Abstract: A novel green manufacturing process for medium and high-density fiberboard (MDF and HDF) production is disclosed, where the green manufacturing process refers to a novel low-emitting manufacture of MDF and HDF in terms of HAP emission. The novel manufacturing process comprises a preconditioning unit operation for raw wood furnish material, where blends comprising two or more woody materials having disparate moisture contents are held in a preconditioning vessel for up to 48 hours under controlled temperature conditions, where the moisture content is homogenized to produce a blend having substantially uniform moisture content. The blend is preconditioned in the novel manufacturing process to facilitate moisture homogenization kinetics, and to uniformly increase the material temperature above the lignin glass transition temperature. Subsequent process steps, such as defibration and fiber drying, require lower temperatures to produce and dry wood fiber, thus lowering HAPs emission.

Abstract: A method for the dry-formation of a deep drawn, three-dimensional wood fiber structural core is provided. The method comprises providing a preformed, substantially flat, dry-formed mat of wood fibers, providing a three-dimensional mold, introducing the dry-formed mat of wood fibers into the three-dimensional mold, and drawing and molding the mat of wood fibers into said three-dimensional wood fiber structural core.

Abstract: A three-dimensional wood fiber structural composite comprises a uniformly strong three-dimensional wood fiber structural core and thin (e.g., ¼? OSB) face plies securely laminated on top and bottom contacting surfaces of the wood fiber structural core, wherein the core has a depth in the vertical axis of up to about 1½? to 1¾?. The structural core includes at least one of laminating platforms, load-bearing diagonal elements, anticline protrusions, ridges, fillets and curved corners. The longitudinal dimensions of adjoining ridges are alternatively shorter and longer to eliminate any uninterrupted straight and clear line of sight along a transverse row of adjoining ridges or valleys formed by the intersection of syncline indentations and anticline protrusions with the horizontal plane of the ridges.

Abstract: A method for the dry-formation of a deep drawn, three-dimensional wood fiber structural core is provided. The method comprises providing a preformed, substantially flat, dry-formed mat of wood fibers, providing a three-dimensional mold, introducing the dry-formed mat of wood fibers into the three-dimensional mold, and drawing and molding the mat of wood fibers into said three-dimensional wood fiber structural core.

Abstract: Lignocellulose is treated with an alkaline pretreatment liquor containing anthraquinone or other pretreatment agent in a continuous process in which the lignocellulose and pretreatment liquor flow countercurrently. The pretreatment agent is substantially soluble in the pretreatment liquor introduced into the pretreatment zone and is substantially insoluble in the pretreatment liquor withdrawn from the pretreatment zone, with the result that the pretreatment agent is effectively recycled within the pretreatment zone.

Abstract: By pretreating lignocellulose with an alkaline pretreatment liquor containing anthraquinone or a related compound, prior to alkaline digestion, a higher yield of pulp having a lower lignin content can be produced using less alkali. The pretreatment step is carried out under conditions that ensure survival of at least 50% of the anthraquinone or related compound in the pretreatment liquor, which is separated from the pretreated lignocellulose and reused to pretreat other lignocellulose.