surfactant, a mixture of an anionic and a zwitterionic surfactant, a mixture of an anionic and an amphoteric surfactant, a mixture of a cationic and a nonionic surfactant, a mixture of a cationic and a zwitterionic surfactant, a mixture of a cationic and an amphoteric surfactant, a mixture of a nonionic and a zwitterionic surfactant, a mixture of a nonionic and an amphoteric surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a surfactant, a mixture of a zwitterionic surfactant, a mixture of a zwitterionic surfactant, a mixture of a surfactant, a mixture of a surfactant, a mixture of a surfactant, a mixture of, A mixture of a zwitterion and an amphoteric surfactant, and a mixture of an amphoteric and an amphoteric surfactant. The invention also includes combinations of two or more surfactants of the same type, for example mixtures of two anionic surfactants.

The molecular weight of the additive may be from about 30g/mol to about 10,000,000 g/mol. The molecular weight of the additive may be from about 500g/mol to about 10,000,000 g/mol. The molecular weight of the additive may be from about 50g/mol to about 10,000,000 g/mol. The molecular weight of the additive may be from about 100g/mol to about 10,000,000 g/mol. The molecular weight of the additive may be from about 250g/mol to about 10,000,000 g/mol. The additive may have a molecular weight of from about 1,000g/mol to about 10,000,000 g/mol. The molecular weight of the additive may be from about 1,000g/mol to about 8,000,000 g/mol. The additive may also have a molecular weight of about 5,000g/mol to about 10,000,000g/mol, about 100,000g/mol to about 10,000,000g/mol, about 500g/mol to about 1,000,000g/mol, about 1,000g/mol to about 2,000,000g/mol, about 1,000g/mol to about 3,000,000g/mol, or about 500g/mol to about 8,000,000 g/mol.

Embodiments of the invention may provide a dry pulp product. The dry pulp product may be made from fibrous material using the method of the present invention and may have an explosive cellular structure. The dry pulp product may be further processed into pellets, briquettes, bales, or other value added products. The dry pulp product may have a particle size (e.g., average particle size) of from about 1mm to about 10mm (e.g., 1.5mm to 9.5mm, 2mm to 9mm, 2.5mm to 8.5mm, 3mm to 8mm, 3.5mm to 7.5mm, 4mm to 7mm, 4.5mm to 6.5mm, or 5mm to 6 mm).

Embodiments of the invention may provide a fiber pellet comprising a fiber material comprising lignin and water. The fiber pellets of the present invention may be substantially dewatered. In other words, the fiber pellets may comprise about 20% or less (e.g., 19% or less, 18% or less, 17% or less, 16% or less, 15% or less, 14% or less, 13% or less, 12% or less, 11% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, 5% or less, 4.5% or less, 4% or less, 3.5% or less, 3% or less, 2.5% or less, 2% or less, 1.5% or less, 1% or less, or 0.5% or less by weight of water based on the total weight of the fiber pellets.

In some embodiments, the fiber pellets may comprise about 0.1% or more (e.g., 19% or more, 18% or more, 17% or more, 16% or more, 15% or more, 14% or more, 13% or more, 12% or more, 11% or more, 10% or more, 9% or more, 8% or more, 7% or more, 6% or more, 5% or more, 4.5% or more, 4% or more, 3.5% or more, 3% or more, 2.5% or more, 2% or more, 1.5% or more, 1% or more, or 0.5% or more by weight of water based on the total weight of the fiber pellets.

In some embodiments, the fiber pellet may comprise about 0.1% to about 20% (e.g., 0.1% to 19%, 0.5% to 18%, 1% to 17%, 1% to 20%, 1% to 19%, 1% to 18%, 1% to 16%, 2% to 18%, 3% to 17%, 4% to 16%, 5% to 15%, 6% to 14, 7% to 13%, 8% to 12%, 9% to 11%, 0.5% to 4.5%, 1% to 5%, 1% to 4.5%, 1% to 4%, 1.5% to 3.5%, or 2% to 3%) by weight of water, based on the total weight of the fiber pellet.

The fiber pellets of the present invention also exhibit significantly improved mechanical properties and structural integrity compared to conventional fiber pellets. For example, the fiber pellets may have a Particle Durability Index (PDI) of 75 or more (e.g., 76 or more, 77 or more, 78 or more, 79 or more, 80 or more, 81 or more, 82 or more, 83 or more, 84 or more, 85 or more, 86 or more, 87 or more, 88 or more, 89 or more, 90 or more, 91 or more, 92 or more, 93 or more, 94 or more, 95 or more, 96 or more, 97 or more, 98 or more, 99 or more, or 100). The PDI of the fiber pellets can be measured using, for example, ASAE standard S269.5R2016. In addition, the fiber pellets of the present invention may have improved structural integrity. For example, substantially minimal degradation of the fiber pellets occurs when immersed in water for about 1 minute to about 1 year. As used herein, "substantially minimal degradation" means that the bulk density of the fiber pellets varies by 10% or less. In other words, when submerged, minimal swelling and/or water adsorption of the fiber pellets occurs.

