Grant: Collaborative Research and Development Grants

BACKGROUND: The declining fibre supply and rising fibre costs in recent years has forced the panel industry in Canada to seek for non-traditional fibre resource including fibre residues as potential source. Sludge is the final solid waste recovered from the wastewater treatment processes in pulp and paper mills, and the largest by-product of the industry. Millions of tons of dry sludge is generated each year in Canada, but most of the sludge has been disposed of through combustion and landfilling, both of which are today restricted by stricker environmental regulations. While several studies have investigated the use of recycled paper fibres mixed with resin for panel manufacturing , no attempts have been made to use the sludge for BINDERLESS medium density fibreboard manufacture. OVERALL OBJECTIVE: This project is to develop novel knowledge and technologies required to manufacture BINDERLESS panels using COMBINED primary and secondary sludge. WORK PLAN: The 3 year project will be completed by a team of complementary expertise from leading research institutions in 5 parts: 1) evaluation of the physical and chemical properties of sludge from various mills and quantification of the effects of pulping processes and raw fibre materials on sludge properties; 2) evaluation of sludge as a filler; 3) biological and chemical modifications of secondary sludge and investigation of its self-bonding mechanism; 4) manufacture of self-bonding fiberboard panels using combined primary and secondary sludge; and 5) development of quality fibreboard panels using less-desirable sludge mixed with virgin fibres and/or resin. BENEFITS: the project first and foremost will contribute to the training of HQP. It will generate the comprehensive knowledge of the physical and chemical properties of various sludge materials, and their variation with pulping process and raw fibre material. This study will fill in our knowledge gaps in the self-bonding mechanism and the biological and chemical modifications of secondary sludge, and will develop processing technologies. The acquired novel knowledge and technologies will allow for the first time to manufacture binderless fibreboards using combined primary and secondary sludge.