Processes, methods, and systems for chemically mechanical cell disruption, and solid and liquid products produced thereby

Abstract

A process is disclosed that includes combining one or more additives with a feedstock comprising fibrous material including lignin, cellulose, and hemicellulose and water to obtain a first mixture, and conditioning the first mixture to obtain a liquid product and a dry pulp product. Also disclosed are the conditioning process and a machine for use in the conditioning process. Also disclosed are the liquid product, dry pulp product, and fiber pellets produced by the disclosed process, and methods for using them.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 749,919, filed Oct. 24, 2018, and the entire contents and gist thereof are incorporated herein by reference as if fully set forth below.

[0002] (Field of Disclosure) This disclosure generally relates to chemical - mechanical conditioning processes. In particular, each embodiment of this disclosure relates to solid and liquid products produced by a chemical - mechanical cell disruption process, its manufacturing system and use system, as well as manufacturing methods and use methods.

Background Art

[0003] Converting raw materials into value-added products that can be used is an invariant area of human innovation that is constantly evolving. Lignocellulosic materials or other lignocellulosic-based materials can be processed into value-added products that can be used, such as paper, packaging materials, biofuels, pellets, etc. The current problem with such processes, like any process, is the high energy input and the addition of strong chemicals required to obtain useful products. When processing lignocellulosic materials, a large amount of shaft work is required to grind the materials to the desired size, and a large amount of additional energy (such as heat and / or pressure) and chemicals (such as strong acids or strong bases) are required to remove excess moisture and inhibitory components. Furthermore, the temperature rise due to the added heat may cause evaporation of the organic raw materials and / or conversion to harmful volatile organic compounds (VOCs), and the VOCs are released into the atmosphere. In some cases, additional energy-intensive and cost-intensive measures must be taken to further treat the released VOCs and other hazardous waste generated during the process. It is desirable to manufacture useful products energy-efficiently without using dangerous and strong chemicals to expand the design space of many industries such as construction / infra, architecture, energy, energy production, packaging, turf / garden products, agriculture, food production, and pollution prevention. Furthermore, it is desirable to retain the content of organic raw materials such as VOCs, nutrients, and organic acids to obtain other useful by-products during processing. Such by-products present attractive opportunities to manufacture value-added products and improve the margin of processing.

[0004] Therefore, there is a need for processes, methods, and systems for manufacturing solid and liquid products from lignocellulosic (or other) raw materials in an energy-efficient and clean manner (i.e., without adding strong chemicals) without releasing harmful by-products such as VOCs. Embodiments of the present disclosure address this need and other needs that will become apparent when the following description is read in conjunction with the drawings. SUMMARY OF THE INVENTION

[0005] This disclosure generally relates to chemical mechanical conditioning processes. In particular, embodiments of the present disclosure relate to solid and liquid products produced by a chemical mechanical cell disruption process, its manufacturing system and use system, as well as manufacturing methods and use methods. An exemplary embodiment of the present invention may provide a process including obtaining a first mixture by combining one or more additives with a raw material containing a fibrous material and water, and conditioning the first mixture to obtain a liquid product and a dry pulp product.

[0006] In any of the embodiments disclosed herein, the fibrous material includes cellulose.

[0007] In any of the embodiments disclosed herein, the fibrous material further includes lignin and hemicellulose.

[0008] In any of the embodiments disclosed herein, the amount of water contained in the raw material is about 10% by weight or more and about 90% by weight or less based on the total weight of the raw material.

[0009] In any of the embodiments disclosed herein, the dry pulp product contains water in an amount of about 35% by weight or less based on the total weight of the dry pulp product.

[0010] In any of the embodiments disclosed herein, the liquid product contains water in an amount of about 50% by weight or more based on the total weight of the liquid product.

[0011] In any of the embodiments disclosed herein, the conditioning includes applying a shear force to the first mixture to increase the pressure of the first mixture and disrupting a plurality of cells of the fibrous material in the first mixture.

[0012] In any of the embodiments disclosed herein, the above adjustment further includes mixing an additive with the fibrous material of the first mixture to form a treated material, removing a first portion of water from the treated material, solubilizing the additive with the first portion of water, and weakening the cell walls of a plurality of cells of the fibrous material in the treated material.

[0013] In any of the embodiments disclosed herein, the above weakening includes reacting the additive with lignin in the cell wall.

[0014] In any of the embodiments disclosed herein, the above adjustment further includes applying a shear force to the treated material to increase the pressure and temperature of the treated material, evaporating a second portion of water in the treated material by separating the fibrous material in the treated material, and releasing the treated material to atmospheric pressure to induce the explosion of a plurality of cells of the fibrous material.

[0015] In any of the embodiments disclosed herein, the above liquid product contains at least 75% of the VOCs present in the raw materials.

[0016] In any of the embodiments disclosed herein, the above adjustment is performed at a maximum temperature of about 200°F or more and about 350°F or less.

[0017] In any of the embodiments disclosed herein, the above additive includes a surfactant.

[0018] In any of the embodiments disclosed herein, the above additive has a molecular weight of about 30 g / mol or more and about 10,000,000 g / mol or less.

[0019] In any of the embodiments disclosed herein, the above process further includes pelletizing the dry solid product to form pellets.

[0020] In any of the embodiments disclosed herein, the liquid product comprises one or more biostimulant compounds and water.

[0021] In any of the embodiments disclosed herein, the one or more biostimulant compounds comprise one or more of minerals, proteins, amino acids, humic acids, fulvic acids, and one or more organic acids.

[0022] In any of the embodiments disclosed herein, the minerals comprise one or more of potassium, phosphors, phosphorus, nitrogen compounds, calcium, magnesium, sulfur, sulfurous, sodium, iron, manganese, zinc, and copper.

[0023] In any of the embodiments disclosed herein, the liquid product further comprises one or more of cellulose, lignin, and hemicellulose.

[0024] An exemplary embodiment of the present invention may provide a dried pulp product produced by any of the processes disclosed herein.

[0025] Another exemplary embodiment of the present invention may provide a liquid product produced by any of the processes disclosed herein.

[0026] Another embodiment of the present invention may provide a chemo-mechanical cell disruption process comprising mixing one or more additives with a fiber material containing water, removing a first portion of water from the fiber material, solubilizing the additives with the first portion of water, weakening the cell walls of a plurality of cells of the fiber material, applying a shear force to the fiber material to increase the pressure and temperature of the fiber material, evaporating a second portion of water in the fiber material by fractionating the fiber material, and releasing the fiber material to atmospheric pressure to induce the disruption of a plurality of cells in the fiber material.

[0027] In any of the embodiments disclosed herein, when mixing a fibrous material with one or more additives, the amount of water contained in the fibrous material is about 5% by weight or more and about 90% by weight or less based on the total weight of the fibrous material.

[0028] In any of the embodiments disclosed herein, when exposing the fibrous material to atmospheric pressure to induce the bursting of a plurality of cells, the amount of water contained in the fibrous material is about 35% by weight or less based on the total weight of the fibrous material.

[0029] In any of the embodiments disclosed herein, the above process is carried out at a maximum temperature of about 200°F or more and about 350°F or less.

[0030] In any of the embodiments disclosed herein, the above additive includes a surfactant.

[0031] In any of the embodiments disclosed herein, the above additive has a molecular weight of about 30 g / mol or more and about 10,000,000 g / mol or less.

[0032] An exemplary embodiment of the present invention may provide a fibrous pulp material produced by any of the processes disclosed herein.

[0033] An exemplary embodiment of the present invention may provide a liquid produced by any of the processes disclosed herein and containing solid fine particles, one or more biostimulating compounds, and water.

[0034] In any of the embodiments disclosed herein, the above one or more biostimulating compounds include one or more of minerals, proteins, amino acids, humic acids, fulvic acids, and one or more organic acids.

[0035] In any of the embodiments disclosed herein, the above one or more organic acids are present in the liquid in an amount of about 0.001% by weight or more and about 10% by weight or less based on the total weight of the liquid.

[0036] In any of the embodiments disclosed herein, the water is present in the liquid in an amount of about 50% by weight or more and about 90% by weight or less based on the total weight of the liquid.

[0037] In any of the embodiments disclosed herein, the liquid further contains lignin, and the lignin is present in the liquid in an amount of about 0.01% by weight or more and about 75% by weight or less based on the total weight of the liquid.

[0038] In any of the embodiments disclosed herein, the minerals include one or more of potassium, phosphorus, nitrogen compounds, calcium, magnesium, sulfur, sodium, iron, manganese, zinc, and copper.

[0039] In any of the embodiments disclosed herein, the solid fine particles have a dry matter weight percentage of about 0.0001% or more and about 50% or less based on the total weight of the liquid.

[0040] An exemplary embodiment of the present disclosure may provide a method for promoting plant growth, which includes administering a liquid obtained by any of the processes disclosed herein to a plant.

[0041] Another embodiment of the present disclosure may provide a fiber pellet, which includes a fibrous material containing a plurality of exposed cellulose fibers, wherein each of the plurality of exposed cellulose fibers is entangled with at least one other exposed cellulose fiber, and water in an amount of about 35% or less based on the total weight of the fiber pellet.

[0042] In any of the embodiments disclosed herein, the fibrous material further includes one or more of lignin and hemicellulose.

[0043] In any of the embodiments disclosed herein, the plurality of exposed cellulose fibers include twisted fibers.

[0044] In any of the embodiments disclosed herein, the fiber pellet has a pellet durability index (PDI) of 75 or more.

[0045] In any of the embodiments disclosed herein, the fiber material includes fibers having an average maximum cross-sectional size of about 100 nanometers to about 1000 microns.

[0046] In any of the embodiments disclosed herein, the fiber pellet does not contain a binder.

[0047] In any of the embodiments disclosed herein, the fiber pellet has a bulk density of about 15 kg / m 3 or more and about 800 kg / m 3 or less.

[0048] In any of the embodiments disclosed herein, the plurality of exposed cellulose fibers are present in the fiber pellet in an amount of 2% by weight or more based on the total weight of the pellet.

[0049] In any of the embodiments disclosed herein, the plurality of exposed cellulose fibers are present in the fiber pellet in an amount of 5% by weight or more based on the total weight of the pellet.

[0050] In any of the embodiments disclosed herein, the plurality of exposed cellulose fibers are present in the fiber pellet in an amount of 5% by weight or more and 80% by weight or less based on the total weight of the pellet.

[0051] In any of the embodiments disclosed herein, the plurality of exposed cellulose fibers are present in the fiber pellet in an amount of 5% by weight or more and 60% by weight or less based on the total weight of the pellet.

[0052] In any of the embodiments disclosed herein, the plurality of exposed cellulose fibers are present in the fiber pellet in an amount of 5% by weight or more and 50% by weight or less based on the total weight of the pellet.

[0053] In any of the embodiments disclosed herein, the fiber material is present in the fiber pellets in an amount of 99.99 wt% or more based on the total weight of the pellets.

[0054] Another embodiment of the present disclosure is a process for increasing the raw material throughput, comprising mixing one or more additives with a raw material comprising a fiber material containing cellulose and water to obtain a first mixture, and densifying the raw material to obtain a product, wherein the throughput of the process is increased by 1 to 30% compared to the process without additives.

[0055] In any of the embodiments disclosed herein, the water is present in the raw material in an amount of about 5 wt% or more and about 30 wt% or less based on the total weight of the raw material.

[0056] In any of the embodiments disclosed herein, the fiber material further comprises lignin.

[0057] In any of the embodiments disclosed herein, the raw material comprises one or more of grains, grasses, cellulosic materials and lignocellulosic materials, bones, food industry processing wastes, and combinations thereof.

[0058] In any of the embodiments disclosed herein, the densifying includes forming the product into one or more of pellets, briquettes, bales, logs, cubes, and combinations thereof.

[0059] These and other aspects of the invention will be described in the following detailed description of the invention and the accompanying drawings. Other aspects and features of the embodiments of the invention will be apparent to those skilled in the art upon consideration of the following description of specific exemplary embodiments of the invention in conjunction with the drawings. Although the features of the invention may be described with respect to certain embodiments and drawings, all embodiments of the invention may include one or more of the features described herein. Also, although one or more embodiments may be described as having certain advantageous features, one or more of such features may be used in various embodiments of the invention described herein. Similarly, although exemplary embodiments may be described below as embodiments of an apparatus, system, or method, it should be understood that such exemplary embodiments may be implemented in various apparatuses, systems, and methods of the invention.

[0060] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the subject matter disclosed herein and serve to explain the principles of the subject matter disclosed herein. These drawings are not intended to limit the scope of the subject matter disclosed herein in any way.

Brief Description of the Drawings

[0061]

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Mode for Carrying Out the Invention

[0062] This specification discloses a comprehensive solution for a process based on compression fragmentation that simultaneously dehydrates, dries, fractionates, extracts, and separates cell-based (biological) materials, particularly materials that are considered difficult to handle in terms of being industrially difficult to process and that have liquid by-products with market value. The techniques disclosed in this specification are independent of the state of biological materials. For example, in addition to the treatment of undried (green) lignocellulosic raw materials, the techniques disclosed in this specification can be very well applied to the treatment of cellulosic used materials such as coffee beans, waste paper, wood-based construction waste, poultry residues such as poultry litter and feathers, biosolids, and compost production.

[0063] As another example, when a liquid extract from Kamogaya was applied to a test lawn, dandelions were removed and the grass grew rapidly. As a result, local governments or lawn mowing contractors can process the cut grass and reapply the extract to the lawn. There are broad attractions in avoiding water conservation and strong fertilizers. Grass extracts also hold further potential. In another test, the Kamogaya extract was processed by heating. The protein coagulated, and as a result, this process became suitable for the much sought-after leaf protein concentrate applications and a highly viable alternative to the Pro-Xan process. Such progress could greatly expand the design space of, for example, the "protein without meat" market.

[0064] The technology disclosed herein not only dehydrates, dries, separates, extracts, and isolates plant materials simultaneously, but also fundamentally changes the resulting fibers with fully exposed plant cells. All of this enables the material to be used for follow-up processing for many industrial applications such as bioenergy raw materials, advanced material production, absorbent manufacturing, soil improvement, water filtration systems, strengthening agents for the construction industry, input into biopharmaceuticals, fungal and yeast substrates, and so on. Some examples of these will be outlined below.

[0065] The technology disclosed herein can condition lignocellulose to an extent optimized for input into industries that utilize pulp, such as the paper industry and fiberboard manufacturing. A significant reduction in particle size enables faster conversion. Many products become feasible, among which notable are carbonized products such as graphene. Regarding graphene, such a process enables lower-cost production and can be added to fabrics for the purposes of better aesthetics and better performance in terms of water absorption and dissipation and insect prevention (e.g., mosquitoes). Graphene is also perfectly suitable as an input material for degradable electronic devices, renewable carbon materials for electrochemical energy storage, and circuit boards, and is a replacement for the millions of tons of hazardous and harmful substances carried into landfills around the world every year.

