Wood drying

Wood is divided, according to its botanical origin, into two kinds: softwoods, from coniferous trees, and hardwoods, from broad-leaved trees. Softwoods are lighter and generally simple in structure, whereas hardwoods are harder and more complex. However, in Australia, softwood generally describes rain forest trees, and hardwood describes Sclerophyll species (Eucalyptus spp). Softwoods such as pine are typically much lighter and easier to process than hardwoods such as fruit tree wood. The density of softwoods ranges from to , while hardwoods are to . Once dried, both consist of approximately 12% of moisture (Desch and Dinwoodie, 1996). Because of hardwood's denser and more complex structure, its permeability is much less than that of softwood, making it more difficult to dry. Although there are about a hundred times more species of hardwood trees than softwood trees, the ability to be dried and processed faster and more easily makes softwood the main supply of commercial wood nowadays. ==Wood–water relationships==

The timber of living trees and fresh logs contains a large amount of water which often constitutes over 50% of the wood's weight. Water has a significant influence on wood. Wood continually exchanges moisture or water with its surroundings, although the rate of exchange is strongly affected by the degree to which wood is sealed. Wood contains water in three forms: ; Free water: The bulk of water contained in the cell lumina is only held by capillary forces. It is not bound chemically and is called free water. Free water is not in the same thermodynamic state as liquid water: energy is required to overcome the capillary forces. Furthermore, free water may contain chemicals, altering the drying characteristics of wood. ; Bound or hygroscopic water: Bound water is bound to the wood via hydrogen bonds. The attraction of wood for water arises from the presence of free hydroxyl (OH) groups in the cellulose, hemicelluloses and lignin molecules in the cell wall. The hydroxyl groups are negatively charged. Because water is a polar liquid, the free hydroxyl groups in cellulose attract and hold water by hydrogen bonding. ; Vapor: Water in cell lumina in the form of water vapour is normally negligible at normal temperature and humidity. Moisture content The moisture content of wood is calculated as the mass change as a proportion of the dry mass, by the formula: : \text{moisture content} = \frac{m_\text{g} - m_\text{od}}{m_\text{od}} \times 100\% Here, m_\text{g} is the green mass of the wood, m_\text{od} is its oven dry mass (the attainment of constant mass generally after drying in an oven set at () for 24 hours as mentioned by Walker et al., 1993). The equation can also be expressed as a fraction of the mass of the water and the mass of the oven dry wood rather than a percentage. For example, (oven dry basis) expresses the same moisture content as 59% (oven dry basis). Fibre saturation point markings on a wood pallet indicate KD: kiln-dried, HT: heat treated, and DB: debarked. Essentially all wood packaging material that is exported to an IPPC member state must have a stamp such as this. When green wood dries, free water from the cell lumina, held by the capillary forces only, is the first to go. Physical properties, such as strength and shrinkage, are generally not affected by the removal of free water. The fibre saturation point (FSP) is defined as the moisture content at which free water should be completely gone, while the cell walls are saturated with bound water. In most types of woods, the fibre saturation point is at 25 to 30% moisture content. Siau (1984) reported that the fibre saturation point X_\text{fsp} (kg/kg) is dependent on the temperature T (°C) according to the following equation: :X_\text{fsp} = 0.30 - (T - 20C)/1000K \; (1.2) Keey et al. (2000) use a different definition of the fibre saturation point (equilibrium moisture content of wood in an environment of 99% relative humidity). Many properties of wood show considerable change as the wood is dried below the fibre saturation point, including: • volume (ideally no shrinkage occurs until some bound water is lost, that is, until wood is dried below FSP); • strength (strengths generally increase consistently as the wood is dried below the FSP, except for impact-bending strength and, in some cases, toughness); • electrical resistivity, which increases very rapidly with the loss of bound water when the wood dries below the FSP. Equilibrium moisture content Wood is a hygroscopic substance. It has the ability to take in or give off moisture in the form of vapour. Water contained in wood exerts vapour pressure of its own, which is determined by the maximum size of the capillaries filled with water at any time. If water vapour pressure in the ambient space is lower than vapour pressure within wood, desorption takes place. The largest-sized capillaries, which are full of water at the time, empty first. Vapour pressure within the wood falls as water is successively contained in smaller capillaries. A stage is eventually reached when vapour pressure within the wood equals vapour pressure in the ambient space above the wood, and further desorption ceases. The amount of moisture that remains in the wood at this stage is in equilibrium with water vapour pressure in the ambient space, and is termed the