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Philippe Evon - One of the best experts on this subject based on the ideXlab platform.
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Twin-Screw Extrusion Process to Produce Renewable Fiberboards
Journal of visualized experiments : JoVE, 2021Co-Authors: Philippe Evon, Pierre-yves Pontalier, Laurent Labonne, Saif Ullah Khan, Pierre Ouagne, Antoine RouillyAbstract:A versatile twin-screw extrusion process to provide an efficient thermo-mechano-chemical pre-treatment on lignocellulosic biomass before using it as source of mechanical reinforcement in fully bio-based Fiberboards was developed. Various lignocellulosic crop by-products have already been successfully pre-treated through this process, e.g., cereal straws (especially rice), coriander straw, shives from oleaginous flax straw, and bark of both amaranth and sunflower stems. The extrusion process results in a marked increase in the average fiber aspect ratio, leading to improved mechanical properties of Fiberboards. The twin-screw extruder can also be fitted with a filtration module at the end of the barrel. The continuous extraction of various chemicals (e.g., free sugars, hemicelluloses, volatiles from essential oil fractions, etc.) from the lignocellulosic substrate, and the fiber refining can, therefore, be performed simultaneously. The extruder can also be used for its mixing ability: a natural binder (e.g., Organosolv lignins, protein-based oilcakes, starch, etc.) can be added to the refined fibers at the end of the screw profile. The obtained premix is ready to be molded through hot pressing, with the natural binder contributing to Fiberboard cohesion. Such a combined process in a single extruder pass improves the production time, production cost, and may lead to reduction in plant production size. Because all the operations are performed in a single step, fiber morphology is better preserved, thanks to a reduced residence time of the material inside the extruder, resulting in enhanced material performances. Such one-step extrusion operation may be at the origin of a valuable industrial process intensification. Compared to commercial wood-based materials, these fully bio-based Fiberboards do not emit any formaldehyde, and they could find various applications, e.g., intermediate containers, furniture, domestic flooring, shelving, general construction, etc.
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VOC and carbonyl compound emissions of a Fiberboard resulting from a coriander biorefinery: comparison with two commercial wood-based building materials
Environmental Science and Pollution Research, 2020Co-Authors: Valérie Simon, Evelien Uitterhaegen, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Anaïs Robillard, Gérard Vilarem, Philippe EvonAbstract:Indoor air quality is a major public health issue. It is related to the choice of construction materials and associated with VOC emissions. Two wood-based commercial panels were tested: a medium-density Fiberboard (MDF) and a chipboard (CH), and they were compared to a material produced from a coriander biorefinery (COR). Indicators chosen to compare the materials were physical properties (density, bending properties, surface hardness, thickness swelling, and water absorption) and VOC emissions. Emissions were evaluated in an environmental chamber at 23 °C, 31 °C, and 36 °C, and during 28 days. Carbonyl emissions on day 1 at 23 °C were 74, 146, and 35 μg m−2 h−1, respectively, for MDF, CH, and COR. Terpenic emissions were 12, 185, and 37 μg m−2 h−1, respectively. Higher temperature resulted in higher emissions which decreased over time, except for formaldehyde. VOC emissions depended largely on material and temperature. Formaldehyde emission was 300 to 600 times lower for coriander boards (< 0.2 μg m−2 h−1), making them significantly more environmentally friendly materials in comparison with MDF and chipboard. These results highlight the interest of coriander by-products as raw materials for producing Fiberboards with low impact on indoor air quality.