[0066] Furthermore, an advanced process has been developed that utilizes organic phenolic chemicals such as humic acid as components for advanced materials used in green energy systems such as supercapacitors. The liquid extract produced by the process of the present disclosure can be rich in humic acid, fulvic acid, and other organic acids.

[0067] The environmental problems imposed by the global plastic supply surplus require solutions for recycling. By utilizing the products of the present disclosure, the use of plastics can be reduced. Such materials are often referred to as wood-plastic composites. When combined with the products of the present disclosure, better cross-linking can occur with plastic raw materials. This improved effect enables the improvement of consumer goods such as composite decking materials. Also, the products disclosed herein provide a small particle size necessary to mimic the appearance of real wood and achieve property improvements.

[0068] Research is also underway to produce sustainable polymers composed of carboxylic acids that prevent the atomization of jet fuel during collisions. Certain products of the present disclosure are rich in organic carboxylic acids.

[0069] Although 3D printing is currently mainstream, the overwhelming majority of materials used are mainly synthetic materials. The products of the present disclosure can be used as filaments for 3D printing due to their improved form factor and small particle size.

[0070] Cellulose nanomaterials such as nanocrystals and nanofibrils are very small cylindrical particles produced from lignocellulosic materials. This technology can accelerate their production and reduce related costs. Cellulose nanomaterials are currently used in various applications such as chemical manufacturing, pulp and paper, composites, food packaging, and cosmetics in many industries, fields, and academic disciplines around the world.

[0071] Cellulose nanocrystals are excellent nanomaterials derived from the most abundant and almost inexhaustible natural polymers such as cellulose. This material holds wide and exciting possibilities in many industries. Exposed cellulose, which was once considered extremely costly to obtain from sources such as trees, can now be converted into nanocrystals used in medicine, materials science, and electronics engineering. The techniques disclosed herein can condition wood fibers by aggregating lignin into exposed "drops" on the cellulose surface, resulting in a more exposed state of cellulose. This effect enables the development of an industrial process for producing cellulose nanocrystals by removing lignin in a more cost-effective and environmentally friendly way.

[0072] The processes and products of the present disclosure can function as raw materials enabling the production of sustainable polymers from fragrance molecules often contained in aromatic species such as pine, larch, and eucalyptus. Considering the struggles arising from polymers and plastics manufactured from conventional petroleum-based raw materials, which have become apparent in today's world, such processes of the present disclosure can provide improvements in polymer production.

[0073] In recent years, advancements in electrochemistry have been made to simplify the creation of beneficial and desired molecules used in drugs, electronic devices, etc. The processes of the present disclosure can generate important reactive intermediate molecules known as carbocations, which are necessary for the ether synthesis from inexpensive carboxylic acids. The products by the techniques disclosed herein are rich in carboxylic acids, thereby providing even more inexpensive raw materials for this extremely important process.

[0074] Many uses in horticulture become available by a unique and cost-effective method that can condition raw, undried lignocellulosic materials according to the techniques of the present disclosure. The range of these uses extends from replacing unsustainable growing substrates such as peat and other non-recyclable materials, to achieving highly effective organic soil improvement and applying liquid extracts as organic fertilizers.

[0075] It has been found that the products of the present disclosure, produced by chemo-mechanical cell disruption of lignocellulosic materials, can store cut plants such as industrial hemp, tomato stems, and / or succulents for extended periods before planting them in soil for rooting. Applying these products to vegetables also allows those vegetables to be stored due to their long storage life.

[0076] Typical greenhouse substrates consist of peat and perlite. Peat is a hydrocarbon and is non-renewable. The processes of the present disclosure can produce woody raw materials in a form factor that contributes to the growth medium. A portion of the products according to the technology can be used in place of a portion of the peat, thereby reducing the dependence on hydrocarbons. Furthermore, the products of the present disclosure can essentially function as an inoculated mushroom growth medium. Due to the expanded form factor, these products can also be compressed into growth mats and erosion control mats, and it is achieved at a significantly reduced cost.

[0077] Hydromulch is a fiber / grass seed / fertilizer mixture applied to steep slopes where erosion can occur. Currently, mechanically processed wood fibers are used as the substrate. In contrast, the products of the present disclosure can provide a superior product that is produced at a much lower price with substantially less energy and emissions. As a result, there is less topsoil erosion and cleaner waterways. Hydroseeding is a mixture of grass seed, fertilizer, and wood fiber. The products of the present disclosure can achieve higher hygroscopicity and thus help promote seed germination.

[0078] The demand for natural and organic foods is increasing rapidly. Conversely, conventional agriculture causes the loss of soil vitality. The products of the present disclosure can create a soil environment that attracts the necessary microbial activities essential for the fixation of nitrogen and other nutrients in the soil due to the properties formed by organic acids, sugars, humic / fulvic acids, and a very diverse amount of amino acids.

[0079] The technology disclosed herein may enable the extraction of biostimulants contained in willow and other water-rich raw materials that were once considered ineffective for treatment due to the associated costs. Furthermore, the characteristics of the products of the present disclosure may provide very specific gene expression and gene regulation that were once considered impossible by organic matter. The pure nature and amount of the contained organic chemicals, such as the various glutamine concentrations contained in various species, provide a very effective horticultural method. For example, a liquid extract produced by the process of the present disclosure using broadleaf tree species can be used as a pecan cloning agent. Pecan trees may be grown from seeds or cloned from the trunk of a living tree. The cloning process has challenges for the survival of the clones. The earlier the clones can add healthy roots, the more dramatically their chances of survival increase. The numerous organic acids contained in the products of the present disclosure are components for generating growth hormones that stimulate healthy and rapid root growth.

[0080] As another example, with respect to certain species of raw materials, particularly with respect to raw materials of bark components, the technology disclosed herein can extract a significant amount of tannins. Research has proven that significant changes in soluble nitrogen appear in the soil after the regular application of tannins and related phenolic compounds. These tannins are utilized as substrates by soil microorganisms, thereby increasing the microbial demand for nitrogen and its immobilization into the microbial biomass. This increase leads to more nitrogen being fixed by the microorganisms, making more nitrogen available for plants.

[0081] The products of the present disclosure can also be provided to the horticultural market, which has a pest control mechanism and a defense mechanism against pests and was once considered an exclusive domain of synthetic chemicals. The allelopathic effect enabled by the products disclosed herein can function, for example, as follows. That is, the liquid extract can enable a new and sustainable approach to weed control. The liquid extract obtained from broad-leaved trees can also be very effective in controlling nematodes, which is essential for protecting millions of dollars' worth of agricultural products. The various combinations of phenols and the over-application of other biostimulants and amino acids are very effective growth control options for synthetic chemicals.

[0082] The technologies disclosed herein, such as fibers and liquid extracts manufactured from fibers, provide input materials that have not been available in the construction market. The availability of fibers can activate the development of newly designed lumber, concrete, and asphalt formulations, resins, and preservatives.

[0083] Wood fibers are very good sound insulation materials. Such products are popular in Europe and are also spreading in the United States. The products of the present disclosure can provide even better sound insulation through improved densification with smaller particle sizes. Such products of the present disclosure can also enable improved fiber-based boards or particle-based boards, such as medium-density fiber (MDF). In the case of applications such as fiber cement siding, the expanded format of the products disclosed herein can provide additional support for concrete-based siding. The technologies disclosed herein also enable the use of alternative board materials, such as giant reed, thereby improving the carbon cycle for the environment. The format of the products of the present disclosure can also reduce the binders used in board structures, thereby providing another environmental advantage.

[0084] The products of the present disclosure can also be used in the advancement of engineering boards and siding. Lignin is a major component of lignocellulosic fibers and is composed of various phenolic groups. Using the phenolic groups contained in the extract, it has become possible to construct sustainable foam boards. This has been made possible by the fact that the present technology can generate a part of the lignin contained in lignocellulosic fibers as solubilized in a liquid extract. These extracted phenols can be utilized in the formulation of foam boards.

[0085] The products disclosed herein can also be useful for reinforcing concrete. To support high loads in concrete, it is necessary to reinforce the concrete. Typically, steel bars are used to reinforce concrete. The products of the present disclosure can be a very excellent reinforcing mechanism for concrete.

[0086] The technology disclosed herein can be used to manufacture engineered bamboo articles such as flooring materials. Bamboo needs to be decomposed before being converted into value-added products. The process of the present disclosure may enable the decomposition of bamboo fibers into materials that can be easily converted into useful products such as bamboo composite boards and bamboo flooring materials.

[0087] The technology disclosed herein may enable the partial removal of lignin from lignocellulosic fibers. This lignin can be recovered in a liquid extract. The lignin can be isolated from this extract and utilized as a component of natural asphalt.

[0088] From certain species of wood such as teak and red oak, the technology disclosed herein produces liquid extracts that can act as natural wood preservatives. Such a process is generally referred to as acetylation. The acetic acid contained in the extract can create an environment free from mold. Although it was once considered insufficient and not adaptable to scale-up to an industrial scale that is cost-effective, the technology disclosed herein may enable acetylation.

[0089] The technology disclosed in this specification can greatly contribute to the environmental market and the environmental improvement market. The products of this disclosure can create various adsorbents and filter materials, and can also accelerate the composting of biosolids. Adsorbents are used in almost all industrial applications where spillage can be a problem. The products disclosed herein can exhibit much higher absorbency than commonly used materials such as clay or sawdust.

[0090] Filtration is part of many industrial processes. Wood fibers are used in many applications. The filtration effect is directly correlated with the surface area of the filter material. The products of this technology can provide a significantly larger surface area than typical machined wood fibers. The processes disclosed herein also have a very high degree of scalability, thereby enabling the addressing of major problems such as the control of red tides and algal problems caused by the outflow of fertilizers.

[0091] Biosolids have become a very big problem in the world. Disposal by soil utilization has proven to be a suboptimal mechanism as it contains metals and other substances. Composting is rapidly becoming a preferred disposal method. The products manufactured by this technology may contain sugars and other molecules that rapidly accelerate the growth of the essential bacteria required. Subsequently, the metabolites of these bacteria increase based on the already high nutrient concentrations contained in the composted biosolids.

[0092] Furthermore, products manufactured by the technology of the present disclosure may richly contain amino acids, which have been found to be very beneficial phytopharmaceutical input materials for combating cancer and other diseases. Diethyl ether extracts and alkaloids can enable anti-cancer agents for the treatment of breast cancer and dysfunctional diseases against human health. Furthermore, it has been found that the quantitative decrease in short-chain fatty acids, particularly butyrate, contributes to the progression of chronic kidney disease and stomach problems. The products disclosed herein may richly contain such short-chain fatty acids when fermented and processed. Depending on the type of raw material, these products may also contain berberine, which helps reduce sugar and leads to maintaining healthy cholesterol levels, and this becomes a powerful tool for the treatment of diabetes.

[0093] Furthermore, various plant-based and non-plant-based raw materials can be extracted for specific pharmaceutical use. This technology is very effective during the processing of hemp and cannabis. Liquid extracts provide beneficial cannabinoids and other functional foods that offer new treatment methods. The various antibacterial properties of flavonoids from the kino (sap) of the eucalyptus tree are also made possible by the inventors' technology.

[0094] This technology can greatly contribute to applications related to human health. Various components of the products disclosed herein can be used to manufacture insecticides and pesticides from intractable foreign raw materials such as oak and bloodroot. This technology also enables very low-cost products for aromatherapy and other terpenes for the input of engineered aromas into cannabis and specialized / engineered wines.

[0095] Experiments are also underway to use this technology to manufacture insoluble dietary fiber and include it as a food additive. Many studies have shown that when good bacteria utilize this type of insoluble fiber as a substrate during the movement of the stomach in the body, physiological and psychological improvements are enhanced.

[0096] Apart from the advantages of the stomach, the short-chain and medium-chain fatty acids made available through the products of the present disclosure can exhibit antibacterial activity against oral bacteria. This type of treatment can contribute to the prevention of tooth and gum diseases.

[0097] Mold has been intensifying as a housing problem for decades. Strongly stimulating chemicals and sprays are the conventional approaches to eradicating the problem. However, by using the products of the present disclosure manufactured from broad-leaved trees and other raw materials rich in phenols, this technology may enable an organic mold control mechanism for moldy basements and the like.

[0098] The technology disclosed herein can be immediately and directly applied to the agricultural market. The disclosed products can not only improve the health of animals when added to feed and drinking water, but also enhance litter and flooring applications. The disclosed products can also be directly applied to the prevention and treatment of animal diseases and illnesses. Furthermore, this technology can contribute to forestry and thereby participate in the circular economy when applied to specially cultivated wood fibers.

[0099] Products such as the fiber materials disclosed herein have a very large surface area and can thus create highly absorbent animal bedding. Due to this attribute, it is possible to manage harmful moisture and deodorization (e.g., ammonia). These products can also be very effective for drying and warming certain species of livestock. For example, piglets are often covered with moisture at birth and have highly sensitive skin. By applying such fiber materials to the skin of piglets after birth, moisture can be rapidly absorbed and dissipated, drying the skin and thereby enabling the body temperature to rise more quickly.

[0100] Due to its large surface area, it is now also possible to produce biochar more efficiently than by conventional methods. Biochar is also a very effective adsorbent and is particularly effective at capturing ammonia. Mixing biochar into the products of the present disclosure can create a healthier environment for livestock, particularly poultry, where moisture and ammonia are problems.

[0101] From the perspective of animal feed, this technology can contribute to the growth and care of many species, including fish. The organic acids in the products of the present disclosure can function as an alternative to antibiotics. Research has shown that pigs fed a diet containing organic acids have improved average daily feed consumption and average daily weight gain. Some products of the present disclosure may contain tryptophan and a very small particle size fibrous substrate with a form factor similar to fermentation residues. Tryptophan is an essential amino acid important for stimulating feed intake and thus growth performance in the diet of pigs. Since monogastric organisms such as pigs do not produce tryptophan, tryptophan must be included as part of a nutritional supplement.

[0102] The products of the present disclosure can also function as a very effective substrate for various yeasts such as Candida Utilis that produce protein. These proteins have the potential to be an alternative to fish feed. Additionally, for some exotic fish with a digestive system like ruminants, the exposed cellulose shown in the products of the present disclosure can be digested more rapidly as a food source. Finally, raw materials such as seaweed and other high-protein herbaceous raw materials can be processed by this technology into alternative plant-based proteins. By using plant-based proteins instead of conventional fishmeal, a fairly large environmental benefit can be obtained.