equilibrium moisture content or EMC (Siau, 1984). Because of its hygroscopicity, wood tends to reach a moisture content that is in equilibrium with the relative humidity and temperature of the surrounding air. The EMC of wood varies with the ambient relative humidity (a function of temperature) significantly, to a lesser degree with the temperature. Siau (1984) reported that the EMC also varies very slightly with species, mechanical stress, drying history of wood, density, extractives content and the direction of sorption in which the moisture change takes place (i.e. adsorption or desorption). Moisture content of wood in service Wood retains its hygroscopic characteristics after it is put into use. It is then subjected to fluctuating humidity, the dominant factor in determining its EMC. These fluctuations may be more or less cyclical, such as diurnal changes or annual seasonal changes. To minimize the changes in wood moisture content or the movement of wooden objects in service, wood is usually dried to a moisture content that is close to the average EMC conditions to which it will be exposed. These conditions vary for interior uses compared with exterior uses in a given geographic location. For example, according to the Australian Standard for Timber Drying Quality (AS/NZS 4787, 2001), the EMC is recommended to be 10–12% for the majority of Australian states, although extreme cases are up to 15 to 18% for some places in Queensland, Northern Territory, Western Australia and Tasmania. However, the EMC is as low as 6 to 7% in dry centrally heated houses and offices or in permanently air-conditioned buildings. Shrinkage and swelling Shrinkage and swelling may occur in wood when the moisture content is changed. Shrinkage occurs as moisture content decreases, while swelling takes place when it increases. Volume change is not equal in all directions. The greatest dimensional change occurs in a direction tangential to the growth rings. Shrinkage from the pith outwards, or radially, is usually considerably less than tangential shrinkage, while longitudinal (along the grain) shrinkage is so slight as to be usually neglected. The longitudinal shrinkage is 0.1% to 0.3%, in contrast to transverse shrinkages, which is 2% to 10%. Tangential shrinkage is often about twice as great as in the radial direction, although in some species it is as much as five times as great. The shrinkage is about 5% to 10% in the tangential direction and about 2% to 6% in the radial direction. Differential transverse shrinkage of wood is related to: • the alternation of late wood and early wood increments within the annual ring; • the influence of wood rays on the radial direction; • the features of the cell wall structure such as microfibril angle modifications and pits; • the chemical composition of the middle lamella. Wood drying may be described as the art of ensuring that gross dimensional changes through shrinkage are confined to the drying process. Ideally, wood is dried to that equilibrium moisture content as will later (in service) be attained by the wood. Thus, further dimensional change will be kept to a minimum. It is probably impossible to completely eliminate dimensional change in wood, but elimination of change in size may be approximated by chemical modification. For example, wood can be treated with chemicals to replace the hydroxyl groups with other hydrophobic functional groups of modifying agents. Among all the existing processes, wood modification with acetic anhydride has been noted for the high anti-shrink or anti-swell efficiency (ASE) attainable without damage to wood. However, acetylation of wood has been slow to be commercialised due to the cost, corrosion and the entrapment of the acetic acid in wood. There is an extensive volume of literature relating to the chemical modification of wood. Drying timber is one method of adding value to sawn products from the primary wood processing industries. According to the Australian Forest and Wood Products Research and Development Corporation (FWPRDC), green sawn hardwood, which is sold at about $350 per cubic metre or less, increases in value to $2,000 per cubic metre or more with drying and processing. However, currently used conventional drying processes often result in significant quality problems from cracks, both externally and internally, reducing the value of the product. For example, in Queensland (Anon, 1997), on the assumption that 10% of the dried softwood is devalued by $200 per cubic metre because of drying defects, saw millers are losing about $5 million a year. In Australia, the loss could be $40 million a year for softwood and an equal or higher amount for hardwood. Thus, proper drying under controlled conditions prior to use is of great importance in timber use, in countries where climatic conditions vary considerably at different times of the year. Drying, if carried out promptly after felling of trees, also protects timber against primary decay, fungal stain and attack by certain kinds of insects. Organisms, which cause decay and stain, generally cannot thrive in timber with a moisture content below 20%. Several, though not all, insect pests can live only in green timber. In addition to the above advantages of drying timber, the following points are also significant: Moisture in wood moves within the wood as liquid or vapour