Aqueous Pretreatment of Lignocellulosic Biomass for Binderless Material Production: Influence of Twin-Screw Extrusion Configuration and Liquid-to-Solid Ratio.

This study was carried out to investigate the continuous aqueous pretreatment of sugarcane bagasse (SCB) through twin-screw extrusion for a new integrated full valorization, where the solid residue (extrudate) was used for the production of bio-based materials by thermocompression and the filtrate for the production of high-value-added molecules. Two configurations, with and without a filtration module, were tested and the influence of the SCB composition and structure on the properties of the materials were determined. The impact of the liquid-to-solid (L/S) ratio was studied (0.65-6.00) in relation to the material properties and the biomolecule extraction yield in the filtrate (with the filtration configuration). An L/S ratio of at least 1.25 was required to obtain a liquid filtrate, and increasing the L/S ratio to 2 increased the extraction yield to 11.5 g/kg of the inlet SCB. The extrudate obtained without filtration yielded materials with properties equivalent to those obtained with filtration for L/S ratios of at least 1.25. Since the molecule extraction process was limited, a configuration without filtration would make it possible to reduce water consumption in the process while obtaining high material properties. Under the filtration configuration, an L/S ratio of 2 was the best tradeoff between water consumption, extraction yield, and the material properties, which included 1485 kg/m3 density, 6.2 GPa flexural modulus, 51.2 MPa flexural strength, and a water absorption (WA) and thickness swelling (TS) of 37% and 44%, respectively, after 24 h of water immersion. The aqueous pretreatment by twin-screw extrusion allowed for the overall valorization of SCB, resulting in materials with significantly improved properties compared to those obtained with raw SCB due to fiber deconstruction.

Twin-Screw Extrusion Process to Produce Renewable Fiberboards.

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.

Impact of Thermomechanical Fiber Pre-Treatment Using Twin-Screw Extrusion on the Production and Properties of Renewable Binderless Coriander Fiberboards.

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.