[0103] Regarding ruminants such as cows, sheep, and goats, the present technology can provide several advantages. The digestive system of ruminants has the potential to digest lignocellulosic materials if the contained lignin is sufficiently conditioned to expose the cellulose. The technology disclosed herein can collect lignin in "droplets", making the cellulose more accessible to cellulase in the animal's intestine, thereby improving digestion and nutritional status. Certain species of wood (e.g., lodgepole pine), which contain a lot of arabinogalactan, lignin, flavonoids, and diterpenes, have also been shown to promote the health of the cow's liver. Making these types of raw materials, especially those that were once considered too difficult to handle, available to ruminants will have a global impact in relation to human nutrition and well-being.

[0104] A certain size of lignocellulosic fiber and a specially designed form factor may enable the targeted activation of organic acids such as butyrate-2, which will generate a specific microbiota in the animal's intestine. The ability of the present technology to process different fiber form factors for each species is extremely important for the commercialization of this process. The beneficial modulation of the gut microbiome is also "butterflied" into a number of metabolic changes and interdependent pathways that produce short-chain fatty acids. These types of prebiotic products are essential for the livestock industry to meet the demand for natural foods.

[0105] The technology disclosed herein can also be for poultry. Recent consumers are avoiding poultry given antibiotics. Antibiotics improve the health and survivability of poultry, but traces of these antibiotics may remain in the birds after slaughter. Tannins have been shown to counter the growth of pathogens in poultry farming because they have antibacterial properties similar to fatty acids. Products disclosed herein, such as liquid extracts, can contain and create beneficial fatty acids and tannins. Therefore, the products of the present disclosure can be included in the poultry feeding system and the water supply system to improve the health of the birds without adding synthetic antibiotics.

[0106] In recent findings, butyric acid produced by the fermentation of certain products of the present disclosure has been found to reduce the occurrence of woody breast in commercial broilers in the poultry industry when mixed with zinc. Woody breast refers to a quality problem caused by muscle abnormalities in a small part of chicken meat. This does not pose a health risk to consumers but can cause the meat to be considered undesirable.

[0107] This technology can also be applied to forestry agriculture, generally referred to as tree farming. Forestry agriculture is a type of agriculture that involves planting, caring for, and maintaining trees or other woody plants. Since the products of the present disclosure are originally obtained from the xylem and phloem of trees, once extracted and processed, they can provide nutrient formulations and care products for this industry. Before this technology, the liquid in trees was evaporated from the fibers and converted into volatile organic compounds, which caused problems with emission regulations.

[0108] The technology disclosed herein can directly contribute to the production of sustainable and clean energy. The applications can range from biofuels and biorefineries to wood pellets and even the conventional fuel hydraulic fracturing industry.

[0109] This technology can utilize undried (wet) raw materials to produce sized and separated fibers that directly create high-durability, low-moisture, high-energy wood pellets. This can be done without using conventional sizing machines such as hammer mills and without requiring very expensive indirect drying systems. Avoiding these systems and their associated capital and operating costs represents a revolutionary paradigm shift in the wood pellet industry. That is, it eliminates the dependence on subsidies and leads to a paradigm shift that provides an alternative to industrial processing on a global scale and very readily available raw materials such as forestry residues and agricultural residues, bamboo, aquatic biomass (e.g., algae, seaweed, kelp, etc.), and other high-moisture species that were once considered too wet to process.

[0110] The technology disclosed herein can also contribute to the value of conventional pelleting methods. Producing high-quality wood pellets by conventional means is a difficult task. Aiming to improve the durability of the pellets, manufacturers have widely searched for effective binders to improve the durability of the pellets. Products of this disclosure, such as dried pulp products, can enable further densification of the pellets and better utilization of lignin for binding when mixed with wood fibers dried by conventional methods.

[0111] The cellulose component of lignocellulosic fibers has always been a promising base stock for the production of cellulosic ethanol. However, to be a viable feedstock, it is necessary to remove lignin to some extent by a biorefinery so that the cellulose is sufficiently exposed to specific cellulases. The processes of the present disclosure can enable the exposure and partial removal of lignin. Further processing may make it possible to easily remove the remaining lignin. Additionally, by using a low operating temperature, the formation of inhibitory components that can adversely affect the effectiveness of cellulases can be prevented. These processes increase the exposure of cellulose and enhance the effectiveness of the enzymes. Such products can also be applied to the production of biobutanol and other bioenergy products. The format of certain products obtained by the techniques disclosed herein is also suitable for enabling cleaner biorefining techniques. Such techniques include, but are not limited to, the organosolv process and the simultaneous saccharification and fermentation (SSF) process.

[0112] The present technology can also be applied to the drilling industry such as for natural gas and oil. For example, in the drilling industry, lost circulation materials are widely used. Lost circulation materials help delay the loss of mud into fractures or highly permeable formations. Since the technology disclosed herein enables the production of smaller particle sizes, products with better fluidity and permeability can be made to seal the cracks and fissures associated with oil drilling. As another example, the tannates obtained from the products of the present technology have been found to be very good and environmentally safe drilling fluids.

[0113] The technology disclosed herein can also directly contribute to the food and beverage market. The products of the present technology can be used to improve several related sensations, including, but not limited to, flavor enhancement, taste, and odor enhancement. These products can also be involved in improving nutrition and the production of sweeteners and can also be involved as an adjunct ingredient in wheat flour-containing foods.

[0114] By utilizing the tannins in the products of the present disclosure, specifically the ellagitannins contained therein, wine producers can design the "dryness" of the products and mimic the effects obtained in the time-consuming oxidation process that was conventionally enabled by oak barrels.

[0115] Similarly, some of the phenolic compounds contained in the products of the present disclosure can supplement food as nutritional value, and the anthocyanins of certain lignocellulosic species have been proven to improve cognitive function.

[0116] As another example, after pulping, the SSF method can be utilized to use the produced acetoin as a food flavor in baked foods. This technology can also be very actively involved in the production of Torula yeast, scientifically known as Candida utilis. The products of the present disclosure can serve as substrates for its growth. Torula yeast is widely used as a flavor in processed foods and pet foods. The foam factor of other products of the present disclosure can also accelerate the production of food-grade cellulose. This product is usually included as a thickening and bulking agent for tomato sauce, salad dressing, ice cream, energy bars, pasta, bread, and many other products.

[0117] This technology can also very effectively contribute to the production of xylitol, a natural alcohol contained in certain lignocellulosic raw materials. Xylitol is widely used as a sugar substitute in "sugar-free" chewing gum, mints, and other candies. The process of the present disclosure can condition raw materials such as birch at a much higher cost-effectiveness and reduce the overall cost. It also enables markets such as paper pulp and biorefineries to provide a by-product stream that was previously lost.

[0118] Pulp is a fibrous material produced chemically or mechanically (or by some combination of chemical and mechanical means) from wood or other cellulosic raw materials. Wood cells have non-living cell walls composed of cellulose fibers, hemicellulose, and lignin, and lignin gives strength to and supports the cell walls. Lignin binds the cellulose fibers together in the cell walls. Therefore, lignin must be removed in order to separate the individual cellulose fibers that will ultimately become paper.

[0119] Conventional pulping processes cause very difficult environmental problems. In fact, the industry has traditionally been one of the largest emitters of industrial exhaust, industrial wastewater, and industrial waste in the world, mainly due to the strong chemicals used. Thousands of tons of pollutants are released every year. The industry is also one of the largest consumers of energy and water in the world, using more water to produce one ton of product than any other industry.

[0120] The industry is under very great pressure from society to address these problems. Research is being conducted on the development of sustainable pulping mechanisms, including the use of environmentally friendly chemicals and a low-energy approach to the mechanical conditioning of raw materials.

[0121] Steam explosion is a very promising process for the industry. However, in its conventional form, it presents many economic problems, including insufficient destruction of lignin-carbohydrate conjugates and the potential for the formation of fermentation-inhibiting components in the case of biorefineries and paper applications. Furthermore, for the engineered lumber sector, it is also necessary to dry the fibers before further processing.

[0122] The technology disclosed in this specification can provide substantial advantages over both conventional processes and steam explosion processes. For conventional processes, strong stimulating chemicals are not used, and little or no decomposition of monosaccharides occurs. The energy requirements are considerably low, and no environmental problems occur. In contrast, the products disclosed in this specification, such as liquid products, can acquire soil nutrients for application and tree biologics. The resulting fibers are also very susceptible to the action of cellulase.

[0123] From the perspectives of biorefining and papermaking, the effects of the process of the present disclosure enable a cost-effective pulping process such as organosolv pulping. This method uses organic solvents to decompose lignin and hemicellulose. This method is considered to be the cleanest among the modern methods used today.

[0124] From the perspective of products, this technology can also significantly reduce the costs required for the production of corrugated cardboard, molded pulp, and fluff pulp. Most of the raw materials required to manufacture these products today are obtained from the recycling industry. A lot of processing is required to make this raw material clean and useful again, resulting in further environmental problems.

[0125] Engineered lumber includes manufactured wood products produced by binding fibers together with adhesives or other fixing methods for forming composite materials. This technology can directly contribute to the production of densified wood, medium-density fiberboard (MDF), and particleboard. This technology can also directly contribute to the developing market for transparent wood.

[0126] All of the aforementioned engineered wood products are manufactured from wood chips, sawmill waste, or even wood shavings, and synthetic resins or other suitable binders that have been press-formed and extruded. Conventionally, it has been necessary to dry the raw materials required for this manufacturing, but the technology disclosed in this specification can essentially dry the raw materials and avoid this costly step in the process. As a result, emissions are also avoided, and the post-separation foam factor of the fibers produced by the process of the present disclosure can help to create strong products. Products manufactured by conventional methods also require binders, but most of them are not sustainable and cause additional environmental problems both during manufacturing and at the time of disposal / recycling. The technology disclosed in this specification requires less binder. Furthermore, the liquid extract produced by the technology disclosed in this specification can be made into a sustainable binding product so as to benefit other markets as described above.

[0127] To effectively utilize the waste stream, it is always necessary to dehydrate, dry, and condition the raw materials. This has conventionally been achieved using various belt presses, extruders, and cyclone processes. Subsequently, additional mechanical processing reduces the size of the waste. The technology disclosed in this specification integrates all of these processes into one and can condition the raw materials to an extent that was not possible heretofore.

[0128] For example, the technology disclosed in this specification can process used coffee beans very efficiently and make them available for pellet production. And the pellets can be incinerated as solid fuel for heat generation or power generation, or used as a flavor smoke product in the rapidly expanding grill industry. As another example, the technology can process poultry quills to produce keratin that provides a foam factor that was previously unavailable for thin film applications and many other applications. As another example, the technology can process citrus peels into a very excellent form that can be used more efficiently in several industrial applications. The extraction liquid obtained by the process of the present disclosure also holds many possibilities, especially in the pursuit of organic chemical synthesis.

[0129] Although certain embodiments of the present disclosure are described in detail, it should be understood that other embodiments are contemplated. Accordingly, it is not intended to limit the scope of the present disclosure to the details of the structure and arrangement of components described in the following description or shown in the drawings. Other embodiments of the present disclosure can be implemented or executed in various ways. Also, when describing embodiments, specific technical terms are used for clarity. Each term is intended in its broadest sense as understood by those skilled in the art and is intended to include all technical equivalents that operate similarly and achieve similar purposes.

[0130] In this specification, the use of terms such as "having", "has", "including", or "includes" is open-ended and is intended to have the same meaning as terms such as "comprising" or "comprises", and is not intended to exclude the existence of other structures, materials, or acts. Similarly, the use of terms such as "can" or "may" is intended to be open-ended and is intended to indicate that the structure, material, or act is not essential, but not using such terms is not intended to indicate that the structure, material, or act is indispensable. The structure, material, or act is so recognized to the extent that they are currently considered indispensable.

[0131] "Comprising", "containing", or "including" means that at least the recited compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, or method steps even if they have the same function as those recited.

[0132] Also, it should be understood that a reference to one or more method steps does not exclude the existence of additional method steps or intermediate method steps between those specifically recited.

[0133] The components described below as constituting the various elements of the present disclosure are intended to be illustrative rather than limiting. It is intended that many suitable components that would perform the same or similar functions as the components described herein be included within the scope of the present disclosure. Such other components not described herein can include, for example, but are not limited to, similar components developed after the development of the subject matter of the present disclosure.

[0134] As used herein, the term "pulp" should be understood to include lignocellulosic materials of various moisture contents, physical properties, bulk densities, or species that have been dewatered, dried, separated, and expanded.

[0135] As used herein, the term "exposed cellulose fiber" should be understood to refer to cellulose fibers or fibrils that are not bound within the cell wall. For example, the cellulose fibers can be exposed by the cell explosion process of the present disclosure.

[0136] As used herein, the term "entangled" should be understood to mean that at least two fibers are entangled when at least a portion of each fiber is intertwined with at least a portion of another fiber and not parallel.

[0137] Disclosed herein is a process that includes obtaining a first mixture by combining one or more additives with a raw material comprising a fiber material containing lignin, cellulose, and hemicellulose and water, and conditioning the first mixture to obtain a liquid product and a dried pulp product.

[0138] Also disclosed herein are conditioning processes, machines, and methods used with the above process.

[0139] Also disclosed herein are liquid products produced by the above process, dried pulp products and / or fiber pulp materials produced by the above process, and fiber pellets produced by the above process.

[0140] Disclosed herein are processes, systems, and methods for treating and / or manufacturing materials comprising a fibrous material. The fibrous material can include natural fibers such as cellulosic fibers. For example, the fibrous material can include wood fibers. The wood fibers may be provided in the form of wood pulp or other lignocellulosic fiber sources. For example, the wood fibers may be provided in the form of southern bleached softwood kraft pulp. Suitable examples of fiber sources include, but are not limited to, fluff pulp, dissolving pulp, mechanical pulp, chemical pulp, chemimechanical pulp, recycled pulp, semichemical pulp, semi-mechanical pulp, weak-cook all-chemical pulp, consumer waste such as clothing, viscose, rayon, lyocell, or any combination thereof. Further, the fibrous material can be any material as long as it contains lignin and hemicellulose.