The fiber pellets may also have a weight of about 15kg/m³Or higher (e.g., 20 kg/m)³Or higher, 25kg/m³Or higher, 30kg/m³Or higher, 35kg/m³Or higher, 40kg/m³Or higher, 45kg/m³Or higher, 50kg/m³Or higher, 60kg/m³Or higher, 70kg/m³Or higher, 80kg/m³Or higher, 90kg/m³Or higher, 100kg/m³Or higher, 150kg/m³Or higher, 200kg/m³Or more, 250kg/m3 or more, 300kg/m³Or higher, 350kg/m³Or higher, 400kg/m³Or higher, 450kg/m³Or higher, 500kg/m³Or higher, 550kg/m³Or higher, 600kg/m³Or higher, 650kg/m³Or higher, 700kg/m³Or higher, or 750kg/m³Or higher) of the bulk density.

The bulk density of the fiber pellets may be about 800kg/m³Or lower (e.g., 20 kg/m)³Or less, 25kg/m³Or less, 30g/m³Or less, 35kg/m³Or less, 40kg/m³Or less, 45kg/m³Or less, 50kg/m³Or less, 60kg/m³Or less, 70kg/m³Or less, 80kg/m³Or less, 90kg/m³Or less, 100kg/m³Or less, 150kg/m³Or less, 200kg/m³Or less, 250kg/m³Or less, 300kg/m³Or less, 350kg/m³Or less, 400kg/m³Or less, 450kg/m³Or less, 500kg/m³Or less, 550kg/m³Or less, 600kg/m³Or less, 650kg/m³Or less, 700kg/m³Or less, or 750kg/m³Or lower).

The bulk density of the fiber pellets may be about 15kg/m³-about 800kg/m³(e.g., 20 kg/m)³-800 kg/m³，25kg/m³-800 kg/m³，30kg/m³-800 kg/m³，35kg/m³-800kg/m³，40kg/m³-800kg/m³，45kg/m³-800kg/m³，50kg/m³-800kg/m³，60kg/m³-800kg/m³，70kg/m³-800kg/m³，80kg/m³-800kg/m³，90kg/m³-800kg/m³，100kg/m³-800kg/m³，150kg/m³-800kg/m³，200kg/m³-800kg/m³，250kg/m³-800kg/m³，300kg/m³-800kg/m³，350kg/m³-800kg/m³，400kg/m³-800kg/m³，450kg/m³-800kg/m³，500kg/m³-800kg/m³，550kg/m³-800kg/m³，600kg/m³-800kg/m³，650kg/m³-800kg/m³，700kg/m³-800kg/m³，750kg/m³-800kg/m³，100kg/m³-750kg/m³，100kg/m³-700kg/m³，150kg/m³-650kg/m³，250kg/m³-750kg/m³，300kg/m³-700kg/m³，350kg/m³-650kg/m³，400kg/m³-600kg/m³Or 450kg/m³-550 kg/m³)。

The fiber pellet may also include a plurality of exposed cellulosic fibers in the fibrous material. As shown in fig. 5B, each of the plurality of exposed cellulosic fibers can be entangled with at least one other exposed cellulosic fiber. The exposed cellulosic fibers can be present in the fibrous pellet in an amount of 2% or more (e.g., 3% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, 9% or more, 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, 80% or more, 85% or more, 95% or more) based on the total weight of the pellet.

The exposed cellulosic fibers can be present in the fibrous pellet in an amount of 99% or less (e.g., 3% or less, 4% or less, 5% or less, 6% or less, 7% or less, 8% or less, 9% or less, 10% or less, 15% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, 45% or less, 50% or less, 55% or less, 60% or less, 65% or less, 70% or less, 75% or less, 80% or less, 85% or less, 90% or less, or 95% or less), based on the total weight of the pellet).