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Production of Fiberboard from rice straw thermomechanical extrudates by thermopressing: influence of fiber morphology, water and lignin content
European Journal of Wood and Wood Products, 2019Co-Authors: Dyna Theng, Bunthan Ngo, Laurent Labonne, Gerard Arbat, Pere Mutjé, Marc Delgado-aguilar, Philippe EvonAbstract:The objective of this study was to investigate the influence of fiber morphology and molding parameters on the mechanical and physical properties of Fiberboards made from rice straw. The rice straw was thermomechanically treated with a twin-screw extruder. Three parameters were investigated: the amount of water added at molding (0–20%), lignin content (0–25%), and the liquid/solid ratio used for extrudate production (0.33–1.07). A Doehlert experimental design was used to evaluate the effects of these factors on Fiberboard properties. A liquid/solid ratio of 0.4 at extrudate production, the addition of 5% water at molding, and a lignin content of 8.9% were found to be optimal for bending properties. The Fiberboard produced in these conditions had a density of 1414 kg/m^3 (i.e. the densest board). Maximum flexural strength and elastic modulus were 50.3 MPa and 8.6 GPa, respectively. A thickness swelling of 23.6% and 17.6% water absorption were observed. The statistical analysis suggested that a good compromise between density and flexural properties could be obtained with the addition of 0% water, a lignin content of 25% and a liquid/solid ratio of 0.33 at extrudate production. Polynomial models suggested that the Fiberboards produced in such conditions would have a maximum flexural strength of 50 MPa, an elastic modulus of 6.0 GPa, a density of 1102 kg/m^3, and a thickness swelling of 24%.
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impact of thermomechanical fiber pre treatment using twin screw extrusion on the production and properties of renewable binderless coriander Fiberboards
International Journal of Molecular Sciences, 2017Co-Authors: Evelien Uitterhaegen, Laurent Labonne, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Philippe EvonAbstract:The aim of this study consisted of manufacturing renewable binderless Fiberboards from coriander straw and a deoiled coriander press cake, thus at the same time ensuring the valorization of crop residues and process by-products. The press cake acted as a natural binder inside the boards owing to the thermoplastic behavior of its protein fraction during thermopressing. The influence of different fiber-refining methods was evaluated and it was shown that a twin-screw extrusion treatment effectively improved fiber morphology and resulted in Fiberboards with enhanced performance as compared to a conventional grinding process. The best Fiberboard was produced with extrusion-refined straw using a 0.4 liquid/solid (L/S) ratio and with 40% press cake addition. The water sensitivity of the boards was effectively reduced by 63% through the addition of an extrusion raw material premixing operation and thermal treatment of the panels at 200 °C, resulting in materials with good performance showing a flexural strength of 29 MPa and a thickness swelling of 24%. Produced without the use of any chemical adhesives, these Fiberboards could thus present viable, sustainable alternatives for current commercial wood-based materials such as oriented strand board, particleboard and medium-density Fiberboard, with high cost-effectiveness.
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Manufacturing of renewable and biodegradable Fiberboards from cake generated during biorefinery of sunflower whole plant in twin-screw extruder: Influence of thermo-pressing conditions
Polymer Degradation and Stability, 2015Co-Authors: Philippe Evon, Virginie Vandenbossche, Luc RigalAbstract:The starting material used in this study was a cake generated during thermo-mechanical fractionation of sunflower (Helianthus annuus L.) whole plant in a twin-screw extruder. It was slightly deoiled (16.7% of oil in dry matter). Composed mainly of fibers and proteins, it could be considered as a natural composite and was processed successfully into Fiberboards by thermo-pressing. This study aimed to evaluate the influence of thermo-pressing conditions on mechanical and heat insulation properties of Fiberboards manufactured from this cake. All Fiberboards were cohesive, proteins and fibers acting respectively as binder and reinforcing fillers. Highest cake quantity (1000 mg/cm²) led to the highest breaking load (60.7 N) with a flexural strength at break quite low (2.9 MPa), lowest elastic modulus (216.6 MPa), and highest Charpy impact strength (6.5 kJ/m² for resilience). The increase of pressure applied during molding (from 320 to 360 kgf/cm²) led to an important increase of elastic modulus (from 352.6 to 728.6 MPa). Besides, Fiberboard molded at 360 kgf/cm² was the most rigid of this study, and logically revealed the most important Shore D surface hardness (52.6°). Moreover, lowest molding time (60 s) led to the highest flexural strength at break (3.9 MPa). The low density of the Fiberboards (less than 0.97) involved promising heat insulation properties. Indeed, thermal conductivity of Fiberboards at 25 °C was low (from 103.5 to 135.7 mW/m K), and decreased with the increase of thickness. According to their mechanical and heat insulation properties, Fiberboards would be potentially usable as inter-layer sheets for pallets, for the manufacture of biodegradable containers (composters, crates for vegetable gardening) by assembly of Fiberboards, or for their heat insulation properties in building industry. Moreover, thermo-pressing was not only a molding operation. It also improved the oil extraction efficiency as a part of residual oil was expressed from cake during molding, and total oil yield reached 79.3% with a pressure applied of 360 kgf/cm².
