Powdered lignin

Patent metadata

Field	Value
Publication number	US-9610706-B2
Application number	US-201514607101-A
Country	US
Kind code	B2
Filing date	Jan 28, 2015
Priority date	Jan 28, 2014
Publication date	Apr 4, 2017
Grant date	Apr 4, 2017

Abstract

Lignin-containing mixtures and methods for making and using same. The lignin-containing mixture can include one or more lignin materials and one or more phenol-aldehyde resins. The mixture can include less than 10 wt % of water.

First claim

What is claimed is:

1. A lignin-containing mixture, comprising:
about 5 wt % to about 50 wt % of a lignin material and about 50 wt % to about 95 wt % of a phenol-aldehyde resin, based on a combined weight of the lignin material and the phenol-aldehyde resin, wherein:
the lignin material and the phenol-aldehyde resin are heterogeneously associated with one another,
the lignin material comprises less than 10 wt % of ash, as measured according to ASTM D2584-11, and
the mixture comprises less than 10 wt % of water.

2. The mixture of claim 1 , wherein the mixture has an explosion constant (K st ) of less than 300 bar m/s, as measured according to ASTM E-1226-12A.

3. The mixture of claim 1 , wherein the mixture has an explosion constant (K st ) of less than 200 bar m/s, as measured according to ASTM E-1226-12A, and a minimum ignition energy (MIE) of at least 500 mJ, as measured according to ASTM E-2019-03 (2013).

4. The mixture of claim 1 , wherein the mixture has a minimum ignition energy (MIE) of at least 100 mJ, as measured according to ASTM E-2019-03(2013).

5. The mixture of claim 1 , wherein the lignin material comprises kraft lignin.

6. The mixture of claim 1 , wherein lignin material has an average particle size of about 1 μm to about 80 μm, and wherein the phenol-aldehyde resin has an average particle size of about 20 μm to about 200 μm.

7. The mixture of claim 1 , wherein the lignin material has a maximum particle size of 200 μm, and wherein the phenol-aldehyde resin has a maximum particle size of 500 μm.

8. The mixture of claim 1 , wherein the lignin material is a powder, and wherein the phenol-aldehyde resin is a powder.

9. The mixture of claim 1 , wherein the mixture comprises about 5wt % to about 25 wt % of the lignin material and about 75 wt % to about 95 wt % of the phenol-aldehyde resin, based on the combined weight of the lignin material and the phenol-aldehyde resin.

10. The mixture of claim 1 , further comprising (1) a filler, (2) an extender, or (3) a filler and an extender.

11. The mixture of claim 10 , wherein the mixture comprises the extender, and wherein the extender comprises corn flour, soy flour, wheat flour, spray dried blood, or any mixture thereof.

12. The mixture of claim 10 , wherein the mixture comprises the filler, and wherein the filler comprises a nut shell, a seed shell, a fruit pit, an animal bone, an inorganic sulfate, a clay, a glass, an inorganic oxide, or any mixture thereof.

13. The mixture of claim 1 , wherein:
the lignin material comprises less than 3 wt % of water,
the lignin material has an average particle size of about 1 μm to about 30 μm and a maximum particle size of 200 μm,
the lignin material comprises kraft lignin,
the lignin material comprises less than 3 wt % of ash, as measured according to ASTM D2584-11,
the phenol-aldehyde resin comprises less than 3 wt % of water,
the phenol-aldehyde resin has an average particle size of about 30 μm to about 100 μm and a maximum particle size of 500 μm,
the phenol-aldehyde resin comprises a phenol-formaldehyde resin,
the mixture has an explosion constant (K st ) of less than 200 bar m/s, as measured according to ASTM E-1226-12A, and
the mixture has a minimum ignition energy (MIE) of at least 500 mJ, as measured according to ASTM E-2019-03(2013).

14. A lignin-containing mixture, comprising:
a powdered kraft lignin comprising less than 5 wt % of water and having an average particle size of about 1 μm to about 80 μm; and
a powdered phenol-formaldehyde resin comprising less than 5 wt % of water and having an average particle size of about 20 μm to about 200 μm, wherein:
the powdered kraft lignin and the phenol-aldehyde resin are heterogeneously associated with one another,
the powdered kraft lignin comprises less than 5 wt % of ash, as measured according to ASTM D2584-11,
the mixture comprises less than 10 wt % of water,
a weight ratio of the powdered kraft lignin to the powdered phenol-formaldehyde resin is about 5:95 to about 50:50, based on a dry weight of the mixture,
the mixture has an explosion constant (K st ) of less than 300 bar m/s, as measured according to ASTM E-1226-12A, and
the mixture has a minimum ignition energy (MIE) of at least 100 mJ, as measured according to ASTM E-2019-03(2013).

15. A method for making a lignin-containing mixture, comprising:
mixing a lignin material and a phenol-aldehyde resin to produce a mixture comprising about 5 wt % of the lignin material and about 50 wt % to about 95 wt % of the phenol-aldehyde resin, based on a combined weight of the lignin material and the phenol-aldehyde resin, wherein:
the lignin material and the phenol-aldehyde resin are heterogeneously associated with one another,
the lignin material comprises less than 10 wt % of ash, as measured according to ASTM D2584-11, and
the mixture comprises less than 10 wt % of water.

16. The method of claim 15 , wherein:
the lignin material has an average particle size of about 1μm to about 30 μm,
the phenol-aldehyde resin has an average particle size of about 30 μm to about 100 μm,
the lignin material comprises kraft lignin comprising less than 10 wt % of water, and
the phenol-aldehyde resin comprises less than 10 wt % of water.

17. The method of claim 15 , further comprising mixing (1) a filler, (2) an extender, or (3) a filler and an extender with the lignin material and the phenol-aldehyde resin to produce the mixture.

18. The method of claim 15 , wherein the mixture has a minimum ignition energy (MIE) of at least 100 mJ, as measured according to ASTM E-2019-03(2013), and an explosion constant (K st ) of less than 300 bar m/s, as measured according to ASTM E-1226-12A.

19. The mixture of claim 1 , further comprising (1) a filler, (2) an extender, or (3) a filler and an extender, wherein the lignin material has an average particle size of about 1 μm to about 80 μm and a maximum particle size of 200 μm, and wherein the phenol-aldehyde resin has an average particle size of about 20 μm to about 200 μm and a maximum particle size of 500 μm.

20. The mixture of claim 1 , further comprising (1) a filler, (2) an extender, or (3) a filler and an extender, wherein:
the extender comprises corn flour, soy flour, wheat flour, spray dried blood, or any mixture thereof,
the filler comprises a nut shell, a seed shell, a fruit pit, or any mixture thereof,
the lignin material has an average particle size of about 1 μm to about 80 μm and a maximum particle size of 200,
the phenol-aldehyde resin has an average particle size of about 20 μm to about 200 μm and a maximum particle size of 500 μm, and
the mixture comprises about 5 wt % to about 15 wt % of the lignin material and about 85wt % to about 95 wt % of the phenol-aldehyde resin, based on the combined weight of the lignin material and the phenol-aldehyde resin.

Assignees

• Georgia Pacific Chemicals Llc

Inventors

• Cothran John D
• Jing Feng

Classifications

• B27N3/002

  characterised by the type of binder (compositions of macromolecular compounds C08L) · CPC title

• B27N1/02 Primary

  Mixing the material with binding agent (mixing in general B01F) · CPC title

• C09J197/005

  Lignin · CPC title