[0141] The fibrous material may be in the form of wood chips, wood fibers, or other wood sources. Other suitable examples of wood sources include, but are not limited to, hardwoods, softwoods, aspen, balsa, beech, birch, mahogany, hickory, maple, oak, teak, eucalyptus, pine, cedar, juniper, douglas fir, sequoia, or any combination thereof. It is understood that other known sources of wood fibers and lignocellulosic materials may also be used. Alternatively, the fibrous material may be provided in the form of natural non-wood fibers or alternative fibers. Suitable examples of natural non-wood alternative fibers that may constitute the fibrous material include, for example, barley, bagasse, bamboo, wheat and wheat straw, flax, hemp, kenaf, arundo donax, corn stalks, jute, ramie, cotton, wool, rye, rice, papyrus, esparto, sisal, grass, manila hemp, shrub, pampas grass, giant reed, alfalfa, viney woody, flower, wisteria, clematis, kudzu, coffee and other beans / bean fruits, stevia and other functional plants, other lignocellulosic species, fast-growing grass, or any combination thereof. It is understood that the fibrous material may include any other natural fibers obtained from any source or any combination of natural fibers. In some embodiments, the fibrous material can be prepared from cellulose fibers produced by mechanical treatment such as hammer milling or other grinding treatment from wood pulp or other prepared fiber sources.

[0142] The fibrous material may include fibers having an average length of about 0.01 mm or more and 12 mm or less. For example, the fibrous material may include fibers having an average length of 0.01 mm or more (e.g., 0.05 mm or more, 0.10 mm or more, 0.15 mm or more, 0.20 mm or more, 0.25 mm or more, 0.30 mm or more, 0.35 mm or more, 0.40 mm or more, 0.45 mm or more, 0.50 mm or more, 0.55 mm or more, 0.60 mm or more, 0.65 mm or more, 0.70 mm or more, 0.75 mm or more, 0.80 mm or more, 0.85 mm or more, 0.90 mm or more, 0.95 mm or more, 1.0 mm or more, 1.1 mm or more, 1.2 mm or more, 1.3 mm or more, 1.4 mm or more, 1.5 mm or more, 1.6 mm or more, 1.7 mm or more, 1.8 mm or more, 1.9 mm or more, 2.0 mm or more, 2.1 mm or more, 2.2 mm or more, 2.3 mm or more, 2.4 mm or more, 2.5 mm or more, 2.6 mm or more, 2.7 mm or more, 2.8 mm or more, 2.9 mm or more, 3.0 mm or more, 3.5 mm or more, 4.0 mm or more, 4.5 mm or more, 5.0 mm or more, 5.5 mm or more, 6.0 mm or more, 6.5 mm or more, 7.0 mm or more, 7.5 mm or more, 8.0 mm or more, 8.5 mm or more, 9.0 mm or more, 9.5 mm or more, 10 mm or more, 10.5 mm or more, 11 mm or more, or 11.5 mm or more).

[0143] In some embodiments, the fibrous material may include fibers having an average length of 12 mm or less (e.g., 11.5 mm or less, 11 mm or less, 10.5 mm or less, 10 mm or less, 9.5 mm or less, 9.0 mm or less, 8.5 mm or less, 8.0 mm or less, 7.5 mm or less, 7.0 mm or less, 6.5 mm or less, 6.0 mm or less, 5.5 mm or less, 5.0 mm or less, 4.5 mm or less, 4.0 mm or less, 3.5 mm or less, 3.0 mm or less, 2.9 mm or less, 2.8 mm or less, 2.7 mm or less, 2.6 mm or less, 2.5 mm or less, 2.4 mm or less, 2.3 mm or less, 2.2 mm or less, 2.1 mm or less, 2.0 mm or less, 1.9 mm or less, 1.8 mm or less, 1.7 mm or less, 1.6 mm or less, 1.5 mm or less, 1.4 mm or less, 1.3 mm or less, 1.2 mm or less, 1.1 mm or less, 1.0 mm or less, 0.95 mm or less, 0.90 mm or less, 0.85 mm or less, 0.80 mm or less, 0.75 mm or less, 0.70 mm or less, 0.65 mm or less, 0.60 mm or less, 0.55 mm or less, 0.50 mm or less, 0.45 mm or less, 0.40 mm or less, 0.35 mm or less, 0.30 mm or less, 0.25 mm or less, 0.20 mm or less, 0.15 mm or less, 0.10 mm or less, 0.05 mm or less).

[0144] In some embodiments, the length of the fibrous material is from 0.01 mm to 12 mm (e.g., from 0.3 mm to 7 mm, from 0.5 mm to 5 mm, from 0.7 mm to 2.8 mm, from 2.9 mm to 8 mm, from 8 mm to 12 mm, from 0.01 mm to 1 mm). In some embodiments, the fibrous material includes a blend of one or more fibers having different average fiber lengths. In other words, in some embodiments, the average fiber length of the fibrous material exhibits bimodality (or trimodality, etc.). In some examples, the average fiber length of the fibrous material can be from about 1 angstrom to about 5000 microns.

[0145] The fibrous material may include fibers having various cross-sectional shapes (e.g., circular, scalloped oval, cross-shaped, hexachannel, etc.). The fibrous material may have a cross-sectional size based on its cross-sectional shape. It should be understood that the term "cross-sectional size" as used herein refers to the maximum dimension in a plane perpendicular to the length of the fiber (i.e., the diameter for a cylindrical fiber and the diagonal for a rectangular fiber). In some embodiments, the average maximum cross-sectional size of the fibers in the fibrous material (i.e., the average diameter in the case of round fibers) is from 100 nanometers to 1000 microns. In some embodiments, the average maximum cross-sectional size of the fibrous material is 100 nanometers or more (e.g., 150 nanometers or more, 250 nanometers or more, 350 nanometers or more, 450 nanometers or more, 550 nanometers or more, 650 nanometers or more, 750 nanometers or more, 850 nanometers or more, 950 nanometers or more, 1 micron or more, 5 microns or more, 10 microns or more, 15 microns or more, 20 microns or more, 25 microns or more, 30 microns or more, 35 microns or more, 40 microns or more, 45 microns or more, 50 microns or more, 55 microns or more, 60 microns or more, 65 microns or more, 70 microns or more, 75 microns or more, 80 microns or more, 85 microns or more, 90 microns or more, 95 microns or more, 100 microns or more, 200 microns or more, 300 microns or more, 400 microns or more, 500 microns or more, 600 microns or more, 700 microns or more, 800 microns or more, or 900 microns or more).

[0146] In some embodiments, the average maximum cross-sectional size of the fiber material can be 1000 microns or less (e.g., 900 microns or less, 800 microns or less, 700 microns or less, 600 microns or less, 500 microns or less, 400 microns or less, 300 microns or less, 200 microns or less, 100 microns or less, 95 microns or less, 90 microns or less, 85 microns or less, 80 microns or less, 75 microns or less, 70 microns or less, 65 microns or less, 60 microns or less, 55 microns or less, 50 microns or less, 45 microns or less, 40 microns or less, 35 microns or less, 30 microns or less, 25 microns or less, 20 microns or less, 15 microns or less, 10 microns or less, 5 microns or less, 1 micron or less, 900 nanometers or less, 800 nanometers or less, 700 nanometers or less, 600 nanometers or less, 500 nanometers or less, 400 nanometers or less, 300 nanometers or less, 200 nanometers or less).

[0147] In some embodiments, the average maximum cross-sectional size of the fibrous material can be from about 100 nanometers to about 1000 microns (e.g., from 100 nanometers to 1 micron, from 1 micron to 10 microns, from 10 microns to 25 microns, from 25 microns to 50 microns, from 50 microns to 75 microns, from 75 microns to 100 microns, from 25 microns to 75 microns, from 25 microns to 100 microns, from 100 nanometers to 10 microns, from 100 nanometers to 25 microns, from 1 micron to 25 microns, from 10 microns to 75 microns, from 1 micron to 1000 microns, from 1 micron to 900 microns, from 1 micron to 800 microns, from 1 micron to 700 microns, from 1 micron to 600 microns, from 1 micron to 500 microns, from 100 microns to 1000 microns, from 100 microns to 900 microns, from 100 microns to 800 microns, from 100 microns to 700 microns, from 100 microns to 600 microns, or from 100 microns to 500 microns). In some embodiments, the fibrous material comprises a blend of one or more fibers having different average maximum cross-sectional sizes. In other words, in some embodiments, the average maximum cross-sectional size of the fibrous material exhibits bimodality (or trimodality, etc.). In some embodiments, the fibers of the fibrous material are present at the nanoscale and can have an average cross-sectional size of from 1 nanometer to 100 nanometers, or from 1 nanometer to 1000 microns.

[0148] Additive substances are also disclosed herein. The additive substances can include, for example, small molecule substances, surfactants, or polymers. Without wishing to be bound by any scientific theory, the additive substances can interact with lignin in the fibrous material to weaken the cell structure of the fibrous material. The additive substances can act catalytically and / or as a drag reducer during processing.

[0149] The additive may be a water-soluble substance capable of interacting with lignin. The additive is, for example, a surfactant. Various surfactants may be included in the present disclosure to interact with the fibrous material during processing (e.g., to weaken the lignin), act catalytically, and act as a drag reducer or dehydrating agent. The surfactant used in the present invention may contain a lipophilic non-polar hydrocarbon group and a polar or ionic (e.g., cationic, anionic, zwitterionic, etc.) functional hydrophilic group. The anionic or polar functional group may be a carboxylic acid group, ester group, amine group, amide group, imide group, hydroxyl group, ether group, nitrile group, phosphate group, sulfate group, or sulfonic acid group. The cationic functional group may be a primary amine group, secondary amine group, tertiary amine group, or quaternary amine group. These surfactants useful in the present invention may be used alone or in combination. Thus, any combination of surfactants may include anionic surfactants, cationic surfactants, nonionic surfactants, zwitterionic surfactants, amphoteric surfactants, and ampholytic surfactants.

[0150] Therefore, the surfactant used in the present invention may be an anionic surfactant. Examples of anionic surfactants include sulfonates such as alkyl sulfonates, alkylbenzene sulfonates, alpha olefin sulfonates, paraffin sulfonates, and alkyl ester sulfonates; sulfates such as alkyl sulfates, alkyl alkoxy sulfates, and alkyl alkoxylated sulfates; phosphates such as monoalkyl phosphates and dialkyl phosphates; phosphonates; carboxylates such as fatty acids, alkyl alkoxy carboxylates, sarcosinates, isethionates, and taurates, but are not limited thereto. Specific examples of carboxylates include sodium cocoyl isethionate, sodium oleoyl methyl taurate, sodium stearate, sodium laures carboxylate, sodium polyacrylate, sodium trideces carboxylate, sodium lauryl sarcosinate, sodium carboxymethyl cellulose, lauroyl sarcosine, and sodium cocoyl sarcosinate. Specific examples of sulfates include sodium dodecyl sulfate (SDS), sodium lauryl sulfate, sodium lauryl ether sulfate, cationic sodium laures sulfate, sodium trideces sulfate, sodium tridecyl sulfate, sodium cocoyl sulfate, and lauric monoglyceride sodium sulfate.

[0151] Suitable sulfonate surfactants include, but are not limited to, alkyl sulfonates, aryl sulfonates, lignosulfonates, linear alkylbenzene sulfonates, monoalkyl sulfosuccinates and dialkyl sulfosuccinates, and monoalkyl sulfophosphates and dialkyl sulfophosphates. Each alkyl group is independently about 2 to 20 carbon atoms and may be ethoxylated with up to about 8 units, preferably up to about 6 units, and on average, for example, 2, 3, or 4 units of ethylene oxide per alkyl group. Exemplary examples of alkyl sulfonates and aryl sulfonates include sodium tridecylbenzene sulfonate (STBS) and sodium dodecylbenzene sulfonate (SDBS).

[0152] Exemplary examples of sulfosuccinates include dimethicone copolyol sulfosuccinate, diamyl sulfosuccinate, dicapryl sulfosuccinate, dicyclohexyl sulfosuccinate, diheptyl sulfosuccinate, dihexyl sulfosuccinate, diisobutyl sulfosuccinate, dioctyl sulfosuccinate, dioctyl sodium sulfosuccinate (DOSS), (C12-15) pareth sulfosuccinate, cetearyl sulfosuccinate, cocopolyglucose sulfosuccinate, cocooyl butyl gluceth-10 sulfosuccinate, deceth-5 sulfosuccinate, deceth-6 sulfosuccinate, dihydroxyethyl sulfosuccinylundecylenate, hydrogenated cottonseed glyceride sulfosuccinate, isodecyl sulfosuccinate, isostearyl sulfosuccinate, laneth-5 sulfosuccinate, laureth sulfosuccinate, laureth-12 sulfosuccinate, laureth-6 sulfosuccinate, laureth-9 sulfosuccinate, lauryl sulfosuccinate, nonoxynol-10 sulfosuccinate, oleth-3 sulfosuccinate, oleyl sulfosuccinate, PEG-10 lauryl citrate sulfosuccinate, sitosereth-14 sulfosuccinate, stearyl sulfosuccinate, tallow, tridecyl sulfosuccinate, ditridecyl sulfosuccinate, bisglycol ricinosulfosuccinate, di(1,3-dimethylbutyl) sulfosuccinate, and silicone copolyol sulfosuccinate, but are not limited thereto.

[0153] Exemplary examples of sulfosuccinates include lauramide-MEA sulfosuccinate, oleamide PEG-2 sulfosuccinate, cocamide MIPA-sulfosuccinate, cocamide PEG-3 sulfosuccinate, isostearamide MEA-sulfosuccinate, isostearamide MIPA-sulfosuccinate, lauramide-MEA sulfosuccinate, lauramide PEG-2 sulfosuccinate, lauramide PEG-5 sulfosuccinate, myristamide MEA-sulfosuccinate, oleamide MEA-sulfosuccinate, oleamide PIPA-sulfosuccinate, oleamide PEG-2 sulfosuccinate, palmitamide PEG-2 sulfosuccinate, palmitoleamide PEG-2 sulfosuccinate, PEG-4 cocamide MIPA-sulfosuccinate, ricinoleamide MEA-sulfosuccinate, stearamide MEA-sulfosuccinate, stearyl sulfosuccinate, tallamido MEA-sulfosuccinate, tallow sulfosuccinate, tallow amide MEA-sulfosuccinate, undecylenamide MEA-sulfosuccinate, undecylenamide PEG-2 sulfosuccinate, wheat germamido MEA-sulfosuccinate, and wheat germamido PEG-2 sulfosuccinate, but are not limited thereto.

[0154] In the case of anionic surfactants, the counterion is typically sodium, but alternatively may be potassium, lithium, calcium, magnesium, ammonium, an amine (primary, secondary, tertiary, or quaternary), or other organic base. Exemplary amines include isopropylamine, ethanolamine, diethanolamine, and triethanolamine. Mixtures of the above cations can also be used.