Luc Rigal - One of the best experts on this subject based on the ideXlab platform.
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Manufacturing of renewable and biodegradable Fiberboards from cake generated during biorefinery of sunflower whole plant in twin-screw extruder: Influence of thermo-pressing conditions
Polymer Degradation and Stability, 2015Co-Authors: Philippe Evon, Virginie Vandenbossche, Luc RigalAbstract:The starting material used in this study was a cake generated during thermo-mechanical fractionation of sunflower (Helianthus annuus L.) whole plant in a twin-screw extruder. It was slightly deoiled (16.7% of oil in dry matter). Composed mainly of fibers and proteins, it could be considered as a natural composite and was processed successfully into Fiberboards by thermo-pressing. This study aimed to evaluate the influence of thermo-pressing conditions on mechanical and heat insulation properties of Fiberboards manufactured from this cake. All Fiberboards were cohesive, proteins and fibers acting respectively as binder and reinforcing fillers. Highest cake quantity (1000 mg/cm²) led to the highest breaking load (60.7 N) with a flexural strength at break quite low (2.9 MPa), lowest elastic modulus (216.6 MPa), and highest Charpy impact strength (6.5 kJ/m² for resilience). The increase of pressure applied during molding (from 320 to 360 kgf/cm²) led to an important increase of elastic modulus (from 352.6 to 728.6 MPa). Besides, Fiberboard molded at 360 kgf/cm² was the most rigid of this study, and logically revealed the most important Shore D surface hardness (52.6°). Moreover, lowest molding time (60 s) led to the highest flexural strength at break (3.9 MPa). The low density of the Fiberboards (less than 0.97) involved promising heat insulation properties. Indeed, thermal conductivity of Fiberboards at 25 °C was low (from 103.5 to 135.7 mW/m K), and decreased with the increase of thickness. According to their mechanical and heat insulation properties, Fiberboards would be potentially usable as inter-layer sheets for pallets, for the manufacture of biodegradable containers (composters, crates for vegetable gardening) by assembly of Fiberboards, or for their heat insulation properties in building industry. Moreover, thermo-pressing was not only a molding operation. It also improved the oil extraction efficiency as a part of residual oil was expressed from cake during molding, and total oil yield reached 79.3% with a pressure applied of 360 kgf/cm².