The exposed cellulosic fibers can be present in an amount of 2% to 99% (e.g., 2% to 98%, 2% to 95%, 2% to 90%, 2% to 85%, 2% to 80%, 2% to 75%, 2% to 70%, 2% to 65, 2% to 60, 2% to 55%, 2% to 50%, 2% to 45%, 2% to 40%, 2% to 35%, 2% to 30%, 2% to 25%, 3% to 99%, 4% to 99%, 5% to 95%, 5% to 90%, 5% to 85%, 5% to 80%, 5% to 75%, 5% to 70%, 5% to 65%, 5% to 60%, 5% to 55%, 5% to 50, 5% -45%, 5% -40%, 5% -35%, 5% -30%, or 5% -25%) is present in the fiber pellets.

Embodiments of the present invention also provide a liquid product derived from a fibrous material, the liquid product comprising solid or liquid particulates, biostimulant compounds, minerals, amino acids, organic acids, proteins, water, and lignin. The biostimulating compounds may include compounds such as humic acid, fulvic acid or other organic acids. The liquid product may also contain other biostimulant compounds including, but not limited to, humic acid derivatives, humates, other organic acids, humus, humins, lignosulfonates, lactic acid, acetic acid, formic acid, citric acid, oxalic acid, uric acid, malic acid, other derivatives of soil organic matter, humic substances, other bioactive compounds, and the like, or any combination thereof. The minerals may include potassium, phosphorus, nitrogen, calcium, magnesium, sulfur, sodium, iron, manganese, zinc, copper, other natural minerals, and the like, or any combination thereof. The liquid product may also comprise amino acids, such as glutamic acid or tryptophan. The liquid product may also contain other volatile and non-volatile organic compounds.

The biostimulant compound may be present in the liquid product in an amount of about 0.001% or more (e.g., 0.005% or more, 0.01% or more, 0.05% or more, 0.1% or more, 0.2% or more, 0.3% or more, 0.4% or more, 0.5% or more, 0.6% or more, 0.7% or more, 0.8% or more, 0.9% or more, l% or more, 1.1% or more, 1.2% or more, 1.3% or more, 1.4% or more, 1.5% or more, 2% or more, 2.5% or more, 3% or more, 3.5% or more, 4% or more, 4.5% or more, 5% or more, 5.5% or more, 6% or more, 6.5% or more, 7% or more, 7.5% or more, 8% or more, 8.5% or more, 9% or more, based on the total weight of the liquid product.

In some embodiments, the biostimulating compound can be present in the liquid product in an amount of about 10% or less (e.g., 0.005% or less, 0.01% or less, 0.05% or less, 0.1% or less, 0.2% or less, 0.3% or less, 0.4% or less, 0.5% or less, 0.6% or less, 0.7% or less, 0.8% or less, 0.9% or less, 1% or less, 1.1% or less, 1.2% or less, 1.3% or less, 1.4% or less, 1.5% or less, 2% or less, 2.5% or less, 3% or less, 3.5% or less, 4% or less, 4.5% or less, 5% or less, 5.5% or less, 6% or less, 6.5% or less, 7% or less, 7.5% or less, 8% or less, 9% or less, based on the total weight of the liquid product.

In some embodiments, the biostimulating compound can be from about 0.001% to about 20% (e.g., 0.005% to 10%, 0.01% to 10%, 0.05% to 10%, 0.1% to 10%, 0.2% to 10%, 0.3% to 10%, 0.4% to 10%, 0.5% to 10%, 0.6% to 10%, 0.7% to 10%, 0.8% to 10%, 0.9% to 10%, 1% to 9.5%, 1% to 9%, 1.5% to 8.5%, 2% to 8%, 2.5% to 7.5%, 3% to 7%, 3% to 6.5%, 3% to 6%, 3% to 5.5%, 3% to 5%, 2.5% to 5%, 1.5% to 5%, 1.4% to 5%, 1.3% -5%, 1.2% -5%, 1.1% -5%, 1% -5%, 0.9% -5%, 0.8% -5%, 0.7% -5%, 0.6% -5%, 0.5% -5%, 0.4% -5%, 0.3% -5%, 0.2% -5%, or 0.1% -5%) in the liquid product.

The liquid product can comprise about 50% or more (e.g., 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, 80% or more, or 85% or more) water, based on the total weight of the liquid product. In some embodiments, the liquid product can comprise about 90% or less (e.g., 55% or less, 60% or less, 65% or less, 70% or less, 75% or less, 80% or less, or 85% or less) water, based on the total weight of the liquid product. In some embodiments, the liquid product can comprise from about 50% to about 90% (e.g., 55% to 85%, 60% to 80%, or 65% to 75%) by weight of water, based on the total weight of the liquid product.

The liquid product can also include lignin in an amount of about 0.01% or more (e.g., 0.05% or more, 0.1% or more, 0.5% or more, 1% or more, 2% or more, 3% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, 9% or more, 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more) by total weight of the liquid product.