[0155] In some embodiments, the surfactant used in the present invention may be a cationic surfactant as long as it also includes at least one surfactant having a net positive charge. Such cationic surfactants mainly include, but are not limited to, primary, secondary, tertiary, or quaternary organic amines. In the case of cationic surfactants, the counterions can be chloride anions, bromide anions, methyl sulfate anions, ethyl sulfate anions, lactate anions, saccharin anions, phosphate anions, acetate anions, and other organic acid anions. Examples of cationic amines include polyethoxylated oleyl / stearylamine, ethoxylated tallow amine, cocoalkylamine, oleylamine, and tallow alkylamine.

[0156] Examples of quaternary amines having a single long alkyl group include cetyltrimethylammonium bromide (CETAB), cetyltrimethylammonium chloride (CETAC), dodecyltrimethylammonium bromide, myristyltrimethylammonium bromide, stearyldimethylbenzylammonium chloride, oleyl dimethylbenzylammonium chloride, lauryltrimethylammonium methosulfate (also known as coco trimonium methosulfate), cetyl-dimethylhydroxyethylammonium dihydrogen phosphate, bath amido propyl conium chloride, coco trimonium chloride, distearyldimonium chloride, wheat germ-amido propyl conium chloride, benzalkonium chloride, stearyl octidium methosulfate, isostearyl aminopropyl-conium chloride, dihydroxypropyl PEG-5 linoleammonium chloride, PEG-2 stearmonium chloride, behentrimonium chloride, dicetyldimonium chloride, tallow trimonium chloride, and behenamidopropyl ethyldimonium ethosulfate.

[0157] Examples of quaternary amines having two long alkyl groups include distearyldimonium chloride, dicetyldimonium chloride, benzethonium chloride, stearyloctyldimonium methosulfate, palmoylethylhydroxyethylmonium methosulfate, dipalmitoylethylhydroxyethylmonium methosulfate, dioleoylethylhydroxyethylmonium methosulfate, and hydroxypropylbisstearyldimonium chloride.

[0158] Examples of quaternary ammonium compounds of imidazoline derivatives include isostearylbenzylimidonium chloride, cocoilbenzylhydroxyethylimidazolinium chloride, cocoilhydroxyethylimidazolinium PG-chloride phosphate, and stearylhydroxyethylimidonium chloride. Other heterocyclic quaternary ammonium compounds such as dodecylpyridinium chloride and cetylpyridinium chloride can also be used.

[0159] The surfactant used in the present invention may be a nonionic surfactant. Examples of nonionic surfactants include, but are not limited to, polyalkylene oxide carboxylic acid esters, fatty acid esters, fatty alcohols, ethoxylated fatty alcohols, poloxamers, polyalkylene oxides, alkanolamides, polyacrylamides, alkoxylated alkanolamides, polyethylene glycol monoalkyl ethers, and alkyl polysaccharides. The polyalkylene oxide carboxylic acid ester has one or two carboxylic acid ester moieties having about 8 to 20 carbon atoms and a polyalkylene oxide moiety containing about 5 to 200 alkylene oxide units. The ethoxylated fatty alcohol contains an ethylene oxide moiety containing about 5 to 150 ethylene oxide units and a fatty alcohol moiety having about 6 to about 30 carbon atoms. The fatty alcohol moiety may be cyclic, linear, or branched, and may be saturated or unsaturated. Some examples of ethoxylated fatty alcohols include ethylene glycol ethers of oleth alcohol, steareth alcohol, lauryl alcohol, and isocetyl alcohol. A poloxamer is a block copolymer of ethylene oxide and propylene oxide and has about 15 to about 100 moles of ethylene oxide. An alkyl polysaccharide ("APS") surfactant (e.g., alkyl polyglycoside) contains a hydrophobic group having about 6 to about 30 carbon atoms and a polysaccharide (e.g., polyglycoside) as a hydrophilic group.

[0160] Specific examples of suitable nonionic surfactants include alkanolamides such as cocamidodiethanolamide ("DEA"), cocamidomonoethanolamide ("MEA"), cocamidomonoisopropanolamide ("MIPA"), PEG-5 cocamid MEA, lauramid DEA, and lauramid MEA; alkylamine oxides such as lauramine oxide, poly-N-vinylformamide, cocamine oxide, cocamidopropylamine oxide, and lauramidopropylamine oxide; polyalkylene oxides such as polyethylene oxide (PEO), polypropylene oxide, and polybutylene oxide; polyethylene glycol (PEG), polypropylene glycol, and their block copolymers; polysorbates or Tweens such as polysorbate 20, polysorbate 40, polysorbate 60, and polysorbate 80; polyacrylamide-co-sodium acrylate (PAAM-co-NaA); polyacrylamide-co-(sodium 2-(acrylamide)-2-methylpropanesulfonate) (PAAM-co-NaAMPS); polyacrylamide-co-(sodium 3-(acrylamide)-3-methylbutanoate) (PAAM-co-NaAMB); and polyacrylamide-co-diacetoneacrylamide (PAAM-coDAAM); acrylamide (AM)-based amphoteric polyelectrolytes (containing both negative and positive charges on the same polymer chain), sodium 2-acrylamido-2-methylpropanesulfonate (NaAMPS), (2-acrylamido 2-methylpropyl)trimethylammonium chloride (AMPTAC), sodium 3-acrylamide-3-methylbutanoate (NaAMB), and 3-((2-acrylamido-2-methylpropyl)dimethylammonio)-1-propanesulfonate (AMPDAPS); gums such as guar gum, xanthan gum, locust bean gum, gellan gum, and gum arabic; fatty acids or fatty acid esters such as sorbitan laurate, sorbitan distearate, lauric acid, isostearic acid, and PEG-150 distearate;Examples include fatty alcohols such as lauryl alcohol or ethoxylated fatty alcohols, and alkyl polyglucosides such as decyl glucoside, lauryl glucoside, and coco glucoside.;

[0161] The surfactant used in the present invention may be amphoteric, meaning that the same molecule has both a formal positive charge and a negative charge. The positive charge group can be quaternary ammonium, phosphonium, or sulfonium, while the negative charge group can be carboxylate, sulfonate, sulfate, phosphate, or phosphonate. Similar to other classifications of surfactants, the hydrophobic moiety may contain one or more long, straight-chain, cyclic, or branched aliphatic chains having about 8 to 18 carbon atoms. Specific examples of amphoteric surfactants include alkyl betaines such as coco dimethyl carboxymethyl betaine, coco betaine, lauryl dimethyl carboxymethyl betaine, lauryl dimethyl α-carboxyethyl betaine, cetyl dimethyl carboxymethyl betaine, lauryl bis-(2-hydroxyethyl) carboxymethyl betaine, stearyl bis-(2-hydroxypropyl) carboxymethyl betaine, oleyl dimethyl γ-carboxypropyl betaine, and lauryl bis-(2-hydroxypropyl) α-carboxy-ethyl betaine, amide propyl betaine; lecithins such as soy lecithin (phosphatidylcholine); and alkyl sultaines such as coco dimethyl sulfopropyl betaine, stearyl dimethyl sulfopropyl betaine, lauryl dimethyl sulfoethyl betaine, lauryl bis-(2-hydroxyethyl) sulfopropyl betaine, and alkyl amide propyl hydroxysultaine.

[0162] The surfactant used in the present invention may be amphoteric. Examples of suitable amphoteric surfactants include alkyl amphocarboxyglycinates and alkyl amphocarboxypropionates, alkyl amphodipropionates, alkyl amphodiacetates, alkyl amphoglycinates, and alkyl amphopropionates, as well as ammonium salts or substituted ammonium salts of alkyliminopropionates, alkyliminodipropionates, and alkyl amphopropyl sulfonates. Specific examples include coco amphodiacetate, coco amphopropionate, coco amphodipropionate, lauro amphodiacetate, lauro amphodipropionate, lauro amphodipropionate, coco amphopropyl sulfonate, capro amphodiacetate, capro amphodiacetate, capro amphodipropionate, and stearo amphodiacetate.

[0163] The surfactant used in the present invention can be a polymer such as N-substituted polyisobutenyl succinimide and succinate, alkyl methacrylate vinyl pyrrolidinone copolymer, polyvinyl pyrrolidone, alkyl methacrylate-dialkylaminoethyl methacrylate copolymer, alkyl methacrylate polyethylene glycol methacrylate copolymer, and polystearamide.

[0164] Alternatively, the surfactant may be an oil-based dispersant. Examples of oil-based dispersants include alkyl succinimides, succinate esters, high molecular weight amines, and Mannich bases and phosphate derivatives. Some specific examples include polyisobutenyl succinimide-polyethylene polyamine, polyisobutenyl succinate ester, polyisobutenyl hydroxybenzyl-polyethylene polyamine, and bis-hydroxypropyl phosphorate.

[0165] The surfactant used in the present invention may be a combination of two or more selected from the group consisting of anionic surfactants, cationic surfactants, nonionic surfactants, zwitterionic surfactants, amphoteric surfactants, and ampholytic surfactants. Suitable examples of combinations of two or more surfactants of the same type include mixtures of two anionic surfactants, mixtures of three anionic surfactants, mixtures of four anionic surfactants, mixtures of two cationic surfactants, mixtures of three cationic surfactants, mixtures of four cationic surfactants, mixtures of two nonionic surfactants, mixtures of three nonionic surfactants, mixtures of four nonionic surfactants, mixtures of two zwitterionic surfactants, mixtures of three zwitterionic surfactants, mixtures of four zwitterionic surfactants, mixtures of two amphoteric surfactants, mixtures of three amphoteric surfactants, mixtures of four amphoteric surfactants, mixtures of two ampholytic surfactants, mixtures of three ampholytic surfactants, and mixtures of four ampholytic surfactants, but are not limited thereto.

[0166] Suitable examples of combinations of two different types of surfactants include, but are not limited to, a mixture of one anionic surfactant and one cationic surfactant, a mixture of one anionic surfactant and one nonionic surfactant, a mixture of one anionic surfactant and one zwitterionic surfactant, a mixture of one anionic surfactant and one amphoteric surfactant, a mixture of one anionic surfactant and one ampholytic surfactant, a mixture of one cationic surfactant and one nonionic surfactant, a mixture of one cationic surfactant and one zwitterionic surfactant, a mixture of one cationic surfactant and one amphoteric surfactant, a mixture of one cationic surfactant and one ampholytic surfactant, a mixture of one nonionic surfactant and one zwitterionic surfactant, a mixture of one nonionic surfactant and one amphoteric surfactant, a mixture of one nonionic surfactant and one ampholytic surfactant, a mixture of one zwitterionic surfactant and one amphoteric surfactant, a mixture of one zwitterionic surfactant and one ampholytic surfactant, and a mixture of one amphoteric surfactant and one ampholytic surfactant. Combinations of two or more surfactants of the same type, for example, a mixture of two anionic surfactants, are also included in the present invention.

[0167] The molecular weight of the additive can be from about 30 g / mol to about 10,000,000 g / mol. The molecular weight of the additive can be from about 500 g / mol to about 10,000,000 g / mol. The molecular weight of the additive can be from about 50 g / mol to about 10,000,000 g / mol. The molecular weight of the additive can be from about 100 g / mol to about 10,000,000 g / mol. The molecular weight of the additive can be from about 250 g / mol to about 10,000,000 g / mol. The molecular weight of the additive can be from about 1,000 g / mol to about 10,000,000 g / mol. The molecular weight of the additive can be from about 1,000 g / mol to about 8,000,000 g / mol. Alternatively, the molecular weight of the additive can be from about 5,000 g / mol to about 10,000,000 g / mol, from about 100,000 g / mol to about 10,000,000 g / mol, from about 500 g / mol to about 1,000,000 g / mol, from about 1,000 g / mol to about 1,000,000 g / mol, from about 1,000 g / mol to about 2,000,000 g / mol, from about 1,000 g / mol to about 3,000,000 g / mol, or from about 500 g / mol to about 8,000,000 g / mol.

[0168] Embodiments of the present disclosure can provide a dried pulp product. The dried pulp product can be manufactured from a fibrous material using the process of the present disclosure and can have a disrupted cell structure. The dried pulp product can be further processed into pellets, briquettes, bales, or other value-added products. The particle size (e.g., average particle diameter) of the dried pulp product can be from about 1 mm to about 10 mm (e.g., from 1.5 mm to 9.5 mm, from 2 mm to 9 mm, from 2.5 mm to 8.5 mm, from 3 mm to 8 mm, from 3.5 mm to 7.5 mm, from 4 mm to 7 mm, from 4.5 mm to 6.5 mm, or from 5 mm to 6 mm).

[0169] Embodiments of the present disclosure can provide fiber pellets containing a fibrous material including lignin and water. The fiber pellets of the present disclosure can be substantially dehydrated. In other words, the amount of water contained in the fiber pellets can be about 20% by weight or less (e.g., 19% by weight or less, 18% by weight or less, 17% by weight or less, 16% by weight or less, 15% by weight or less, 14% by weight or less, 13% by weight or less, 12% by weight or less, 11% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, 5% by weight or less, 4.5% by weight or less, 4% by weight or less, 3.5% by weight or less, 3% by weight or less, 2.5% by weight or less, 2% by weight or less, 1.5% by weight or less, 1% by weight or less, or 0.5% by weight or less) based on the total weight of the fiber pellets.

[0170] In some embodiments, the amount of water contained in the fiber pellets can be about 0.1% by weight or more (e.g., 19% by weight or more, 18% by weight or more, 17% by weight or more, 16% by weight or more, 15% by weight or more, 14% by weight or more, 13% by weight or more, 12% by weight or more, 11% by weight or more, 10% by weight or more, 9% by weight or more, 8% by weight or more, 7% by weight or more, 6% by weight or more, 5% by weight or more, 4.5% by weight or more, 4% by weight or more, 3.5% by weight or more, 3% by weight or more, 2.5% by weight or more, 2% by weight or more, 1.5% by weight or more, 1% by weight or more, or 0.5% by weight or more) based on the total weight of the fiber pellets.

[0171] In some embodiments, the amount of water contained in the fiber pellets can be from about 0.1 wt% to about 20 wt% (e.g., from 0.1 wt% to 19 wt%, from 0.5 wt% to 18 wt%, from 1 wt% to 17 wt%, from 1 wt% to 20 wt%, from 1 wt% to 19 wt%, from 1 wt% to 18 wt%, from 1 wt% to 16 wt%, from 2 wt% to 18 wt%, from 3 wt% to 17 wt%, from 4 wt% to 16 wt%, from 5 wt% to 15 wt%, from 6 wt% to 14 wt%, from 7 wt% to 13 wt%, from 8 wt% to 12 wt%, from 9 wt% to 11 wt%, from 0.5 wt% to 4.5 wt%, from 1 wt% to 5 wt%, from 1 wt% to 4.5 wt%, from 1 wt% to 4 wt%, from 1.5 wt% to 3.5 wt%, or from 2 wt% to 3 wt%) based on the total weight of the fiber pellets.