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New thermal insulation Fiberboards from cake generated during biorefinery of sunflower whole plant in a twin-screw extruder
Industrial Crops and Products, 2015Co-Authors: Philippe Evon, Virginie Vandenbossche, Pierre-yves Pontalier, Luc RigalAbstract:The objective of this study was to manufacture new thermal insulation Fiberboards by thermo-pressing. The starting material was a slightly deoiled cake (17.6% oil content), generated during the biorefinery of sunflower (Helianthus annuus L.) whole plant in a co-rotating (Clextral BC 45, France) twin-screw extruder. All Fiberboards produced were cohesive mixtures of proteins and lignocellulosic fibers, acting respectively as binder and reinforcing fillers in what could be considered as a natural composite. The molding experiments were conducted using a 400 ton capacity heated hydraulic press (Pinette Emidecau Industries, France). The influence of molding conditions on board density, mechanical properties and heat insulation properties was examined. Molding conditions included mold temperature (140-200°C), pressure applied (150-250 kgf/cm²) and molding time (40-76 s), and these greatly affected board density and thus the mechanical and heat insulation properties. Board density increased with increasingly extreme molding conditions, rising from 500 to 858 kg/m³. The mechanical properties increased at the same time (from 52 to 660 kPa for flexural strength at break, from 5.9 to 49.4 MPa for elastic modulus, from 0.5 to 7.7 kJ/m² for Charpy impact strength, and from 19.2 to 47.1° for Shore D surface hardness). Conversely, heat insulation properties improved with decreasing board density, and the lowest thermal conductivity (88.5 mW/m K at 25°C) was obtained with the least dense Fiberboard. The latter was produced with a 140°C mold temperature, a 150 kgf/cm² pressure applied and a 40 s molding time. A medium mold temperature (160°C) was needed to obtain a good compromise between mechanical properties (272 kPa for flexural strength at break, 26.3 MPa for elastic modulus, 3.2 kJ/m² for Charpy impact strength, and 37.3° for Shore D surface hardness), and heat insulation properties (99.5 mW/m K for thermal conductivity).The corresponding board density was medium (687 kg/m³). Because of their promising heat insulation properties, these new Fiberboards could be positioned on walls and ceilings for thermal insulation of buildings. The bulk cake also revealed very low thermal conductivity properties (only 65.6 mW/m K at 25°C) due to its very low bulk density (204 kg/m³). It could be used as loose fill in the attics of houses.
Evelien Uitterhaegen - One of the best experts on this subject based on the ideXlab platform.
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VOC and carbonyl compound emissions of a Fiberboard resulting from a coriander biorefinery: comparison with two commercial wood-based building materials
Environmental Science and Pollution Research, 2020Co-Authors: Valérie Simon, Evelien Uitterhaegen, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Anaïs Robillard, Gérard Vilarem, Philippe EvonAbstract:Indoor air quality is a major public health issue. It is related to the choice of construction materials and associated with VOC emissions. Two wood-based commercial panels were tested: a medium-density Fiberboard (MDF) and a chipboard (CH), and they were compared to a material produced from a coriander biorefinery (COR). Indicators chosen to compare the materials were physical properties (density, bending properties, surface hardness, thickness swelling, and water absorption) and VOC emissions. Emissions were evaluated in an environmental chamber at 23 °C, 31 °C, and 36 °C, and during 28 days. Carbonyl emissions on day 1 at 23 °C were 74, 146, and 35 μg m−2 h−1, respectively, for MDF, CH, and COR. Terpenic emissions were 12, 185, and 37 μg m−2 h−1, respectively. Higher temperature resulted in higher emissions which decreased over time, except for formaldehyde. VOC emissions depended largely on material and temperature. Formaldehyde emission was 300 to 600 times lower for coriander boards (< 0.2 μg m−2 h−1), making them significantly more environmentally friendly materials in comparison with MDF and chipboard. These results highlight the interest of coriander by-products as raw materials for producing Fiberboards with low impact on indoor air quality.
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impact of thermomechanical fiber pre treatment using twin screw extrusion on the production and properties of renewable binderless coriander Fiberboards
International Journal of Molecular Sciences, 2017Co-Authors: Evelien Uitterhaegen, Laurent Labonne, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Philippe EvonAbstract:The aim of this study consisted of manufacturing renewable binderless Fiberboards from coriander straw and a deoiled coriander press cake, thus at the same time ensuring the valorization of crop residues and process by-products. The press cake acted as a natural binder inside the boards owing to the thermoplastic behavior of its protein fraction during thermopressing. The influence of different fiber-refining methods was evaluated and it was shown that a twin-screw extrusion treatment effectively improved fiber morphology and resulted in Fiberboards with enhanced performance as compared to a conventional grinding process. The best Fiberboard was produced with extrusion-refined straw using a 0.4 liquid/solid (L/S) ratio and with 40% press cake addition. The water sensitivity of the boards was effectively reduced by 63% through the addition of an extrusion raw material premixing operation and thermal treatment of the panels at 200 °C, resulting in materials with good performance showing a flexural strength of 29 MPa and a thickness swelling of 24%. Produced without the use of any chemical adhesives, these Fiberboards could thus present viable, sustainable alternatives for current commercial wood-based materials such as oriented strand board, particleboard and medium-density Fiberboard, with high cost-effectiveness.
