In-situ monitoring of changes in ultrastructure and mechanical properties of flax cell walls during controlled heat treatment.

Plant fibres are increasingly used as reinforcements, especially in thermoplastic composites. Understanding the impact of temperature on the properties of these fibres is an important issue for the manufacturing of high-performance materials with minimal defects. In this work, the structural evolution and mechanical behaviour of flax fibre cell walls were dynamically monitored by temperature-controlled X-ray diffraction and nanoindentation from 25 to 230 °C; detailed biochemical analysis was also conducted on fibre samples after each heating step. With increasing temperature up to 230 °C, a decrease in the local mechanical performance of the flax cell walls, of about -72 % for the indentation modulus and -35 % for the hardness, was measured. This was associated with a decrease in the packing of the cellulose crystal lattice (increase in d-spacing d200), as well as significant mass losses measured by thermogravimetric analysis and changes in the biochemical composition, i.e. non-cellulosic polysaccharides attributed to the middle lamellae but also to the cell walls. This work, which proposes for the first time an in-situ investigation of the dynamic temperature evolution of the flax cell wall properties, highlights the reversible behaviour of their crystalline structure (i.e. cellulose) and local mechanical properties after cooling to room temperature, even after exposure to high temperatures.

In Situ Tensile Testing under High-Speed Optical Recording to Determine Hierarchical Damage Kinetics in Polymer Layers of Flax Fibre Elements.

This study aims at better understanding the damage and fracture kinetics in flax fibre elements at both the unitary and bundle scales, using an experimental setup allowing optical observation at high recording rate in the course of tensile loading. Defects and issues from flax unitary fibre extraction are quantitated using polarized light microscopy. Tensile loading is conducted according to a particular setup, adapted to fibres of 10 to 20 µm in diameter and 10 mm in length. Optical recording using a high-speed camera is performed during loading up to the failure at acquisition, with speed ranging from 108,000 to 270,000 frames per second. Crack initiation in polymer layers of fibre elements, propagation as well as damage mechanisms are captured. The results show different failure scenarios depending on the fibre element's nature. In particular, fractured fibres underline either a fully transverse failure propagation or a combination of transverse and longitudinal cracking with different balances. Image recordings with high time resolution of down to 3.7 µs suggest an unstable system and transverse crack speed higher than 4 m/s and a slower propagation for longitudinal crack deviation. Failure propagation monitoring and fracture mechanism studies in individual natural fibre or bundles, using tensile load with optical observation, showed contrasted behaviour and the importance of the structural scale exanimated. This study can help in tailoring the eco-design of flax-based composites, in terms of toughness and mechanical performances, for both replacement of synthetic fibre materials and innovative composites with advanced properties.

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.

Holistic Valorization of Hemp through Reductive Catalytic Fractionation.

Despite the increased use of hemp fiber, negligible attention has been given to upgrade the hemp hurd, which constitutes up to 70 wt % of the hemp stalk and is currently considered a low-value byproduct. In this work, valorization of hemp hurd was performed by reductive catalytic fractionation (RCF) in the presence of a metal catalyst. We found an unexpectedly high yield of monophenolic compounds (38.3 wt %) corresponding to above 95% of the theoretical maximum yield. The high yield is explained by both a thin cell wall and high S-lignin content. In addition, organosolv pulping was performed to generate a pulp that was bleached to produce dissolving-grade pulp suitable for textile fiber production (viscosity, 898 mL/g; ISO-brightness, 90.2%) and nanocellulose. Thus, we have demonstrated a novel value chain from a low-value side stream of hemp fiber manufacture that has the potential to increase textile fiber production with 100% yield and also give bio-oil for green chemicals.