In some embodiments, the liquid product can comprise lignin in an amount of about 75% or less (e.g., 0.05% or less, 0.1% or less, 0.5% or less, 1% or less, 2% or less, 3% or less, 4% or less, 5% or less, 6% or less, 7% or less, 8% too less, 9% or less, 10% or less, 15% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, 45% or less, 50% or less, 55% or less, 60% or less, 65% or less, or 70% or less) by total weight of the liquid product.

In some embodiments, the liquid product can include lignin in an amount of about 0.01% to about 75% (e.g., 0.05% to 75%, 0.1% to 75%, 0.5% to 75%, 1% to 75%, 2% to 75%, 3% to 75%, 4% to 75%, 5% to 75%, 6% to 75%, 7% to 75%, 8% to 75%, 9% to 75%, 10% to 75%, 15% to 75%, 20% to 75%, 25% to 75%, 30% to 70%, 35% to 65%, 40% to 60%, or 45% to 55%) by total weight of the liquid product.

The liquid product may also comprise various dry substances. In other words, the liquid product can have a solids content of about 0.0001% or more (e.g., 0.0005% or more, 0.001% or more, 0.005% or more, 0.01% or more, 0.05% or more, 0.1% or more, 0.5% or more, 1% or more, 1.5% or more, 2% or more, 2.5% or more, 3% or more, 3.5% or more, 4% or more, 4.5% or more, 5% or more, 6% or more, 7% or more, 8% or more, 9% or more, 10% or more, 11% or more, 12% or more, 13% or more, 14% or more, 15% or more, 16% or more, 17% or more, 18% or more, 19% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more), or more, based on the total weight of the liquid product).

In some embodiments, the liquid product can have a solids content of about 50% or less (e.g., 0.0005% or less, 0.001% or less, 0.005% or less, 0.01% or less, 0.05% or less, 0.1% or less, 0.5% or less, 1% or less, 1.5% or less, 2% or less, 2.5% or less, 3% or less, 3.5% or less, 4% or less, 4.5% or less, 5% or less, 6% or less, 7% or less, 8% or less, 9% or less, 10% or less, 11% or less, 12% or less, 13% or less, 14% or less, 15% or less, 16% or less, 17% or less, 18% or less, 19% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, or 45% or less) based on the total amount of the liquid product.

In some embodiments, the liquid product can have a viscosity of about 0.0001% to about 50% (e.g., 0.0005% to 50%, 0.001% to 50%, 0.005% to 50%, 0.01% to 50%, 0.05% to 50%, 0.1% to 50%, 0.5% to 50%, 1% to 50%, 0.0005% to 20%, 0.001% to 20%, 0.005% to 20%, 0.01% to 20%, 0.05% to 20%, 0.1% to 20%, 0.5% to 20%, 1% to 20%, 0.0005% to 19%, 0.001% to 18%, 0.005% to 17%, 0.01% to 16%, 0.05% to 15%, 0.1% to 14%, 0.5% to 13%, 1% to 12%, 1.5% to 11%, 2% to 10%, 2% to 9%, 2% -8%, 2% -7%, 2% -6%, 2% -5%, 2.5% -4.5% or 3% -4%).

The liquid product may also be acidic. For example, the pH of the liquid product can be about 7 or less (e.g., 6.5 or less, 6 or less, 5.5 or less, 5 or less, 4.5 or less, 4 or less, 3.5 or less, 3 or less, 2.5 or less, 2 or less, 1.5 or less, 1 or less, or 0.5 or less). In some embodiments, the pH of the liquid product can be about 0 or higher (e.g., 6.5 or higher, 6 or higher, 5.5 or higher, 5 or higher, 4.5 or higher, 4 or higher, 3.5 or higher, 3 or higher, 2.5 or higher, 2 or higher, 1.5 or higher, 1 or higher, or 0.5 or higher). In some embodiments, the pH of the liquid product can be from 0 to about 7 (e.g., 0.5 to 6.5, 1 to 6, 1.5 to 5.5, 2 to 5, 2.5 to 4.5, 3 to 4, 0 to 6.5, 0 to 6, 0 to 5.5, 0 to 5,0 to 4.5, or 0 to 4).

In addition, the liquid product may entrain all VOCs present in the feed in liquid form on the substrate. In other words, because the VOCs are substantially present in the liquid product, the process of making the liquid product may produce substantially trace amounts of VOCs in the gas phase. As used herein, the term "substantially trace amounts of VOCs" refers to the production of about 10ppm or less of VOCs.