through several types of passageways, based on the nature of the driving force, (e.g. pressure or moisture gradient), and variations in wood structure, These are discussed here, including capillary action, which is a mechanism for free water transport in permeable softwoods. Total pressure difference is the driving force during wood vacuum drying. Capillary action Capillary forces determine the movements (or absence of movement) of free water. It is due to both adhesion and cohesion. Adhesion is the attraction between water to other substances and cohesion is the attraction of the molecules in water to each other. As wood dries, evaporation of water from the surface sets up capillary forces that exert a pull on the free water in the zones of wood beneath the surfaces. When there is no longer any free water in the wood capillary forces are no longer of importance. Moisture content differences The chemical potential is explained here since it is the true driving force for the transport of water in both liquid and vapour phases in wood. Classification of timbers for drying The timbers are classified as follows according to their ease of drying and their proneness to drying degrade: ; Highly refractory woods: These woods are slow and difficult to dry if the final product is to be free from defects, particularly cracks and splits. Examples are heavy structural timbers with high density such as ironbark (Eucalyptus paniculata), blackbutt (E. pillularis), southern blue gum (E. globulus) and brush box (Lophostemon cofertus). They require considerable protection and care against rapid drying conditions for the best results. ; Moderately refractory woods: These timbers show a moderate tendency to crack and split during seasoning. They can be seasoned free from defects with moderately rapid drying conditions (i.e. a maximum dry-bulb temperature of 85 °C can be used). Examples are Sydney blue gum (E. saligna) and other timbers of medium density, have developed a simple model of wood drying as a function of these three variables. Although the analysis was done for red oak, the procedure may be applied to any species of wood by adjusting the constant parameters of the model. Simply put, the model assumes that the rate of change of the moisture content M with respect to time t is proportional to how far the wood sample is from its equilibrium moisture content M_e, which is a function of the temperature T and relative humidity h: :\frac{dM}{dt} = -\frac{M - M_e}{\tau} where \tau is a function of the temperature T and a typical wood dimension L and has units of time. The typical wood dimension is roughly the smallest value of (L_r,\, L_t,\, L_L/10) which are the radial, tangential and longitudinal dimensions respectively, in inches, with the longitudinal dimension divided by ten because water diffuses about 10 times more rapidly in the longitudinal direction (along the grain) than in the lateral dimensions. The solution to the above equation is: :\frac{M - M_e}{M_0 - M_e} = e^{-\frac{t}{\tau}} Where M_0 is the initial moisture content. It was found that for red oak lumber, the "time constant" \tau was well expressed as: :\tau = \frac{L^n}{a + bp_\text{sat}(T)} where a, b and n are constants and p_\text{sat}(T) is the saturation vapor pressure of water at temperature T. For time measured in days, length in inches, and p_\text{sat} measured in mmHg, the following values of the constants were found for red oak lumber. :a = 0.0575 :b = 0.00142 :n = 1.52 Solving for the drying time yields: :t = -\tau\,\ln\left(\frac{M - M_e}{M_0 - M_e}\right) = \frac{-L^n}{a + bp_\text{sat}(T)}\,\ln\left(\frac{M - M_e}{M_0 - M_e}\right) For example, at 150°F, using the Arden Buck equation, the saturation vapor pressure of water is found to be about . The time constant for drying a red oak board at 150°F is then \tau = 3.03 days, which is the time required to reduce the moisture content to 1/e = 37% of its initial deviation from equilibrium. If the relative humidity is 0.50, then using the Hailwood-Horrobin equation the moisture content of the wood at equilibrium is about 7.4%. The time to reduce the lumber from 85% moisture content to 25% moisture content is then about 4.5 days. Higher temperatures will yield faster drying times, but they will also create greater stresses in the wood due because the moisture gradient will be larger. For firewood, this is not an issue but for woodworking purposes, high stresses will cause the wood to crack and be unusable. Normal drying times to obtain minimal seasoning checks (cracks) in 25mm (1inch or 4/4 lumber) Red Oak ranges from 22 to 30 days, and in 8/4, (50mm or 2inch) it will range from 65 to 90 days. ==Methods of drying timber==