[0172] The fiber pellets of the present disclosure can exhibit substantially improved mechanical properties and structural integrity compared to conventional fiber pellets. For example, the pellet durability index (PDI) of the fiber pellets can be 75 or more (e.g., 76 or more, 77 or more, 78 or more, 79 or more, 80 or more, 81 or more, 82 or more, 83 or more, 84 or more, 85 or more, 86 or more, 87 or more, 88 or more, 89 or more, 90 or more, 91 or more, 92 or more, 93 or more, 94 or more, 95 or more, 96 or more, 97 or more, 98 or more, 99 or more, or 100). The PDI of the fiber pellets can be measured, for example, using ASAE Standard S269.5 R2016. Further, the fiber pellets of the present disclosure can have improved structural integrity. For example, the fiber pellets exhibit substantially minimal degradation when placed in water for about 1 minute to about 1 year. As used herein, "substantially minimal degradation" is defined as a change in the bulk density of the fiber pellets of 10% or less. In other words, the fiber pellets have minimal swelling and / or water absorption when in water.

[0173] Also, the fiber pellets have a bulk density of about 15 kg / m 3 or more (e.g., 20 kg / m 3 or more, 25 kg / m 3 or more, 30 kg / m3 above, 35 kg / m 3 above, 40 kg / m 3 above, 45 kg / m 3 above, 50 kg / m 3 above, 60 kg / m 3 above, 70 kg / m 3 above, 80 kg / m 3 above, 90 kg / m 3 above, 100 kg / m 3 above, 150 kg / m 3 above, 200 kg / m 3 above, 250 kg / m 3 above, 300 kg / m 3 above, 350 kg / m 3 above, 400 kg / m 3 above, 450 kg / m 3 above, 500 kg / m 3 above, 550 kg / m 3 above, 600 kg / m 3 above, 650 kg / m 3 above, 700 kg / m 3 above, or 750 kg / m 3 above) and can be.

[0174] The bulk density of the fiber pellets is about 800 kg / m 3 below (for example, 20 kg / m 3 below, 25 kg / m 3 below, 30 kg / m 3 below, 35 kg / m 3 below, 40 kg / m 3 below, 45 kg / m 3 below, 50 kg / m 3 below, 60 kg / m 3 below, 70 kg / m 3 below, 80 kg / m 3 below, 90 kg / m 3 below, 100 kg / m 3 below, 150 kg / m 3 below, 200 kg / m 3 below, 250 kg / m 3 below, 300 kg / m 3 below, 350 kg / m 3 below, 400 kg / m 3The following is 450 kg / m 3 The following is 500 kg / m 3 The following is 550 kg / m 3 The following is 600 kg / m 3 The following is 650 kg / m 3 The following is 700 kg / m 3 The following, or 750 kg / m 3 The following) can be.

[0175] The bulk density of the fiber pellets is about 15 kg / m 3 The following is about 800 kg / m 3 The following (for example, 20 kg / m 3 The following is 800 kg / m 3 The following is 25 kg / m 3 The following is 800 kg / m 3 The following is 30 kg / m 3 The following is 800 kg / m 3 The following is 35 kg / m 3 The following is 800 kg / m 3 The following is 40 kg / m 3 The following is 800 kg / m 3 The following is 45 kg / m 3 The following is 800 kg / m 3 The following is 50 kg / m 3 The following is 800 kg / m 3 The following is 60 kg / m 3 The following is 800 kg / m 3 The following is 70 kg / m 3 The following is 800 kg / m 3 The following is 80 kg / m 3 The following is 800 kg / m 3 The following is 90 kg / m 3 The following is 800 kg / m 3 The following is 100 kg / m 3 The following is 800 kg / m 3 The following is 150 kg / m 3 The following is 800 kg / m 3 The following is 200 kg / m 3 The following is 800 kg / m 3 The following is 250 kg / m 3 The following is 800 kg / m 3 The following is 300 kg / m 3 The following is 800 kg / m 3 The following is 350 kg / m3 Above 800 kg / m 3 Below, 400 kg / m 3 Above 800 kg / m 3 Below, 450 kg / m 3 Above 800 kg / m 3 Below, 500 kg / m 3 Above 800 kg / m 3 Below, 550 kg / m 3 Above 800 kg / m 3 Below, 600 kg / m 3 Above 800 kg / m 3 Below, 650 kg / m 3 Above 800 kg / m 3 Below, 700 kg / m 3 Above 800 kg / m 3 Below, 750 kg / m 3 Above 800 kg / m 3 Below, 100 kg / m 3 Above 750 kg / m 3 Below, 100 kg / m 3 Above 700 kg / m 3 Below, 150 kg / m 3 Above 650 kg / m 3 Below, 250 kg / m 3 Above 750 kg / m 3 Below, 300 kg / m 3 Above 700 kg / m 3 Below, 350 kg / m 3 Above 650 kg / m 3 Below, 400 kg / m 3 Above 600 kg / m 3 、 or 450 kg / m 3 Above 550 kg / m 3 Below) can be.

[0176] The fiber pellet may also contain a plurality of exposed cellulose fibers in the above fiber material. Each of the plurality of exposed cellulose fibers may be entangled with at least one other exposed cellulose fiber, as shown in FIG. 5B. The amount of the exposed cellulose fibers present in the fiber pellet may be 2% by weight or more (for example, 3% by weight or more, 4% by weight or more, 5% by weight or more, 6% by weight or more, 7% by weight or more, 8% by weight or more, 9% by weight or more, 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more) based on the total weight of the pellet.

[0177] The amount of the exposed cellulose fibers present in the fiber pellet may be 99% by weight or less (for example, 3% by weight or less, 4% by weight or less, 5% by weight or less, 6% by weight or less, 7% by weight or less, 8% by weight or less, 9% by weight or less, 10% by weight or less, 15% by weight or less, 20% by weight or less, 25% by weight or less, 30% by weight or less, 35% by weight or less, 40% by weight or less, 45% by weight or less, 50% by weight or less, 55% by weight or less, 60% by weight or less, 65% by weight or less, 70% by weight or less, 75% by weight or less, 80% by weight or less, 85% by weight or less, 90% by weight or less, or 95% by weight or less) based on the total weight of the pellet.

[0178] The amount of exposed cellulose fibers present in the fiber pellets can be 2% by weight or more and 99% by weight or less (e.g., 2% by weight or more and 98% by weight or less, 2% by weight or more and 95% by weight or less, 2% by weight or more and 90% by weight or less, 2% by weight or more and 85% by weight or less, 2% by weight or more and 80% by weight or less, 2% by weight or more and 75% by weight or less, 2% by weight or more and 70% by weight or less, 2% by weight or more and 65% by weight or less, 2% by weight or more and 60% by weight or less, 2% by weight or more and 55% by weight or less, 2% by weight or more and 50% by weight or less, 2% by weight or more and 45% by weight or less, 2% by weight or more and 40% by weight or less, 2% by weight or more and 35% by weight or less, 2% by weight or more and 30% by weight or less, 2% by weight or more and 25% by weight or less, 3% by weight or more and 99% by weight or less, 4% by weight or more and 99% by weight or less, 5% by weight or more and 99% by weight or less, 5% by weight or more and 95% by weight or less, 5% by weight or more and 90% by weight or less, 5% by weight or more and 85% by weight or less, 5% by weight or more and 80% by weight or less, 5% by weight or more and 75% by weight or less, 5% by weight or more and 70% by weight or less, 5% by weight or more and 65% by weight or less, 5% by weight or more and 60% by weight or less, 5% by weight or more and 55% by weight or less, 5% by weight or more and 50% by weight or less, 5% by weight or more and 45% by weight or less, 5% by weight or more and 40% by weight or less, 5% by weight or more and 35% by weight or less, 5% by weight or more and 30% by weight or less, or 5% by weight or more and 25% by weight or less) based on the total weight of the pellets.

[0179] Embodiments of the present disclosure can also provide liquid products derived from the above fiber materials, and the liquid products include solid or liquid particles, biostimulant compounds, minerals, amino acids, organic acids, proteins, water, and lignin. The biostimulant compounds can include compounds such as humic acid, fulvic acid, or other organic acids. The liquid products can also include other biostimulant compounds, and examples of other biostimulant compounds include humic acid derivatives, humates, other organic acids, humus, humins, lignosulfonates, lactic acid, acetic acid, formic acid, citric acid, oxalic acid, uric acid, malic acid, other derivatives of soil organic matter, humic substances, other bioactive compounds, etc., or any combination thereof, but are not limited thereto. The minerals can include potassium, phosphorus, nitrogen, calcium, magnesium, sulfur, sodium, iron, manganese, zinc, copper, or other natural minerals, etc., or any combination thereof. The liquid products can further include amino acids such as glutamic acid or tryptophan. The liquid products can further include other volatile organic compounds and non-volatile organic compounds.

[0180] The amount of the biostimulant compound present in the liquid product can be about 0.001% by weight or more (e.g., 0.005% by weight or more, 0.01% by weight or more, 0.05% by weight or more, 0.1% by weight or more, 0.2% by weight or more, 0.3% by weight or more, 0.4% by weight or more, 0.5% by weight or more, 0.6% by weight or more, 0.7% by weight or more, 0.8% by weight or more, 0.9% by weight or more, 1% by weight or more, 1.1% by weight or more, 1.2% by weight or more, 1.3% by weight or more, 1.4% by weight or more, 1.5% by weight or more, 2% by weight or more, 2.5% by weight or more, 3% by weight or more, 3.5% by weight or more, 4% by weight or more, 4.5% by weight or more, 5% by weight or more, 5.5% by weight or more, 6% by weight or more, 6.5% by weight or more, 7% by weight or more, 7.5% by weight or more, 8% by weight or more, 8.5% by weight or more, 9% by weight or more, or 9.5% by weight or more) based on the total weight of the liquid product.

[0181] In some embodiments, the amount of the biostimulant compound present in the liquid product can be about 10 wt% or less (e.g., 0.005 wt% or less, 0.01 wt% or less, 0.05 wt% or less, 0.1 wt% or less, 0.2 wt% or less, 0.3 wt% or less, 0.4 wt% or less, 0.5 wt% or less, 0.6 wt% or less, 0.7 wt% or less, 0.8 wt% or less, 0.9 wt% or less, 1 wt% or less, 1.1 wt% or less, 1.2 wt% or less, 1.3 wt% or less, 1.4 wt% or less, 1.5 wt% or less, 2 wt% or less, 2.5 wt% or less, 3 wt% or less, 3.5 wt% or less, 4 wt% or less, 4.5 wt% or less, 5 wt% or less, 5.5 wt% or less, 6 wt% or less, 6.5 wt% or less, 7 wt% or less, 7.5 wt% or less, 8 wt% or less, 8.5 wt% or less, 9 wt% or less, or 9.5 wt% or less) based on the total weight of the liquid product.

[0182] In some embodiments, the amount of the biostimulant compound present in the liquid product can be from about 0.001 wt% to about 20 wt% (e.g., from 0.005 wt% to 10 wt%, from 0.01 wt% to 10 wt%, from 0.05 wt% to 10 wt%, from 0.1 wt% to 10 wt%, from 0.2 wt% to 10 wt%, from 0.3 wt% to 10 wt%, from 0.4 wt% to 10 wt%, from 0.5 wt% to 10 wt%, from 0.6 wt% to 10 wt%, from 0.7 wt% to 10 wt%, from 0.8 wt% to 10 wt%, from 0.9 wt% to 10 wt%, from 1 wt% to 10 wt%, from 1 wt% to 9.5 wt%, from 1 wt% to 9 wt%, from 1.5 wt% to 8.5 wt%, from 2 wt% to 8 wt%, from 2.5 wt% to 7.5 wt%, from 3 wt% to 7 wt%, from 3 wt% to 6.5 wt%, from 3 wt% to 6 wt%, from 3 wt% to 5.5 wt%, from 3 wt% to 5 wt%, from 2.5 wt% to 5 wt%, from 2 wt% to 5 wt%, from 1.5 wt% to 5 wt%, from 1.4 wt% to 5 wt%, from 1.3 wt% to 5 wt%, from 1.2 wt% to 5 wt%, from 1.1 wt% to 5 wt%, from 1 wt% to 5 wt%, from 0.9 wt% to 5 wt%, from 0.8 wt% to 5 wt%, from 0.7 wt% to 5 wt%, from 0.6 wt% to 5 wt%, from 0.5 wt% to 5 wt%, from 0.4 wt% to 5 wt%, from 0.3 wt% to 5 wt%, from 0.2 wt% to 5 wt%, or from 0.1 wt% to 5 wt%) based on the total weight of the liquid product.

[0183] The amount of water contained in the liquid product can be about 50% by weight or more (e.g., 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, or 85% by weight or more) based on the total weight of the liquid product. In some embodiments, the amount of water contained in the liquid product can be about 90% by weight or less (e.g., 55% by weight or less, 60% by weight or less, 65% by weight or less, 70% by weight or less, 75% by weight or less, 80% by weight or less, or 85% by weight or less) based on the total weight of the liquid product. In some embodiments, the amount of water contained in the liquid product can be about 50% by weight or more and about 90% by weight or less (e.g., 55% by weight or more and 85% by weight or less, 60% by weight or more and 80% by weight or less, or 65% by weight or more and 75% by weight or less) based on the total weight of the liquid product.

[0184] Also, the amount of lignin contained in the liquid product can be about 0.01% by weight or more (e.g., 0.05% by weight or more, 0.1% by weight or more, 0.5% by weight or more, 1% by weight or more, 2% by weight or more, 3% by weight or more, 4% by weight or more, 5% by weight or more, 6% by weight or more, 7% by weight or more, 8% by weight or more, 9% by weight or more, 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, or 70% by weight or more) based on the total weight of the liquid product.

[0185] In some embodiments, the amount of lignin contained in the liquid product can be about 75% by weight or less (e.g., 0.05% by weight or less, 0.1% by weight or less, 0.5% by weight or less, 1% by weight or less, 2% by weight or less, 3% by weight or less, 4% by weight or less, 5% by weight or less, 6% by weight or less, 7% by weight or less, 8% by weight or less, 9% by weight or less, 10% by weight or less, 15% by weight or less, 20% by weight or less, 25% by weight or less, 30% by weight or less, 35% by weight or less, 40% by weight or less, 45% by weight or less, 50% by weight or less, 55% by weight or less, 60% by weight or less, 65% by weight or less, or 70% by weight or less) based on the total weight of the liquid product.

