Ionic Liquids for the Production of Man-Made Cellulosic Fibers: Opportunities and Challenges

Optimization of Dry-Jet Wet Spinning of Regenerated Cellulose Fibers Using [mTBDH][OAc] as a Solvent

Superbase-based ionic liquids (ILs) have demonstrated excellent dissolution capability for cellulose, and employing the dry-jet wet spinning process, high-tenacity regenerated textile fibers have been made. Among a range of superbase-based ILs, [mTBDH][OAc] exhibited not only good spinnability but also exceptional recyclability, making it highly suitable for a closed-loop production of regenerated cellulose fibers. To further optimize the spinning process, we investigated the influence of the cellulosic raw materials and the IL with residual water on spinnability and fiber properties. In addition, single-filament spinning and multifilament spinning using spinnerets with different hole densities were investigated to reveal the upscaling challenges of the dry-jet wet spinning process. The air gap conditions, for example, temperature and moisture concentration were simulated using COMSOL multiphysics. The results indicate that the presence of a small amount of water (3 wt%) in the IL has a positive effect on spinnability, while the mechanical properties of the fibers remain unchanged.

Progress, Challenge and Perspective of Fabricating Cellulose

Cellulose as the most abundant biopolymers on Earth, presents appealing performance in mechanical properties, thermal management, and versatile functionalization. The development of fabrication methods closely relates to enrich its functionality and reduce manufacture cost. However, cellulose is hard to be dissolved by most common solvents or melt due to its recalcitrant property. Herein, the recent progress of fabricating cellulose is summarized. First, the unique hierarchical structure of cellulose is fully investigated and the resulted processability is highlighted in directions of down to nanocellulose, dissolution, and thermoplastic processing. Then, the reported fabrication methods are summarized in three aspects: (1) self-assembly from nano/micro cellulose suspensions, especially the self-assembly of cellulose nanocrystals; (2) dissolution-regeneration-drying, covering spinning and solvent infusion processing; and (3) thermoplastic processing, focusing on analysis of the setup and the morphology changes of the prepared products. In each aspect, the flowchart of the fabrication process, the behind mechanism, fabricated products, and effects of processing parameters are explored. Finally, this review provides a perspective on the further direction of fabricating cellulose, especially the challenges toward mass production of cellulose. This article is protected by copyright. All rights reserved.

Production of rayon fibres from cellulosic pulps: State of the art and current developments

The increasing demand for cellulosic fibres is continuously driven by the growing earth population and requirements of the textile industry. The annual cotton production of ca. 25 million tons is no longer enough to meet the market demands. This market gap of cellulosic fibres is progressively filled by regenerated cellulosic fibres derived from the dissolving pulp. The conventional industrial process of viscose production is far from being environmentally friendly due to the use of hazardous reagents. Alternatively, new trends in the production of regenerated fibres are related to the direct dissolution of cellulose in appropriate environmentally sound recyclable solvents, allowing high quality rayon fibres. This article reviews the sources of dissolving pulps used for the production of viscose and its quality parameters related to the performance of viscose production. The prospective cellulose regeneration processes, both commercialized and under development, are reviewed regarding current and future developments in the area.

Trends on the Cellulose-Based Textiles: Raw Materials and Technologies

There is an emerging environmental awareness and social concern regarding the environmental impact of the textile industry, highlighting the growing need for developing green and sustainable approaches throughout this industry's supply chain. Upstream, due to population growth and the rise in consumption of textile fibers, new sustainable raw materials and processes must be found. Cellulose presents unique structural features, being the most important and available renewable resource for textiles. The physical and chemical modification reactions yielding fibers are of high commercial importance today. Recently developed technologies allow the production of filaments with the strongest tensile performance without dissolution or any other harmful and complex chemical processes. Fibers without solvents are thus on the verge of commercialization. In this review, the technologies for the production of cellulose-based textiles, their surface modification and the recent trends on sustainable cellulose sources, such as bacterial nanocellulose, are discussed. The life cycle assessment of several cellulose fiber production methods is also discussed.

Biodegradable Cellulose Film Prepared From Banana Pseudo-Stem Using an Ionic Liquid for Mango Preservation

The excessive use and disposal of plastic packaging materials have drawn increasing concerns from the society because of the detrimental effect on environment and ecosystems. As the most widely used fruit packing material, polyethylene (PE) film is not suitable for long-term preservation of some tropical fruits, such as mangos, due to its inferior gas permeability. Cellulose based film can be made from renewable resources and is biodegradable and environmental-friendly, which makes it a promising alternative to PE as a packaging material. In this study, cellulose film synthesized from delignified banana stem fibers via an ionic liquid 1-Allyl-3-methylimidazolium chloride ([AMIm][Cl]) were evaluated as packing material for mangos preservation. The moisture vapor transmission rate and gas transmission rate of the synthesized cellulose film were 1,969.1 g/(m²⋅24 h) and 10,015.4 ml/(m²⋅24 h), respectively, which are significantly higher than those of commercial PE films. The high permeability is beneficial to the release of ethylene so that contribute to extend fruit ripening period. As a result, cellulose film packaging significantly decreased the disease and color indexes of mangos, while prolonged the storage and shelf life of marketable fruits. In addition, the cellulose film was decomposed in soils in 4 weeks, indicating an excellent biodegradability as compared to the PE plastic film.