Broadly, there are two methods by which timber can be dried: • natural drying or air drying • artificial drying Air drying Air drying is the drying of timber by exposing it to the air. The technique of air drying consists mainly of making a stack of sawn timber (with the layers of boards separated by stickers) on raised foundations, in a clean, cool, dry and shady place. Rate of drying largely depends on climatic conditions, and on the air movement (exposure to the wind). For successful air drying, a continuous and uniform flow of air throughout the pile of the timber needs to be arranged. Vacuum kiln These kilns can be the fastest to dry and most efficient with energy usage. In a vacuum, water boils at a lower temperature. In addition to increased speed, a vacuum kiln can also produce an improved quality in the wood. Low ambient pressure does lower the boiling point of water but the amount of energy required to convert the liquid to vapor is the same. Savings come from not being required to heat a huge building and not being required to vent the heat while lowering humidity. Since all free water can be removed at below 115 °F, quality is improved. While conventional drying uses warm, dry air to skim water off the surface, vacuum kilns can boil water from within the wood. This enables a good vacuum kiln to dry very thick wood very quickly. It is possible to dry 12/4 Red Oak fresh off the saw to 7% in 11 days. Since wood is dried with a vapor gradient - vapor pressure to ambient pressure - humidity can be kept very high. Because of this, a good vacuum kiln can dry 4.5" thick White Oak fresh off the saw to 8% in less than a month, a feat that was previously thought to be impossible. Solar kiln A solar kiln is a cross between kiln drying and air drying. These kilns are generally a greenhouse with a high-temperature fan and either vents or a condensing system. Solar kilns are slower and variable due to the weather, but are low cost. But there are competing perspectives, e.g., "Duhamel, who made many experiments on this important subject, states, that timber for the joiner's use is best put in water for some time, and afterwards dried; as it renders the timber less liable to warp and crack in drying; but, he adds, 'where strength is required it ought not to be put in water.'" Boiling or steam seasoning Submersion in boiling water or the application of steam speeds the drying of wood. This method is said to cause less shrinkage "… but it is expensive to use, and reduces the strength and elasticity of the timber." Chemical or salt seasoning Salt seasoning is the submersion of wood in a solution of urea, sodium nitrate, all of which act as dehydrating agents. Then the wood is air dried. Electrical seasoning Electrical seasoning involves running an electric current through the lumber causing heat to be generated and drying the wood. This method is expensive but is fast and uniform quality. Freeze drying Freeze drying is accomplished by lowering the pressure in a chamber containing the wood to a few millibars, while lowering the temperature of the chamber to below the eutectic point of the material. Heat is typically added slowly to the material to allow the water contained in the wood to sublimate directly into vapor, and be deposited on the sides of the vacuum chamber or in the cold trap through which the chamber is evacuated. Freeze drying through sublimation typically takes about 10 times the energy that is taken through evaporation of water by heat. In practice, freeze drying of wood can be accomplished by placing room temperature wood in a vacuum chamber that can be chilled to -30 degrees C or lower, evacuating the chamber to a few millibars, and at the same time cooling the chamber to a freezing temperature. The latent heat of the ice in the wood will come out through the water vapor, which will condense as ice on the inside of the chamber. After a few hours under vacuum and freezing conditions, the chamber is returned to normal pressure, the wood removed and bagged in plastic to keep water from condensing on it, and allowed to return to room temperature over a few hours to a day. The cycle is then repeated, each time the latent heat in the wood is removed through the water content in the wood sublimating and/or evaporating and condensing on the sides of the container and in the cold trap. The cycles are repeated until the moisture content of the wood is at a pre-determined acceptable level. Instead of cycling the wood in the chamber, heat can be added to the wood at a rate that matches the rate of sublimation of ice in the wood to water vapor, which is deposited on the inside of the chamber or in the cold trap. An advantage of freeze drying wood is that the form of the wood is maintained, and shrinkage does not typically occur. Shrinkage will occur over time after the wood is freeze dried, but this typically will not cause defects in the wood. ==Drying defects==

Drying defects are the most common form of degrade in timber, next to natural problems such as knots. (Innes, 1996). Collapse is a defect that results from the physical flattening of fibres to above the fibre saturation point and is thus not a form of shrinkage anisotropy. The standard organizations in Australia and New Zealand (AS/NZS 4787, 2001) have developed a standard for timber quality. The five measures of drying quality include: • moisture content gradient and presence of residual drying stress (case-hardening); • surface, internal and end checks; • collapse; • distortions; • discolouration caused by drying. ==Wood-drying kiln==