Laurent Labonne - One of the best experts on this subject based on the ideXlab platform.
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Twin-Screw Extrusion Process to Produce Renewable Fiberboards
Journal of visualized experiments : JoVE, 2021Co-Authors: Philippe Evon, Pierre-yves Pontalier, Laurent Labonne, Saif Ullah Khan, Pierre Ouagne, Antoine RouillyAbstract:A versatile twin-screw extrusion process to provide an efficient thermo-mechano-chemical pre-treatment on lignocellulosic biomass before using it as source of mechanical reinforcement in fully bio-based Fiberboards was developed. Various lignocellulosic crop by-products have already been successfully pre-treated through this process, e.g., cereal straws (especially rice), coriander straw, shives from oleaginous flax straw, and bark of both amaranth and sunflower stems. The extrusion process results in a marked increase in the average fiber aspect ratio, leading to improved mechanical properties of Fiberboards. The twin-screw extruder can also be fitted with a filtration module at the end of the barrel. The continuous extraction of various chemicals (e.g., free sugars, hemicelluloses, volatiles from essential oil fractions, etc.) from the lignocellulosic substrate, and the fiber refining can, therefore, be performed simultaneously. The extruder can also be used for its mixing ability: a natural binder (e.g., Organosolv lignins, protein-based oilcakes, starch, etc.) can be added to the refined fibers at the end of the screw profile. The obtained premix is ready to be molded through hot pressing, with the natural binder contributing to Fiberboard cohesion. Such a combined process in a single extruder pass improves the production time, production cost, and may lead to reduction in plant production size. Because all the operations are performed in a single step, fiber morphology is better preserved, thanks to a reduced residence time of the material inside the extruder, resulting in enhanced material performances. Such one-step extrusion operation may be at the origin of a valuable industrial process intensification. Compared to commercial wood-based materials, these fully bio-based Fiberboards do not emit any formaldehyde, and they could find various applications, e.g., intermediate containers, furniture, domestic flooring, shelving, general construction, etc.
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Production of Fiberboard from rice straw thermomechanical extrudates by thermopressing: influence of fiber morphology, water and lignin content
European Journal of Wood and Wood Products, 2019Co-Authors: Dyna Theng, Bunthan Ngo, Laurent Labonne, Gerard Arbat, Pere Mutjé, Marc Delgado-aguilar, Philippe EvonAbstract:The objective of this study was to investigate the influence of fiber morphology and molding parameters on the mechanical and physical properties of Fiberboards made from rice straw. The rice straw was thermomechanically treated with a twin-screw extruder. Three parameters were investigated: the amount of water added at molding (0–20%), lignin content (0–25%), and the liquid/solid ratio used for extrudate production (0.33–1.07). A Doehlert experimental design was used to evaluate the effects of these factors on Fiberboard properties. A liquid/solid ratio of 0.4 at extrudate production, the addition of 5% water at molding, and a lignin content of 8.9% were found to be optimal for bending properties. The Fiberboard produced in these conditions had a density of 1414 kg/m^3 (i.e. the densest board). Maximum flexural strength and elastic modulus were 50.3 MPa and 8.6 GPa, respectively. A thickness swelling of 23.6% and 17.6% water absorption were observed. The statistical analysis suggested that a good compromise between density and flexural properties could be obtained with the addition of 0% water, a lignin content of 25% and a liquid/solid ratio of 0.33 at extrudate production. Polynomial models suggested that the Fiberboards produced in such conditions would have a maximum flexural strength of 50 MPa, an elastic modulus of 6.0 GPa, a density of 1102 kg/m^3, and a thickness swelling of 24%.
