Weyerhaeuser Company Limited

Domtar Paper Company, LLC

Brian Wester

Michael David Vrbanac

Michael James Yancey

Ramon Charles Dezutter

Mengkui Luo

James E Sealey, Ii

W Harvey Persinger, Jr

Michael R Hansen

Julie A Reimer

Ramon C Dezutter

David W Bickell

Robert A Veleber

Brian E Dennis

Peter K Lau

Bruno S Marcoccia

Harshad Pande

The present invention relates to a method of making a fiber-reinforced cementitious composite material which finds widespread applicability in a variety of construction and related applications. The composite comprises cellulosic fibrous material in order to provide the composite with the desired performance characteristics. Notably, at least a portion of the cellulosic fibrous material comprises surfaced enhanced pulp fiber, which desirably enhances the processing characteristics of the material, as well enhancing the characteristics of the finished composite product. The method of making a fiber-reinforced cementitious composite comprising the steps of providing a cementitious composition, and providing cellulosic fibrous material. The present method further includes blending the cementitious composition and the cellulosic fibrous material to form the cementitious composite. The surface enhanced pulp fiber preferably comprises approximately 1-10%, by weight, of the cellulosic fibrous material, and the cellulosic fibrous material exhibits an enhanced Bauer-McNett long fiber fraction. The cellulosic fibrous material preferably exhibits at least a 10% increase in length-weighted average fiber length (LWAFL), in comparison to a cellulosic fibrous material which is devoid of surface enhanced pulp fiber. The cellulosic fibrous material requires relatively reduced refining energy, in comparison to a cellulosic fibrous material which is devoid of surface enhanced pulp fiber, to reach a predetermined freeness CSF (Canadian Standard Freeness) value.

Surface enhanced pulp fibers in fiber cement

This invention provides a dried singulated crosslinked cellulose pulp fiber product as well as an apparatus and a method for forming singulated, crosslinked, and dried fibers. In accordance with the process, a feed pulp containing a crosslinker is delivered to a jet drier. The jet drier singulates and dries the feed pulp. The singulated and dried fibers are collected from the jet drier. The feed pulp may be further treated with a treatment substance. The jet drier may be maintained at negative pressure. The product fibers may have low knot count, a low fines count, as well improved kink, curl, and twist. The apparatus for carrying out the process may include a pretreatment station for supplying the treatment substance, a pulp feed device designed for pulp, a pulp feed device designed for pulp and foam suspensions, and/or a fiber separation station having a vacuum conveyor.

System for making dried singulated crosslinked cellulose pulp fibers

A pulp product that has a low COD is comprised of an unbleached pulp that is soaked and washed in alkaline water for a sufficient time so that the COD after soaking and washing is less than or equal to 3.0 kg/1000 kg of dry pulp. The pulp is produced by repetitively soaking and washing an unbleached pulp in alkaline water that is never allowed to drop below pH 7.0. The pulp is soaked and washed for a total of at least 400 minutes at an elevated temperature to produce the pulp product that has a low COD.

Process for producing very low COD unbleached pulp

A process for making a composition for conversion to lyocell fiber where the process comprises pulping a raw material in a digester to provide an alkaline pulp, wherein the raw material comprises sawdust in an amount greater than 0 % up to 100 %; and contacting the alkaline pulp comprising cellulose and at least about 7 % hemicellulose under alkaline conditions with an amount of an oxidant sufficient to reduce the average degree of polymerization of the cellulose to within the range of from about 200 to about 1100, without substantially reducing the hemicellulose content of the pulp or substantially increasing the copper number.

Process for making composition for conversion to lyocell fiber from sawdust

A process for making a pulp product that has a low COD is comprised of soaking and washing pulp in alkaline water for a sufficient time so that the COD after soaking and washing is less than or equal to 2.0 kg/1000 kg of dry pulp. The process includes repetitively soaking and washing an unbleached pulp in alkaline water that is never allowed to drop below pH 7.0. In this process, the pulp is soaked and washed for a total of at least 220 minutes at an elevated temperature to produce the pulp product that has a low COD.

Process for making a very low COD unbleached pulp

This invention provides a dried singulated crosslinked cellulose pulp fiber product as well as an apparatus and a method for forming singulated, crosslinked, and dried fibers. In accordance with the process, a feed pulp containing a crosslinker is delivered to a jet drier. The jet drier singulates and dries the feed pulp. The singulated and dried fibers are collected from the jet drier. The feed pulp may be further treated with a treatment substance. The jet drier may be maintained at negative pressure. The product fibers may have low knot count, a low fines count, as well improved kink, curl and twist. The apparatus for carrying out the process may include a pretreatment station for supplying the treatment substance, a pulp feed device designed for pulp, a pulp feed device designed for pulp and foam suspensions, and/or a fiber separation station having a vacuum conveyor.

Process for producing dried singulated crosslinked cellulose pulp fibers

This invention provides a dried singulated cellulose pulp fiber product as well as an apparatus and a method for forming singulated and dried fibers. In accordance with the process a feed pulp is delivered to a jet drier. The jet drier singulates and dries the feed pulp. The singulated and dried fibers are collected from the jet drier. The feed pulp may be treated with a treatment substance. The jet drier may be maintained at negative pressure. The product fibers may have low knot count, a low fines count, as well improved kink, curl and twist. The apparatus for carrying out the process may include a pretreatment station for supplying the treatment substance, a pulp feed device designed for pulp, a pulp feed device designed for pulp and foam suspensions, and/or a fiber separation station having a vacuum conveyor.

Process to produce dried singulated cellulose pulp fibers

Drying system for producing dried singulated cellulose pulp fibers

System for producing dried singulated cellulose pulp fibers using a jet drier and injected steam

A process for making lyocell fibers including the steps of pulping raw material in a digester to provide an alkaline pulp, wherein the raw material includes sawdust in an amount greater than 0% up to 100%; contacting the alkaline pulp including cellulose and at least about 7% hemicellulose under alkaline conditions with an amount of an oxidant sufficient to reduce the average degree of polymerization of the cellulose to the range of from about 200 to about 1100 without substantially reducing the hemicellulose content or substantially increasing the copper number of the pulp; and forming fibers from the pulp.

Process for making lyocell fiber from sawdust pulp

A process for making singulated pulp flakes is provided. The process includes dewatering liquid pulp stock to a consistency of about 30 to about 50% solids. The process includes initial flaking to break up the dewatered pulp bundles into semi-uniform flakes having a median size of from about 3 to about 5 mmand a consistency of from about 33 to about 55% solids. The process includes drying the flaked pulp to a consistency of from about 85 to about 97% solids. The process includes flaking a second time to separate the flakes that may have bonded during drying. The product 'singulated' flakes then go to a baler for packaging. In another embodiment, the process includes blending the liquid pulp stock with at least one adjuvant prior to dewatering.

Flowable and meterable densified fiber flake

The present invention is directed to a new form of pulp that is a flake having a specific size, density, and wet dispersibility. The flakes are easy to meter in specified quantities when adding to cementitious products, because bulk quantities of the flakes flow well in conduits and other enclosed containers. The pulp flakes can supply sufficient cellulose fiber to an extrusion process due to the flakes' high fiber density. The pulp flakes have a wet dispersability that is comparable to some pulp sheets that have not been hammermilled. In one embodiment of the invention, a pulp flake is provided that has a wet dispersion of from about 60 to about 240 counts as measured by a standard British disintegrator. Another embodiment of a pulp flake has a density of from about 0.3 to about 0.7 g/cc. In one embodiment, the pulp flake has a size of from about 3 to about 5 mm .

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Sumner, WA, United States of America

Brian Wester