Green Conducting Cellulose Yarns for Machine-Sewn Electronic Textiles

The emergence of "green" electronics is a response to the pressing global situation where conventional electronics contribute to resource depletion and a global build-up of waste. For wearable applications, green electronic textile (e-textile) materials present an opportunity to unobtrusively incorporate sensing, energy harvesting, and other functionality into the clothes we wear. Here, we demonstrate electrically conducting wood-based yarns produced by a roll-to-roll coating process with an ink based on the biocompatible polymer:polyelectrolyte complex poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS). The developed e-textile yarns display a, for cellulose yarns, record-high bulk conductivity of 36 Scm-1, which could be further increased to 181 Scm-1 by adding silver nanowires. The PEDOT:PSS-coated yarn could be machine washed at least five times without loss in conductivity. We demonstrate the electrochemical functionality of the yarn through incorporation into organic electrochemical transistors (OECTs). Moreover, by using a household sewing machine, we have manufactured an out-of-plane thermoelectric textile device, which can produce 0.2 μW at a temperature gradient of 37 K.

Close Packing of Cellulose and Chitosan in Regenerated Cellulose Fibers Improves Carbon Yield and Structural Properties of Respective Carbon Fibers

A low carbon yield is a major limitation for the use of cellulose-based filaments as carbon fiber precursors. The present study aims to investigate the use of an abundant biopolymer chitosan as a natural charring agent particularly on enhancing the carbon yield of the cellulose-derived carbon fiber. The ionic liquid 1,5-diazabicyclo[4.3.0]non-5-enium acetate ([DBNH]OAc) was used for direct dissolution of cellulose and chitosan and to spin cellulose-chitosan composite fibers through a dry-jet wet spinning process (Ioncell). The homogenous distribution and tight packing of cellulose and chitosan revealed by X-ray scattering experiments enable a synergistic interaction between the two polymers during the pyrolysis reaction, resulting in a substantial increase of the carbon yield and preservation of mechanical properties of cellulose fiber compared to other cobiopolymers such as lignin and xylan.

CE and asymmetrical flow-field flow fractionation studies of polymer interactions with surfaces and solutes reveal conformation changes of polymers

Amphiphilic diblock copolymers consisting of a hydrophobic core containing a polymerized ionic liquid and an outer shell composed of poly(N-isoprolylacrylamide) were investigated by capillary electrophoresis and asymmetrical flow-field flow fractionation. The polymerized ionic liquid comprised poly(2-(1-butylimidazolium-3-yl)ethyl methacrylate tetrafluoroborate) with a constant block length (n = 24), while the length of the poly(N-isoprolylacrylamide) block varied (n = 14; 26; 59; 88). Possible adsorption of the block copolymer on the fused silica capillary, due to alterations in the polymeric conformation upon a change in the temperature (25 and 45 °C), was initially studied. For comparison, the effect of temperature on the copolymer conformation/hydrodynamic size was determined with the aid of asymmetrical flow-field flow fractionation and light scattering. To get more information about the hydrophilic/hydrophobic properties of the synthesized block copolymers, they were used as a pseudostationary phase in electrokinetic chromatography for the separation of some model compounds, that is, benzoates and steroids. Of particular interest was to find out whether a change in the length or concentration of the poly(N-isoprolylacrylamide) block would affect the separation of the model compounds. Overall, our results show that capillary electrophoresis and asymmetrical flow-field flow fractionation are suitable methods for characterizing conformational changes of such diblock copolymers.

Fungal Treatment Modifies Kraft Lignin for Lignin- and Cellulose-Based Carbon Fiber Precursors

The kraft lignin's low molecular weight and too high hydroxyl content hinder its application in bio-based carbon fibers. In this study, we were able to polymerize kraft lignin and reduce the amount of hydroxyl groups by incubating it with the white-rot fungus Obba rivulosa. Enzymatic radical oxidation reactions were hypothesized to induce condensation of lignin, which increased the amount of aromatic rings connected by carbon-carbon bonds. This modification is assumed to be beneficial when aiming for graphite materials such as carbon fibers. Furthermore, the ratio of remaining aliphatic hydroxyls to phenolic hydroxyls was increased, making the structure more favorable for carbon fiber production. When the modified lignin was mixed together with cellulose, the mixture could be spun into intact precursor fibers by using dry-jet wet spinning. The modified lignin leaked less to the spin bath compared with the unmodified lignin starting material, making the recycling of spin-bath solvents easier. The stronger incorporation of modified lignin in the precursor fibers was confirmed by composition analysis, thermogravimetry, and mechanical testing. This work shows how white-rot fungal treatment can be used to modify the structure of lignin to be more favorable for the production of bio-based fiber materials.

