Fiber Composites Manufacturing

Cellulose fibers have inherent properties, such as tensile strength and density, that can add considerable value to durable materials. These include products ranging from fiberboard, whose solids are almost entirely wood-based, to siding composed of wood-cement mixtures. Such wood composites have been manufactured for decades, but have primarily used virgin fiber supplies. A number of technologies are being developed that can produce high-quality materials with low-value lignocellulose feedstocks that have previously not been exploited by industry (Hunt and Scott 1988).

Argonne National Laboratory has developed phosphate ceramics, known as Ceramicrete, that can replace traditional cement in durable building products such as sheathing and door cores, and offer mechanical advantages over existing products including strength, density and flame resistance. Phosphate ceramics can encapsulate low-level hazardous wastes without leaching, which allows for safe recycling of paper mill residue and treated wood. Because of the cement-like nature of the ceramic, wood wastes utilized do not have to be dry. The moisture present in the wood wastes can be beneficial because it helps to moisten the ceramic. This innovative process joins established wood waste recycling products, such as the use of sawdust in extruded plastic composites (Wagh 2005).

Much of the development of novel wood composite manufacturing is focused on maintaining compatibility with current industrial infrastructure. These composites are gaining in popularity mainly because the net energy required to produce them is expected to be less than that needed to make similar products from solid wood. These composites would be made from harvesting residues.  The University of Minnesota-Duluths Natural Resources Research Institute and the Argonne National Laboratory are leading the way domestically in developing commercially acceptable products.