[0186] In some embodiments, the amount of lignin contained in the liquid product can be from about 0.01 wt% to about 75 wt% (e.g., from 0.05 wt% to 75 wt%, from 0.1 wt% to 75 wt%, from 0.5 wt% to 75 wt%, from 1 wt% to 75 wt%, from 2 wt% to 75 wt%, from 2 wt% to 75 wt%, from 3 wt% to 75 wt%, from 4 wt% to 75 wt%, from 5 wt% to 75 wt%, from 6 wt% to 75 wt%, from 7 wt% to 75 wt%, from 8 wt% to 75 wt%, from 9 wt% to 75 wt%, from 10 wt% to 75 wt%, from 15 wt% to 75 wt%, from 20 wt% to 75 wt%, from 25 wt% to 75 wt%, from 30 wt% to 70 wt%, from 35 wt% to 65 wt%, from 40 wt% to 60 wt%, or from 45 wt% to 55 wt%) based on the total weight of the liquid product.

[0187] The liquid product can also contain various dry matters. In other words, the solids content of the liquid product can be from about 0.0001 wt% (e.g., 0.0005 wt% or more, 0.001 wt% or more, 0.005 wt% or more, 0.01 wt% or more, 0.05 wt% or more, 0.1 wt% or more, 0.5 wt% or more, 1 wt% or more, 1.5 wt% or more, 2 wt% or more, 2.5 wt% or more, 3 wt% or more, 3.5 wt% or more, 4 wt% or more, 4.5 wt% or more, 5 wt% or more, 6 wt% or more, 7 wt% or more, 8 wt% or more, 9 wt% or more, 10 wt% or more, 11 wt% or more, 12 wt% or more, 13 wt% or more, 14 wt% or more, 15 wt% or more, 16 wt% or more, 17 wt% or more, 18 wt% or more, 19 wt% or more, 20 wt% or more, 25 wt% or more, 30 wt% or more, 35 wt% or more, 40 wt% or more, or 45 wt% or more) based on the total weight of the liquid product.

[0188] In some embodiments, the solids content of the liquid product can be about 50 wt% or less (e.g., 0.0005 wt% or less, 0.001 wt% or less, 0.005 wt% or less, 0.01 wt% or less, 0.05 wt% or less, 0.1 wt% or less, 0.5 wt% or less, 1 wt% or less, 1.5 wt% or less, 2 wt% or less, 2.5 wt% or less, 3 wt% or less, 3.5 wt% or less, 4 wt% or less, 4.5 wt% or less, 5 wt% or less, 6 wt% or less, 7 wt% or less, 8 wt% or less, 9 wt% or less, 10 wt% or less, 11 wt% or less, 12 wt% or less, 13 wt% or less, 14 wt% or less, 15 wt% or less, 16 wt% or less, 17 wt% or less, 18 wt% or less, 19 wt% or less, 20 wt% or less, 25 wt% or less, 30 wt% or less, 35 wt% or less, 40 wt% or less, or 45 wt% or less) relative to the total weight of the liquid product.

[0189] In some embodiments, the solids content of the liquid product is from about 0.0001 wt% to about 50 wt% (e.g., from 0.0005 wt% to 50 wt%, from 0.001 wt% to 50 wt%, from 0.005 wt% to 50 wt%, from 0.01 wt% to 50 wt%, from 0.05 wt% to 50 wt%, from 0.1 wt% to 50 wt%, from 0.5 wt% to 50 wt%, from 1 wt% to 50 wt%, from 0.0005 wt% to 20 wt%, from 0.001 wt% to 20 wt%, from 0.005 wt% to 20 wt%, from 0.01 wt% to 20 wt%, from 0.05 wt% to 20 wt%, from 0.1 wt% to 20 wt%, from 0.5 wt% to 20 wt%, from 1 wt% to 20 wt%, from 0.0005 wt% to 19 wt%, from 0.001 wt% to 18 wt%, from 0.005 wt% to 17 wt%, from 0.01 wt% to 16 wt%, from 0.05 wt% to 15 wt%, from 0.1 wt% to 14 wt%, from 0.5 wt% to 13 wt%, from 1 wt% to 12 wt%, from 1.5 wt% to 11 wt%, from 2 wt% to 10 wt%, from 2 wt% to 9 wt%, from 2 wt% to 8 wt%, from 2 wt% to 7 wt%, from 2 wt% to 6 wt%, from 2 wt% to 5 wt%, from 2.5 wt% to 4.5 wt%, or from 3 wt% to 4 wt%) based on the total weight of the liquid product and can be such.

[0190] The liquid product may be acidic. For example, the liquid product may have a pH of about 7 or less (e.g., 6.5 or less, 6 or less, 5.5 or less, 5 or less, 4.5 or less, 4 or less, 3.5 or less, 3 or less, 2.5 or less, 2 or less, 1.5 or less, 1 or less, or 0.5 or less). In some embodiments, the pH of the liquid product may be about 0 or more (e.g., 6.5 or more, 6 or more, 5.5 or more, 5 or more, 4.5 or more, 4 or more, 3.5 or more, 3 or more, 2.5 or more, 2 or more, 1.5 or more, 1 or more, or 0.5 or more). In some embodiments, the pH of the liquid product may be about 0 or more and about 7 or less (e.g., 0.5 or more and 6.5 or less, 1 or more and 6 or less, 1.5 or more and 5.5 or less, 2 or more and 5 or less, 2.5 or more and 4.5 or less, 3 or more and 4 or less, 0 or more and 6.5 or less, 0 or more and 6 or less, 0 or more and 5.5 or less, 0 or more and 5 or less, 0 or more and 4.5 or less, or 0 or more and 4 or less).

[0191] Furthermore, the liquid product can carry substantially all of the VOCs that are present in liquid form in the raw materials. In other words, since the VOCs are substantially confined in the liquid product, the VOCs in the gas phase generated by the manufacturing process of the liquid product are substantially in trace amounts. As used herein, the phrase "substantially trace amounts of VOCs" means that the generation amount of VOCs is about 10 ppm or less.

[0192] Also disclosed herein is a method for promoting plant growth using the above liquid product. The method may include administering the liquid product to the plant. Various liquid products can be prepared as described above and are considered to be within the scope of the present disclosure and understood.

[0193] Here, exemplary embodiments of the disclosed technology are referred to in detail. Those examples are shown in the accompanying drawings and disclosed herein. Where convenient, the same reference numerals are used throughout the drawings to indicate the same or similar parts.

[0194] FIG. 1 is a flowchart showing an exemplary process 100 of the present disclosure. As shown in block 110, an additive 112 can be mixed with a raw material 114 to obtain a first mixture 116. The raw material 114 can include a fibrous material and water. The fibrous material can include lignin and can be selected from the fibrous materials of the present disclosure. Examples of the additive 112 are as described above, but it should be understood that other elements such as inhibitors, defoamers, indicators, dyes, etc. may be included in the additive 112. The process 100 can then proceed to block 120 or other steps (not shown) of the process 100.

[0195] Regarding the raw material 114, the amount of water contained in the raw material 114 can be about 5 wt% or more (e.g., 10 wt% or more, 15 wt% or more, 20 wt% or more, 25 wt% or more, 30 wt% or more, 35 wt% or more, 40 wt% or more, 45 wt% or more, 50 wt% or more, 55 wt% or more, 60 wt% or more, 65 wt% or more, 70 wt% or more, 75 wt% or more, 80 wt% or more, 85 wt% or more, or 90 wt% or more) based on the total weight of the raw material 114. Also, the amount of water contained in the raw material 114 can be about 95 wt% or less (e.g., 10 wt% or less, 15 wt% or less, 20 wt% or less, 25 wt% or less, 30 wt% or less, 35 wt% or less, 40 wt% or less, 45 wt% or less, 50 wt% or less, 55 wt% or less, 60 wt% or less, 65 wt% or less, 70 wt% or less, 75 wt% or less, 80 wt% or less, 85 wt% or less, or 90 wt% or less) based on the total weight of the raw material 114. Alternatively, the amount of water contained in the raw material 114 can be about 5 wt% or more and about 95 wt% or less (e.g., 5 wt% or more and 90 wt% or less, 10 wt% or more and 90 wt% or less, 15 wt% or more and 85 wt% or less, 20 wt% or more and 80 wt% or less, 25 wt% or more and 75 wt% or less, 30 wt% or more and 70 wt% or less, 35 wt% or more and 65 wt% or less, 40 wt% or more and 60 wt% or less, or 45 wt% or more and 55 wt% or less) based on the total weight of the raw material 114.

[0196] Referring now to block 120, in block 120, the first mixture 116 can be adjusted to obtain a liquid product 122 and a dry pulp product 124. The detailed steps of the adjustment in block 120 are more specifically outlined by FIG. 3. The liquid product 122 can carry with it substantially all of the VOCs that are present in liquid form in the raw material 114. In other words, the adjustment step in block 120 generates substantially undetectable amounts of gaseous VOCs. This is because the VOCs are substantially contained within the liquid product 122. Examples of the liquid product 122 are as described above, but it should be understood that the liquid product 122 can have a composition according to any embodiment of the present disclosure.

[0197] The adjustment step in block 120 can be carried out at a temperature that requires little or no additional heat. In other words, the adjustment can be substantially self-heating without the need for an external heat source. For example, the adjustment step in block 120 can be carried out at a temperature of about 350°F or less (e.g., 340°F or less, 330°F or less, 320°F or less, 310°F or less, 300°F or less, 290°F or less, 280°F or less, 270°F or less, 260°F or less, 250°F or less, 240°F or less, 230°F or less, 220°F or less, or 210°F or less). Also, the adjustment step in block 120 can be carried out at a temperature of about 200°F or more (e.g., 340°F or more, 330°F or more, 320°F or more, 310°F or more, 300°F or more, 290°F or more, 280°F or more, 270°F or more, 260°F or more, 250°F or more, 240°F or more, 230°F or more, 220°F or more, or 210°F or more). Further, the adjustment step in block 120 can be carried out at a temperature of about 200°F or more and about 350°F or less (e.g., 210°F or more and 340°F or less, 220°F or more and 330°F or less, 230°F or more and 320°F or less, 240°F or more and 310°F or less, 250°F or more and 300°F or less, 200°F or more and 300°F or less, 210°F or more and 290°F or less, 220°F or more and 280°F or less, 230°F or more and 270°F or less, or 240°F or more and 260°F or less).

[0198] The dried pulp product 124 can contain a fiber material and water. The fiber material can be substantially the same as the fiber material of the raw material 114. The dried pulp product 124 may be substantially dehydrated. For example, the amount of water contained in the dried pulp product 124 can be about 35% by weight or less (e.g., 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less) based on the total weight of the dried pulp product 124. Also, the amount of water contained in the dried pulp product 124 can be about 0.5% by weight or more (e.g., 30% by weight or more, 25% by weight or more, 20% by weight or more, 15% by weight or more, 10% by weight or more, 5% by weight or more, 4% by weight or more, 3% by weight or more, 2% by weight or more, or 1% by weight or more) based on the total weight of the dried pulp product 124. Alternatively, the amount of water contained in the dried pulp product 124 can be about 0.5% by weight or more and about 35% by weight or less (e.g., 0.5% by weight or more and 30% by weight or less, 1% by weight or more and 25% by weight or less, 2% by weight or more and 20% by weight or less, 3% by weight or more and 15% by weight or less, 4% by weight or more and 10% by weight or less, 5% by weight or more and 10% by weight or less, 5% by weight or more and 15% by weight or less, 5% by weight or more and 20% by weight or less, 5% by weight or more and 25% by weight or less, 5% by weight or more and 30% by weight or less, 10% by weight or more and 30% by weight or less, 15% by weight or more and 30% by weight or less, or 20% by weight or more and 30% by weight or less) based on the total weight of the dried pulp product 124. The process 100 may end after block 120 or may proceed to block 130. The process 100 may additionally proceed to other steps (not shown) of the process 100.

[0199] In block 130, the dried pulp product 124 can be further processed into useful products. For example, the dried pulp product 124 can be pelletized to form fiber pellets. Examples of fiber pellets are as described above, but it should be understood that the fiber pellets can have a composition according to any embodiment of the present disclosure. Fiber pellets produced by the techniques disclosed herein are shown in FIG. 4B and compared with fiber pellets produced by a conventional process shown in FIG. 4A. Further, a scanning electron microscope (SEM) image of fiber pellets produced by a conventional process is shown in FIG. 5A and compared with the SEM image of fiber pellets produced by the process of the present disclosure shown in FIG. 5B. Alternatively, the dried pulp product 124 can be pulverized into fine particles. The fine particles can be used in packaging materials, fiberboards, paperboards, etc. The dried pulp product 124 can also be used for papermaking or for the production of other lignocellulosic products. The dried pulp product 124 can also be used as a binder fiber to improve the mechanical properties of other fiber materials. Process 100 can end and be completed after block 130. However, in other embodiments, process 100 can continue to proceed to other processing steps not shown.

[0200] FIG. 2 is a flowchart showing a conventional process 200. As shown in block 210, the raw material 214a can be subjected to a mechanical pulverization process. A first amount of shaft work is required to complete the mechanical pulverization process. Conventionally, the work required for block 210 is time-consuming and costly, resulting in an inefficient process. The equipment required for the mechanical pulverization process is also expensive, complex, and difficult to maintain. Therefore, block 210 of the conventional process 200 is undesirable. The conventional process 200 can then proceed to block 220.

[0201] In block 220, the pulverized raw material 214b can be dried by one or more dryers to obtain a dried raw material 214c. The above-mentioned one or more dryers require additional shaft work to move the pulverized raw material 214b into the dryer, and the above-mentioned one or more dryers also require additional heat to raise the temperature of the pulverized raw material 214b. Typically, to evaporate water, the energy required to heat one or more dryers is very high and extremely costly. Furthermore, as a result of using high temperatures to dry the pulverized raw material 214b, some VOCs are released. Those VOCs need to be further processed, either requiring additional expensive equipment and energy requirements or simply being released into the atmosphere, causing harmful environmental impacts. Therefore, block 220 of the conventional process 200 is not desirable. The conventional process 200 can then proceed to block 230.

[0202] In block 230, a mechanical pulverization process can be performed on the dried raw material 214c to obtain a dried pulp product 234. Similar to block 210, a second amount of shaft work is also required to complete this mechanical pulverization process. Conventionally, the work required for block 230 is time-consuming and costly, resulting in an inefficient process. The equipment required for the mechanical pulverization process is also expensive, complex, and difficult to maintain. Furthermore, the mechanical pulverization process cannot completely pulp, i.e., finely pulverize, the dried raw material 214c. The fibers must be further pulverized, which either reduces the overall strength or is left as is, increasing aggregation and reducing uniformity. Therefore, block 230 of the conventional process 200 is not desirable. The conventional process 200 can end and be completed after block 230. However, in other embodiments, the conventional process 200 can continue to proceed to other process steps not shown.