A variety of wood drying kiln technologies exist today: conventional, dehumidification, solar, vacuum and radio frequency. Conventional wood dry kilns (Rasmussen, 1988) are either package-type (sideloader) or track-type (tram) construction. Most hardwood lumber kilns are sideloader kilns in which fork trucks are used to load lumber packages into the kiln. Most softwood lumber kilns are track types in which lumber packages are loaded on kiln/track cars for loading the kiln. Modern high-temperature, high-air-velocity conventional kilns can typically dry green lumber in 10 hours down to a moisture content of 18%. However, 1-inch-thick green Red Oak requires about 28 days to dry down to a moisture content of 8%. Heat is typically introduced via steam running through fin/tube heat exchangers controlled by on/off pneumatic valves. Less common are proportional pneumatic valves or even various electrical actuators. Humidity is removed via a system of vents, the specific layout of which are usually particular to a given manufacturer. In general, cool dry air is introduced at one end of the kiln while warm moist air is expelled at the other. Hardwood conventional kilns also require the introduction of humidity via either steam spray or cold water misting systems to keep the relative humidity inside the kiln from dropping too low during the drying cycle. Fan directions are typically reversed periodically to ensure even drying of larger kiln charges. Most softwood lumber kilns operate below temperature. Hardwood lumber kiln drying schedules typically keep the dry bulb temperature below . Difficult-to-dry species might not exceed . Dehumidification kilns are very similar to conventional kilns in basic construction. Drying times are usually comparable. Heat is primarily supplied by an integral dehumidification unit which also serves to remove humidity. Auxiliary heat is often provided early in the schedule where the heat required may exceed the heat generated by the DH unit. Solar kilns are conventional kilns, typically built by hobbyists to keep initial investment costs low. Heat is provided via solar radiation, while internal air circulation is typically passive. In 1949 a Chicago company introduced a wood drying kiln that used infrared lamps that they claimed reduced the standard drying time from 14 days to 45 minutes. Newer wood drying technologies have included the use of reduced atmospheric pressure to attempt to speed up the drying process. A variety of vacuum technologies exist, varying primarily in the method heat is introduced into the wood charge. Hot water platten vacuum kilns use aluminum heating plates with the water circulating within as the heat source, and typically operate at significantly reduced absolute pressure. Discontinuous and SSV (super-heated steam) use atmosphere to introduce heat into the kiln charge. Discontinuous technology allows the entire kiln charge to come up to full atmospheric pressure, the air in the chamber is then heated, and finally vacuum is pulled. SSV run at partial atmospheres (typically around 1/3 of full atmospheric pressure) in a hybrid of vacuum and conventional kiln technology (SSV kilns are significantly more popular in Europe where the locally harvested wood is easier to dry versus species found in North America). RF/V (radio frequency + vacuum) kilns use microwave radiation to heat the kiln charge, and typically have the highest operating cost due to the heat of vaporization being provided by electricity rather than local fossil fuel or waste wood sources. Valid economic studies of different wood drying technologies are based on the total energy, capital, insurance/risk, environmental impacts, labor, maintenance, and product degrade costs for the task of removing water from the wood fiber. These costs (which can be a significant part of the entire plant costs) involve the differential impact of the presence of drying equipment in a specific plant. An example of this is that every piece of equipment (in a lumber manufacturing plant) from the green trimmer to the infeed system at the planer mill is the "drying system". Since thousands of different types of wood products manufacturing plants exist around the globe, and may be integrated (lumber, plywood, paper, etc.) or stand alone (lumber only), the true costs of the drying system can only be determined when comparing the total plant costs and risks with and without drying. The total (harmful) air emissions produced by wood kilns, including their heat source, can be significant. Typically, the higher the temperature the kiln operates at, the larger amount of emissions are produced (per pound of water removed). This is especially true in the drying of thin veneers and high-temperature drying of softwoods. == OSHA Standards regarding Dry Kiln Facilities ==

1910.265(f)(3)(i)(a): Main kiln doors shall be provided with a method of holding them open while kiln is being loaded. 1910.265(f)(3)(i)(b): Counterweights on vertical lift doors shall be boxed or otherwise guarded. 1910.265(f)(3)(i)(c): Adequate means shall be provided to firmly secure main doors, when they are disengaged from carriers and hangers, to prevent toppling. 1910.265(f)(3)(ii)(a): If operating procedures require access to kilns, kilns shall be provided with escape doors that operate easily from the inside, swing in the direction of exit, and are located in or near the main door at the end of the passageway. 1910.265(f)(3)(ii)(b): Escape doors shall be of adequate height and width to accommodate an average size man. 1910.265(f)(4): Pits. Pits shall be well ventilated, drained, and lighted, and shall be large enough to safely accommodate the kiln operator together with operating devices such as valves, dampers, damper rods, and traps. ==See also==