The invention also discloses a method for promoting plant growth by using the liquid product. The method comprises applying a liquid product to the plant. It is contemplated and understood that within the scope of the present invention, various liquid products may be formulated in the manner described above.

Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. For convenience, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

Fig. 1 shows a flow diagram of an exemplary process 100 of the present invention. As shown in block 110, an additive 112 is mixed with a raw material 114 to obtain a first mixture 116. The feedstock 114 may comprise a fibrous material and water, and the fibrous material may comprise lignin and be selected from the fibrous materials of the present invention. Examples of additives 112 are described above, but it should be understood that other ingredients may be present in additives 112, such as inhibitors, defoamers, indicators, dyes, and the like. The process 100 may then proceed to block 120 or other steps of the process 100 not shown.

With respect to feedstock 114, feedstock 114 can comprise water in an amount of about 5% or more (e.g., 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, 80% or more, 85% or more, 90% or more) by total weight of feedstock 114. The feedstock 114 can also include water in an amount of about 95% or less (e.g., 10% or less, 15% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, 45% or less, 50% or less, 55% or less, 60% or less, 65% or less, 70% or less, 75% or less, 80% or less, 85% or less, or 90% or less) by total weight of the feedstock 114. Alternatively, the feedstock 114 can contain water in an amount of about 5% to about 95% (e.g., 5% to 90%, 10% to 90%, 15% to 85%, 20% to 80%, 25% to 75%, 30% to 70%, 35% to 65%, 40% to 60%, or 45% to 55%) by total weight of the feedstock 114.

Referring now to block 120, in block 120, the first mixture 116 is conditioned to obtain a liquid product 122 and a dry slurry product 124. Fig. 3 outlines the other steps of the adjustment of block 120 in more detail. The liquid product 122 may entrain substantially all of the VOCs present in liquid form in the feedstock 114. In other words, the conditioning step of block 120 may produce substantially undetectable amounts of VOCs in the gas phase because the VOCs are substantially contained in the liquid product 122. Examples of liquid products 122 are described above, but it is understood that liquid products 122 may have a composition according to any embodiment of the invention.

The conditioning step of block 120 may be performed at a temperature that requires little heating. In other words, the conditioning can be essentially self-heating without the need for an external heat source. For example, the conditioning step of block 120 may occur at about 350 ° f or less (e.g., a temperature of 340 ° f or less, 330 ° f or less, 320 ° f or less, 310 ° f or less, 300 ° f). F or less, 290F or less, 280F or less, 270F or less, 260F or less, 250F or less, 240F or less, 230F or less, 220F or less, or 210F or less). The conditioning step of block 120 may also occur at a temperature of about 200 ° f or more (e.g., 340 ° f or more, 330 ° f or more, 320 ° f or more, 310 ° f or more, 300 ° f or more, 290 ° f or more, 280 ° f or more, 270 ° f or more, 260 ° f or more, 250 ° f or more, 240 ° f or more, 230 ° f or more, 220 ° f or more, or 210 ° f or more). The conditioning step of block 120 may also occur at a temperature of about 200F to about 350F (e.g., 210F to 340F, 220F to 330F, 230F to 320F, 240F to 310F, 250F to 300F, 200F to 300F, 210F to 290F, 220F to 280F, 230F to 270F, or 240F to 260F).

The dry slurry product 124 may include a fibrous material and water, and the fibrous material may be substantially similar to the fibrous material of the feedstock 114. The dry pulp product 124 may also be substantially dewatered. For example, the dry pulp product 124 can include water in an amount of about 35% or less (e.g., 30% or less, 25% or less, 20% or less, 15% or less, 10% or less, 5% or less, 4% or less, 3% or less, 2% or less, or 1% or less) based on the total weight of the dry pulp product. The dry pulp product 124 can also include water in an amount of about 0.5% or more (e.g., 30% or more, 25% or more, 20% or more, 15% or more, 10% or more, 5% or more, 4% or more, 3% or more, 2% or more, or 1% or more) based on the total weight of the dry pulp product. The dry pulp product can also include water in an amount of about 0.5% to about 35% (e.g., 0.5% to 30%, 1% to 25%, 2% to 20%, 3% to 15%, 4% to 10%, 5% to 15%, 5% to 20%, 5% to 25%, 5% to 30%, 10% to 30%, 15% to 30%, or 20% to 30%) by total weight of the dry pulp product 124. The process 100 may terminate at block 120, or the process 100 may then proceed to block 130. The process 100 may additionally perform other steps of the process 100 that are not shown.