[0203] In contrast to the conventional process 200, the processes of the present disclosure, such as the process 100 of FIG. 1, require only a little additional shaft work and little or no additional heat. Moreover, as described above, the processes of the present disclosure can substantially entrain all of the liquid VOCs into the liquid product, reducing the overall environmental impact. Further, since there is little additional heat, the keratinization of the fibers of the fibrous material during the processes of the present disclosure can be reduced. As a result, the fibers are mechanically superior and much more compressible than the fibers produced by conventional processes. Thus, the processes of the present disclosure are more cost-effective, energy-efficient, and environmentally friendly than conventional processes used to achieve the same goals.

[0204] FIG. 3A shows a flowchart of an exemplary conditioning process 300 of the present disclosure. As will be appreciated, the conditioning process 300 can be performed substantially at block 120 of FIG. 1. As shown, at block 310, the fibrous material (i.e., in the first mixture 116) can be substantially interacted with an additive. This interaction can form a substantially treated material between the additive and the fibrous material. Without wishing to be bound by any scientific theory, the additive can interact with lignin in the fibrous material to reduce the rigidity of the lignocellulose cells and increase the plasticity of the lignin. The conditioning process 300 can then proceed to block 320 or other steps (not shown) of the conditioning process 300.

[0205] In block 320, a first portion of the water in the fibrous material (i.e., the treated material obtained in block 310) can be released. Without wishing to be bound by any scientific theory, the additive exerts a dehydrating effect or a fluid resistance reducing effect on the fibrous material, and can release a first amount of free water from the fibrous material. This effect increases the amount of water removed by the conditioning process 300 and reduces the need for an additional drying step. The conditioning process 300 can then proceed to block 330 or other steps (not shown) of the conditioning process 300.

[0206] In block 330, an additive can be injected into the fibrous material (i.e., in the treated material). Without wishing to be bound by any scientific theory, the first released portion of water solubilizes the additive and enables the additive to penetrate into the fibrous material. The conditioning process 300 can then proceed to block 340 or other steps (not shown) of the conditioning process 300.

[0207] In block 340, the fibrous material and the injected additive can be made to interact to weaken the lignin in the fibrous material. As described above in block 310, without wishing to be bound by any scientific theory, the additive can interact with the lignin in the fibrous material to reduce the rigidity of the lignocellulose cells and increase the plasticity of the lignin. The injection in block 330 can further enhance the interaction and can further homogenize the treated material in block 340. The conditioning process 300 can then proceed to block 350 as shown in Figure 3B, proceed to other steps (not shown) of the conditioning process 300, or end after block 340.

[0208] Figure 3B shows a flowchart of an exemplary conditioning process 300 of the present disclosure. A system and machine for implementing the process are shown in detail in FIG. 4. As shown, at block 350, a pressure gradient can be applied to the fibrous material. This increase in pressure can raise the temperature of the material. Without wishing to be bound by any scientific theory, the flow resistance reducing property of the additive can increase the frictional force acting on the fibrous material. Since the additive reduces the rigidity and increases the plasticity of lignin in the fibrous material, the lignin (and thus the fibrous material) can remain in its original state without being destroyed even when the temperature rises. The conditioning process 300 can then proceed to block 360 or other steps (not shown) of the conditioning process 300.

[0209] At block 360, a shear force can be applied to the fibrous material. The applied shear force can increase the frictional force acting on the fibrous material, causing the internal temperature of the fibrous material to rise further. Since the additive reduces the rigidity and increases the plasticity of lignin in the fibrous material, the lignin (and thus the fibrous material) can remain in its original state without being destroyed even when the temperature rises. The conditioning process 300 can then proceed to block 370 or other steps (not shown) of the conditioning process 300. Note that the pressure gradient step of block 350 and the shear force step of block 360 may be performed in any order or simultaneously with each other.

[0210] In block 370, by separating the fibrous material, a second portion of water in the fibrous material (i.e., the treated material) can be evaporated. As will be appreciated, shear force and frictional force can separate the fibrous material and additional free water is released. The temperature rise due to shear force and pressure gradient can also evaporate the released free water. Without wishing to be bound by any scientific theory, the lignin inside the cell wall of the fibrous material is plasticized by an additive and can "inflate like a balloon" under pressure. In other words, when the water contained inside the individual cells of the fibrous material begins to evaporate due to the temperature rise caused by the pressure gradient and shear force / frictional force, the plasticized lignin in the cell wall can expand without rupturing, like a balloon being filled with hot air. When the cell volume increases under frictional force, shear force, rising temperature and rising pressure, the cells can further separate the fibrous material while remaining intact. The conditioning process 300 can then proceed to block 380 or other steps (not shown) of the conditioning process 300.

[0211] In block 380, the fibrous material (i.e., in the treated material) can be rapidly released to atmospheric pressure. Without wishing to be bound by any scientific theory, the rapid depressurization of this fibrous material can cause chemo-mechanical cell disruption of the fibrous material. In other words, the "balloon-like" cells in the fibrous material can be completely ruptured, releasing intracellular water and enabling further fractionation of the fibrous material. As will be understood, during conditioning, the fibrous material can be subjected to significant stress due to the pressure gradient, shear forces, frictional forces, and increasing temperature, resulting in the expansion of the cells containing the evaporated water. Without wishing to be bound by any scientific theory, the cells can be made expandable by the interaction of lignin and additives. By rapidly returning the fibrous material to atmospheric conditions, the chemo-mechanical cell disruption process can be induced, releasing the last portion of water to obtain the dry pulp product 124. It will also be understood that each portion of the water released during the conditioning process 300 may contain other components and can be recovered as the liquid product 122. The conditioning process 300 can then end after block 380 or proceed to other steps (not shown) of the conditioning process 300.

[0212] Disclosed herein is a machine 600 that can be used in the processes described herein. For example, as shown in FIG. 6, a machine 600 for chemo-mechanical cell disruption can be provided. The machine 600 can include an inlet 610. The raw material can enter the machine 600 through the inlet 610. The machine can include an outlet 620. The machine can include an internal chamber 630 that is connected to the inlet and the outlet. The internal chamber 630 has an inner surface. The machine can include a shaft 640 that extends across the inlet 610, the outlet 620, and the internal chamber 630. The shaft 640 has a plurality of grooves circumferentially disposed around the shaft 640, and the plurality of grooves have a first portion and a second portion. The first portion of the groove can have a first pitch, and the second portion of the groove can have a second pitch that is different from the first pitch. For example, the first pitch can be greater than the second pitch.

[0213] The inner chamber 630 may further comprise one or more shearing members 632 disposed on the inner surface and corresponding to the second portion of the groove. For example, the one or more shearing members 632 may comprise a shear knife. Other forms of shearing members may be used instead of the shear knife. The shear knife may be fabricated at any height, length, or angle desired to obtain a shearing force between the one or more shearing members 632 and the plurality of grooves.

[0214] The shaft may be configured to rotate about the longitudinal axis shared with the inner chamber 630, and by the rotation, a shearing force can be applied between the second portion of the groove and the one or more shearing members 632.

[0215] The machine may further comprise a protective shield 650 extending from the outer surface of the machine 600 and substantially surrounding the outlet 620. The protective shield 650 has an internal space 652 between the protective shield 650 and the outlet 620. The machine 600 may also comprise an outlet gate 622 configured to control the size of the outlet. The outlet gate 622 may be configured to expand and / or contract to control the flow rate of the material passing through the machine 600.

[0216] As described above, the raw material can enter the machine 600 through the inlet 610. The raw material may be mixed with an additive before proceeding through the machine 600 to weaken the cell walls of the fibrous material in the raw material. Thereafter, the raw material begins to receive a shearing force due to the rotation of the shaft 640 contacting the shearing member 632 within the inner chamber 630. When the shearing force begins to act on the fibrous material in the raw material, the internal pressure and temperature begin to rise due to the frictional force separating the fibrous material. As the material continues to move through the inner chamber 630 and continues to be sheared by the shearing member 632, the temperature and pressure continue to rise, so that water can be removed from the raw material. The weakened cell walls may begin to swell due to the increase in temperature and pressure. Thereafter, the fibrous material can pass through the outlet 620 and the outlet gate 622 that controls the discharge rate of the fibrous material. When the fibrous material exits the outlet 620, it can be rapidly released to atmospheric pressure, thereby inducing cell explosion.

[0217] In addition, in this specification, a process for increasing the raw material throughput according to the present disclosure is disclosed. One or more additives can be mixed with the raw material to obtain a first mixture. The raw material can include a fibrous material and water, and the fibrous material can include lignin. Suitable examples of the fibrous material and the additive are as described above, but other examples may also be used. A suitable example of the moisture content in the raw material is as described above. The raw material can be densified to form a product. The product can be in the form of pellets, briquettes, bales, logs, etc. As can be understood, the product can have a bulk density and PDI substantially similar to those of the above-described fiber pellets. This is because the fiber pellets and the product are produced by a similar process. The throughput of the process can be increased by 1% to 60% (for example, 1% to 30%) compared to the throughput of the process without additives. Without wishing to be bound by any scientific theory, the additive functions as a drag reducer, increases the throughput of the densification step, and increases the proportion of the product produced. Such an embodiment can be used, for example, to increase the animal feed production rate.

[0218] Examples The following examples are presented by way of illustration and not by way of limitation.

[0219] 800 pounds of wood chips with an initial moisture content of 50% derived from Cryptomeria japonica were adjusted by the process of the present disclosure for 1 hour or more to a moisture content of 18%. In this process, 48 kW of additional energy was used. While being conveyed, the produced fibers were air-dried to a moisture content of 16%. This was pulverized to produce pellets with a pellet durability index of 99, a moisture content of 4%, and a bulk density of 750 kg / m 3 When submerged in water for 2 minutes, the deterioration shown by the pellets was very limited. No steam was injected during the adjustment process. No additional heat energy was added during pelletization. A liquid extract containing the following components, schematically shown in Table I, was also produced by this adjustment. Table I. Example of Liquid Product Composition [Table 1]

[0220] As shown in various drawings and as described above, although the present disclosure has been described in connection with a plurality of exemplary embodiments, it is understood that other similar embodiments can be used, that is, changes and additions can be made to the above embodiments to achieve the same functions as the present disclosure without departing from the present disclosure. For example, in various embodiments of the present disclosure, methods and compositions have been described in accordance with the disclosed aspects of the subject matter. However, other methods or compositions equivalent to these described embodiments are also contemplated by the teachings of this specification. Therefore, the present disclosure should not be limited to any embodiment and should be construed in accordance with the scope and range of the appended claims.

[0221] It should be understood that the embodiments and claims disclosed herein are not limited in their application to the details of the structures and arrangements of the components described in the above description and shown in the drawings. Rather, the above description and drawings provide examples of the contemplated embodiments. The embodiments and claims disclosed herein allow for other embodiments and for various ways of practicing and implementing. Also, it should be understood that the terminology and jargon used herein are for illustrative purposes and should not be regarded as limiting the scope of the claims.

[0222] Therefore, those skilled in the art will understand that the concepts underlying the present application and the claims can be readily utilized as a basis for the design of other structures, methods, and systems for carrying out some of the objectives of the embodiments and claims presented in the present application. For this reason, it is important that the claims be regarded as including such equivalent structures.

[0223] Furthermore, the purpose of the above abstract is to enable each patent office and the public, especially those skilled in the art who are not familiar with patent and legal terms or expressions, to quickly determine the nature and gist of the technical disclosure of this application at a glance. The abstract is not intended to define the scope of the claims of this application, nor is it intended to limit the scope of the claims in any way. The present invention is intended to be defined by the claims attached hereto.

Claims

1. A step of preparing a raw material containing a fiber material and water, and a step of adjusting the raw material to obtain a liquid product and a dry pulp product, wherein the step of adjusting the raw material includes a step of putting the raw material into a chamber having a shaft, a step of applying a shearing force to the raw material by rotating the shaft, the step of applying a shearing force to the fiber material to increase the pressure and temperature of the fiber material, and a step of inducing cell explosion of a plurality of cells of the fiber material, wherein the shaft has one or more grooves arranged circumferentially around the shaft, and a process for obtaining a liquid product and a dry pulp product, wherein no external heating is performed on the chamber when the shearing force is applied.

2. The process according to claim 1, wherein the fiber material contains cellulose.

3. The process according to claim 2, wherein the fiber material further contains lignin and hemicellulose.

4. The process according to claim 1, wherein the amount of water contained in the raw material is about 10% by weight or more and about 90% by weight or less based on the total weight of the raw material.

5. The process according to claim 4, wherein the dry pulp product contains water in an amount of about 35% by weight or less based on the total weight of the dry pulp product without further drying after the cell explosion is induced.

6. The process according to claim 4, wherein the liquid product contains water in an amount of about 50% by weight or more based on the total weight of the liquid product.

7. The process according to claim 1, wherein in the step of applying a shearing force to the raw material, a second portion of water is removed from the raw material.

8. The process according to claim 1, wherein the liquid product contains at least 75% of the VOCs present in the raw material.

9. The process according to claim 1, wherein the adjustment is performed at a maximum temperature of about 93°C or more and about 177°C or less.

10. The process according to claim 1, further comprising a step of pelletizing the dry pulp product to form pellets.

11. The process according to claim 1, wherein the liquid product contains water and one or more of minerals, proteins, amino acids, humic acids, fulvic acids, and organic acids.

12. ​ The process according to claim 11, wherein the mineral comprises one or more of potassium, phosphorus, nitrogen compounds, calcium, magnesium, sulfur, sulfur (IV) (sulfurous), sodium, iron, manganese, zinc, and copper.

13. The process according to claim 11, wherein the liquid product further comprises one or more of cellulose, lignin, and hemicellulose.

14. The process according to claim 1, wherein the step of inducing cell disruption comprises exposing the fibrous material to a pressure lower than the pressure in the chamber.

15. The process according to claim 14, wherein the low pressure is atmospheric pressure.

16. The process according to claim 1, wherein the fibrous material is derived from wood.

17. The process according to claim 1, wherein the fibrous material comprises wood chips.

18. The process according to claim 1, wherein the chamber further comprises a plurality of shear members disposed on the inner surface of the chamber.

19. The process according to claim 18, wherein rotation of the shaft applies a shearing force to the fibrous material disposed between the plurality of shear members and the one or more grooves.

20. The process according to claim 1, wherein the dried pulp product comprises exposed cellulose fibers.

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