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impact of thermomechanical fiber pre treatment using twin screw extrusion on the production and properties of renewable binderless coriander Fiberboards
International Journal of Molecular Sciences, 2017Co-Authors: Evelien Uitterhaegen, Laurent Labonne, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Philippe EvonAbstract:The aim of this study consisted of manufacturing renewable binderless Fiberboards from coriander straw and a deoiled coriander press cake, thus at the same time ensuring the valorization of crop residues and process by-products. The press cake acted as a natural binder inside the boards owing to the thermoplastic behavior of its protein fraction during thermopressing. The influence of different fiber-refining methods was evaluated and it was shown that a twin-screw extrusion treatment effectively improved fiber morphology and resulted in Fiberboards with enhanced performance as compared to a conventional grinding process. The best Fiberboard was produced with extrusion-refined straw using a 0.4 liquid/solid (L/S) ratio and with 40% press cake addition. The water sensitivity of the boards was effectively reduced by 63% through the addition of an extrusion raw material premixing operation and thermal treatment of the panels at 200 °C, resulting in materials with good performance showing a flexural strength of 29 MPa and a thickness swelling of 24%. Produced without the use of any chemical adhesives, these Fiberboards could thus present viable, sustainable alternatives for current commercial wood-based materials such as oriented strand board, particleboard and medium-density Fiberboard, with high cost-effectiveness.
Thierry Véronèse - One of the best experts on this subject based on the ideXlab platform.
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VOC and carbonyl compound emissions of a Fiberboard resulting from a coriander biorefinery: comparison with two commercial wood-based building materials
Environmental Science and Pollution Research, 2020Co-Authors: Valérie Simon, Evelien Uitterhaegen, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Anaïs Robillard, Gérard Vilarem, Philippe EvonAbstract:Indoor air quality is a major public health issue. It is related to the choice of construction materials and associated with VOC emissions. Two wood-based commercial panels were tested: a medium-density Fiberboard (MDF) and a chipboard (CH), and they were compared to a material produced from a coriander biorefinery (COR). Indicators chosen to compare the materials were physical properties (density, bending properties, surface hardness, thickness swelling, and water absorption) and VOC emissions. Emissions were evaluated in an environmental chamber at 23 °C, 31 °C, and 36 °C, and during 28 days. Carbonyl emissions on day 1 at 23 °C were 74, 146, and 35 μg m−2 h−1, respectively, for MDF, CH, and COR. Terpenic emissions were 12, 185, and 37 μg m−2 h−1, respectively. Higher temperature resulted in higher emissions which decreased over time, except for formaldehyde. VOC emissions depended largely on material and temperature. Formaldehyde emission was 300 to 600 times lower for coriander boards (< 0.2 μg m−2 h−1), making them significantly more environmentally friendly materials in comparison with MDF and chipboard. These results highlight the interest of coriander by-products as raw materials for producing Fiberboards with low impact on indoor air quality.
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impact of thermomechanical fiber pre treatment using twin screw extrusion on the production and properties of renewable binderless coriander Fiberboards
International Journal of Molecular Sciences, 2017Co-Authors: Evelien Uitterhaegen, Laurent Labonne, Thierry Talou, Stéphane Ballas, Thierry Véronèse, Othmane Merah, Philippe EvonAbstract:The aim of this study consisted of manufacturing renewable binderless Fiberboards from coriander straw and a deoiled coriander press cake, thus at the same time ensuring the valorization of crop residues and process by-products. The press cake acted as a natural binder inside the boards owing to the thermoplastic behavior of its protein fraction during thermopressing. The influence of different fiber-refining methods was evaluated and it was shown that a twin-screw extrusion treatment effectively improved fiber morphology and resulted in Fiberboards with enhanced performance as compared to a conventional grinding process. The best Fiberboard was produced with extrusion-refined straw using a 0.4 liquid/solid (L/S) ratio and with 40% press cake addition. The water sensitivity of the boards was effectively reduced by 63% through the addition of an extrusion raw material premixing operation and thermal treatment of the panels at 200 °C, resulting in materials with good performance showing a flexural strength of 29 MPa and a thickness swelling of 24%. Produced without the use of any chemical adhesives, these Fiberboards could thus present viable, sustainable alternatives for current commercial wood-based materials such as oriented strand board, particleboard and medium-density Fiberboard, with high cost-effectiveness.