In block 130, the dry pulp product 124 may also be processed into a useful product. For example, the dry slurry product 124 may be pelletized to form fiber pellets. Examples of fiber pellets are described above, but it should be understood that fiber pellets may have a composition according to any embodiment of the present invention. Fig. 4B shows fiber pellets produced by the technique of the present invention, as compared to fiber pellets produced by the conventional process as shown in fig. 4A. In addition, fig. 5A shows a Scanning Electron Microscope (SEM) image of the fiber pellets produced by the conventional method, and fig. 5B shows an SEM image of the fiber pellets produced by the method of the present invention. Alternatively, the dry pulp product 124 can be ground into fine particles. The fine particles are useful in packaging materials, fiber board, paperboard, and the like. The dry pulp product 124 may also be used for papermaking or for the production of other lignocellulose-based products. The dry pulp product 124 may also be used as a binder fiber to improve the mechanical properties of other fibrous materials. The process 100 may terminate and complete at block 130. However, in other embodiments, the process 100 may proceed to other process steps not shown.

Fig. 2 shows a flow diagram of a conventional process 200. As shown in block 210, the feedstock 214a is subjected to a mechanical grinding process. The mechanical grinding process also requires a first amount of shaft work to be performed. The work required for block 210 is typically time consuming and expensive, resulting in an inefficient process. The equipment required for the mechanical milling process is also expensive, complex and difficult to maintain. Thus, block 210 of the conventional process 200 is not desirable. The conventional process 200 may then proceed to block 220.

In block 220, the ground feedstock 214b is dried by one or more dryers to obtain a dried feedstock 214 c. The one or more dryers require additional shaft work to move the ground feedstock 2l4b through the dryers and the one or more dryers also require additional heat to raise the temperature of the ground feedstock 2l4 b. The energy required to heat the dryer or dryers (typically used to evaporate water) is very high and cost prohibitive. In addition, the high temperature used to dry the ground feedstock 2l4b resulted in the release of some VOCs. The VOCs must then be further processed, which requires additional expensive equipment and energy requirements; or simply release the VOCs into the atmosphere, with deleterious effects on the environment. Thus, block 220 of the conventional process 200 is not desirable. The conventional process 200 may then proceed to block 230.

In block 230, the dried raw material 2l4c is subjected to a mechanical milling process to obtain a dried dry pulp product 234. The mechanical grinding process also requires a second amount of shaft work to be performed, as indicated at block 210. The work required for block 230 is typically time consuming and expensive, resulting in an inefficient process. The equipment required for the mechanical milling process is also expensive, complex and difficult to maintain. Furthermore, the mechanical milling process cannot completely pulp or pulverize the dry starting material 2l4 c. The fibers must be ground to reduce overall strength; or left intact to improve agglomeration and reduce uniformity. Thus, block 230 of the conventional process 200 is not desirable. The conventional process 200 may terminate and complete at block 230. However, in other embodiments, the conventional process 200 may proceed to other process steps not shown.

The process of the present invention, such as process 100 in fig. 1, requires little additional shaft work and requires little to no heating as compared to conventional process 200. As noted above, the process of the present invention may also entrain substantially all VOCs in liquid form in the liquid product, thereby reducing overall environmental impact. In addition, since there is little heating, the fibers in the fibrous material are less subject to keratinization in the process of the present invention. As a result, mechanically superior fibers have higher compressibility than fibers produced by conventional processes. Thus, the process of the present invention is more cost effective, energy efficient and environmentally friendly than conventional processes for achieving the same objectives.

Fig. 3a shows a flow chart of an exemplary conditioning process 300 of the present invention. It should be understood that the conditioning process 300 may occur substantially during block 120 of fig. 1. As shown, in block 310, the fibrous material (i.e., in the first mixture 116) may substantially interact with the additive. This interaction may form a substantially treated material between the additive and the fibrous material. Without wishing to be bound by any scientific theory, the additive may interact with lignin in the fibrous material to reduce the rigidity of the lignocellulosic cells and increase the plasticity of the lignin. The conditioning process 300 may then proceed to block 320 or to other steps of the conditioning process 300 that are not shown.

In block 320, a first portion of water in the fibrous material (i.e., from the treated material in block 310) may be released. Without wishing to be bound by any scientific theory, the additive may have a dewatering or drag reducing effect on the fibrous material to release a first amount of free water from the fibrous material. This effect increases the amount of water removed by the conditioning process 300, which may reduce the need for additional drying steps. The conditioning process 300 may then proceed to block 330 or other steps of the conditioning process 300 not shown.

In block 330, an additive may be added to the fibrous material (i.e., in the treated material). Without wishing to be bound by any scientific theory, the released first portion of water may dissolve the additive, thereby allowing the additive to be incorporated into the fibrous material. The conditioning process 300 may then proceed to block 340 or to other steps of the conditioning process 300 that are not shown.

At block 340, the fibrous material may interact with the added additives to attenuate the lignin in the fibrous material. As described above in block 310, without wishing to be bound by any scientific theory, the additive may interact with lignin in the fibrous material to reduce the rigidity of the lignocellulosic cells and increase the plasticity of the lignin. The addition of block 330 may further increase the interaction and homogenization of the treated material at block 340. The conditioning process 300 may then proceed to block 350 as shown in fig. 3b, proceed to other steps of the conditioning process 300 that are not shown, or terminate at block 340.

Fig. 3b shows a flow chart of an exemplary conditioning process 300 of the present invention. Figure 4 shows in detail the system and the machine for carrying out the process. As shown, in block 350, a pressure gradient may be applied to the fiber material. This pressure increase may result in an increase in the temperature of the material. Without wishing to be bound by any scientific theory, the drag reduction properties of the additive may increase the frictional forces on the fibrous material. The lignin in the wood material has reduced rigidity and increased plasticity due to the additives, so that the lignin (and thus the fibrous material) can remain intact without breaking with increasing temperature. The conditioning process 300 may then proceed to block 360 or to other steps of the conditioning process 300 that are not shown.

In block 360, a shear force may be applied to the fibrous material. The applied shear force may increase the frictional force acting on the fibrous material, thereby further increasing the internal temperature of the fibrous material. The lignin in the wood material has reduced rigidity and increased plasticity due to the additives, so that the lignin (and thus the fibrous material) can remain intact without breaking with increasing temperature. The conditioning process 300 may then proceed to block 370 or to other steps of the conditioning process 300 that are not shown. It should be appreciated that the pressure gradient step of block 350 and the shear force step of block 360 may occur in any order or may occur simultaneously with one another.

In block 370, a second portion of the water in the fibrous material (i.e., the treated material) may be evaporated by fractionating the fibrous material. It will be appreciated that shear and friction forces may fractionate the fibrous material, thereby releasing additional free water. The temperature increase due to shear forces and pressure gradients can also cause free water to evaporate as it is released. Without wishing to be bound by any scientific theory, the lignin in the cell walls of the fibrous material has been plasticized by the additive, limiting the possibility of "swelling" under pressure. In other words, due to the temperature increase caused by the pressure gradient and shear/friction forces, the water contained inside the individual cells of the fibrous material starts to evaporate and the total accelerating lignin of the cell walls starts to swell but not to break, just like a hot air filled hot balloon. As the volume of the cells increases under frictional and shear forces and elevated temperatures and pressures, the cells may remain intact while the fibrous material may be further separated. The conditioning process 300 may then proceed to block 380 or other steps of the conditioning process 300 not shown.

In block 380, the fibrous material (i.e., in the treated material) may be rapidly exposed to atmospheric pressure. Without wishing to be bound by any scientific theory, this rapid decompression of the fibrous material causes chemi-mechanical-cellular blasting of the fibrous material. In other words, the "swollen" cells in the fibrous material can now be completely ruptured, releasing the water within the cells and further separating the fibrous material. It is understood that due to pressure gradients, shear forces, friction forces and temperature increases, the fibrous material may be subjected to significant stresses during conditioning, resulting in the swollen cells containing evaporated water. Due to the interaction of lignin with the additives, the cells can swell without wishing to be bound by any scientific theory. The rapid return of the fibrous material to atmospheric conditions may induce a chemical mechanical cell explosion process, releasing a final portion of the water and obtaining a dry pulp product 124. It should also be understood that in the conditioning process 300, the released portion of the water may contain other components and may be recovered as the liquid product 122. The conditioning process 300 may then terminate at block 380 or may proceed to other steps not shown by the conditioning process 300.

The present invention discloses a machine 600 that can be used in the processes described herein. For example, a machine 600 for chemical-mechanical cell blasting may be provided, as shown in fig. 6. The machine 600 includes an inlet 610, and the material may enter the machine 600 through the inlet 610. The machine may include an outlet 620. The machine may include an interior chamber 630 connecting the inlet and the outlet, the interior chamber 630 having an interior surface. The machine may include a shaft 640 spanning the inlet 610, the outlet 620, and the interior chamber 630, the shaft 640 having a plurality of threads disposed circumferentially about the shaft 640, the plurality of threads having a first portion and a second portion. The first portion of the thread has a first pitch and the second portion of the thread may have a second pitch different from the first pitch. For example, the first pitch may be greater than the second pitch.

The internal chamber 630 may also include one or more shear members 632 disposed on the inner surface and corresponding to the second portion of the threads. For example, the one or more cutting members 632 may comprise a knife cutter. Other forms of cutting member may be used in place of the knife cutter. The knife trimmer may be prepared at any height, length or angle necessary to achieve a shear force between the one or more shear members 632 and the plurality of threads.

The shaft may be configured to rotate about a longitudinal axis shared with the interior chamber 630, and the rotation may apply a shear force between the second portion of the threads and the one or more shear members 632.

The machine also includes a protective cover 650 extending from an outer surface of the machine 600 and substantially surrounding the outlet 620, the protective cover 650 having an interior space 652 between the protective cover 650 and the outlet 620. The machine 600 may also include an outlet gate 622 configured to control the size of the outlet. The outlet gate 622 may be configured to expand and/or contract to control the flow of material through the machine 600.

As discussed, the feedstock may enter the machine 600 through an inlet 610. The feedstock may be mixed with additives to weaken the cell walls of the fibrous material in the feedstock prior to entering the machine 600. Upon entering the interior of the inner chamber 630, the material may begin to be subjected to shear forces from the rotation of the shaft 640 in contact with the shear member 632. As shear forces begin to act on the fibrous material in the feedstock, the frictional forces that fractionate the fibrous material will cause the internal pressure and temperature to begin to rise. As the material continues to move through the internal chamber 630 and shear due to the shearing member 632, water may be removed from the feedstock as the temperature and pressure continue to rise. As a result of the increased temperature and pressure, the weakened cell walls may begin to swell. The fibrous material may then pass through an outlet 620 and an outlet gate 622 may control the outlet flow of the fibrous material. The fibrous material may be rapidly exposed to atmospheric pressure as it exits the outlet 620, causing the cells to explode.

Methods for increasing feedstock throughput are also disclosed. One or more additives are mixed with the raw materials to obtain a first mixture. The feedstock may comprise fibrous material and water, and the fibrous material may comprise lignin. Suitable examples of fibrous materials and additives are described above, however, other examples may be used. Suitable examples of water content in the feed are also described above. The feedstock may be densified to form a product. The product may be in the form of pellets, briquettes, bales, logs, and the like. It will be appreciated that the product may have bulk density properties and PDI substantially similar to the fiber pellets described above, as the fiber pellets and product are produced using similar processes. The throughput of the process may be increased from 1% to 60% (e.g., 1% to 30%) relative to the throughput of the process without the additive. Without wishing to be bound by any scientific theory, the additive may act as a drag reducer to increase the throughput of the densification step, thereby increasing the production rate of the product. Such embodiments can be used to increase the productivity of, for example, animal feed.

Examples

The following examples are provided by way of illustration and not limitation.

800 pounds of loblolly pine chips having an initial moisture content of 50% were adjusted to a moisture content of 18% by the process of the present invention over a 1 hour period. An additional energy of 48kW is used in the process. During the transport, the resulting fibers were air dried to a moisture content of 16%. It was ground to have a durability index of 99, a water content of 4% and a bulk density of 750kg/m³The pellets of (4). When immersed in water for two minutes, the pellets exhibited very limited degradation. Steam was added during the conditioning. No additional heat energy was added during the granulation process. A liquid extract was also prepared from the conditioning, which contained the following ingredients listed in table I.

Table i liquid product composition examples

While the present invention has been described in connection with a number of exemplary aspects, as illustrated in the accompanying drawings and discussed above, it is to be understood that other similar aspects may be used or modifications and additions may be made to the described aspects for performing the same function of the present invention without deviating therefrom. For example, in various aspects of the invention, methods and compositions are described in accordance with aspects of the presently disclosed subject matter. However, other equivalent methods or compositions related to these described aspects are also contemplated by the teachings of the present invention. Accordingly, the present invention should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims.

It is to be understood that the disclosed embodiments and claims are not limited in their application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. Rather, the description and drawings provide examples of the embodiments contemplated. The disclosed embodiments and claims are also capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting to the claims.

Those skilled in the art will appreciate, therefore, that the conception upon which this application is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present embodiments and claims. It is important, therefore, that the claims be regarded as including such equivalent constructions.

Further, the purpose of the foregoing Abstract is to enable the patent office and the public generally, and especially the practitioners in the art who are not familiar with patent and legal terms or phraseology, to determine quickly from a cursory inspection the nature of the application. The abstract is neither intended to define the claims of the application nor is it intended to be limiting as to the scope of the claims in any way. Rather, the invention is intended to be defined by the appended claims.