Pretreatment for biorefineries: a review of common methods for efficient utilisation of lignocellulosic materials

The implementation of biorefineries based on lignocellulosic materials as an alternative to fossil-based refineries calls for efficient methods for fractionation and recovery of the products. The focus for the biorefinery concept for utilisation of biomass has shifted, from design of more or less energy-driven biorefineries, to much more versatile facilities where chemicals and energy carriers can be produced. The sugar-based biorefinery platform requires pretreatment of lignocellulosic materials, which can be very recalcitrant, to improve further processing through enzymatic hydrolysis, and for other downstream unit operations. This review summarises the development in the field of pretreatment (and to some extent, of fractionation) of various lignocellulosic materials. The number of publications indicates that biomass pretreatment plays a very important role for the biorefinery concept to be realised in full scale. The traditional pretreatment methods, for example, steam pretreatment (explosion), organosolv and hydrothermal treatment are covered in the review. In addition, the rapidly increasing interest for chemical treatment employing ionic liquids and deep-eutectic solvents are discussed and reviewed. It can be concluded that the huge variation of lignocellulosic materials makes it difficult to find a general process design for a biorefinery. Therefore, it is difficult to define "the best pretreatment" method. In the end, this depends on the proposed application, and any recommendation of a suitable pretreatment method must be based on a thorough techno-economic evaluation.

Cellulose in Ionic Liquids and Alkaline Solutions: Advances in the Mechanisms of Biopolymer Dissolution and Regeneration

This review is focused on assessment of solvents for cellulose dissolution and the mechanism of regeneration of the dissolved biopolymer. The solvents of interest are imidazole-based ionic liquids, quaternary ammonium electrolytes, salts of super-bases, and their binary mixtures with molecular solvents. We briefly discuss the mechanism of cellulose dissolution and address the strategies for assessing solvent efficiency, as inferred from its physico-chemical properties. In addition to the favorable effect of lower cellulose solution rheology, microscopic solvent/solution properties, including empirical polarity, Lewis acidity, Lewis basicity, and dipolarity/polarizability are determinants of cellulose dissolution. We discuss how these microscopic properties are calculated from the UV-Vis spectra of solvatochromic probes, and their use to explain the observed solvent efficiency order. We dwell briefly on use of other techniques, in particular NMR and theoretical calculations for the same purpose. Once dissolved, cellulose is either regenerated in different physical shapes, or derivatized under homogeneous conditions. We discuss the mechanism of, and the steps involved in cellulose regeneration, via formation of mini-sheets, association into “mini-crystals”, and convergence into larger crystalline and amorphous regions. We discuss the use of different techniques, including FTIR, X-ray diffraction, and theoretical calculations to probe the forces involved in cellulose regeneration.

High-Performance Acetylated Ioncell-F Fibers with Low Degree of Substitution

Cellulose acetate is one of the most important cellulose derivatives. Herein we present a method to access cellulose acetate with a low degree of substitution through a homogeneous reaction in the ionic liquid 1,5-diazabicyclo[4.3.0]non-5-enium acetate ([DBNH][OAc]). This ionic liquid has also been identified as an excellent cellulose solvent for dry-jet wet fiber spinning. Cellulose was dissolved in [DBNH][OAc] and esterified in situ to be immediately spun into modified cellulose filaments with a degree of substitution (DS) value of 0.05-0.75. The structural properties of the resulting fibers, which are characterized by particularly high tensile strength values (525-750 MPa conditioned and 315-615 MPa wet) and elastic moduli between 10-26 GPa, were investigated by birefringence measurements, wide-angle X-ray scattering, and molar mass distribution techniques while their unique interactions with water have been studied through dynamic vapor sorption. Thus, an understanding of the novel process is gained, and the advantages are demonstrated for producing high-value products such as textiles, biocomposites, filters, and membranes.

Conversion of wood-biopolymers into macrofibers with tunable surface energy via dry-jet wet-spinning

ABSTRACT

Surface chemistry of regenerated all-wood-biopolymer fibers that are fine-tuned by composition of cellulose, lignin and xylan is elucidated via revealing their surface energy and adhesion. Xylan additive resulted in thin fibers and decreased surface energy of the fiber outer surfaces compared to the cellulose fibers, or when lignin was used as an additive. Lignin increased the water contact angle on the fiber surface and decreased adhesion force between the fiber cross section and a hydrophilic probe, confirming that lignin reduced fiber surface affinity to water. Lignin and xylan enabled fiber decoration with charged groups that could tune the adhesion force between the fiber and an AFM probe. The fibers swelled in water: the neat cellulose fiber cross section area increased 9.2%, the fibers with lignin as the main additive 9.1%, with xylan 6.8%, and the 3-component fibers 5.5%. This indicates that dimensional stability in elevated humidity is improved in the case of 3-component fiber compared to 2-component fibers. Xylan or lignin as an additive neither improved strength nor elongation at break. However, improved deformability was achieved when all the three components were incorporated into the fibers.

Enhanced stabilization of cellulose-lignin hybrid filaments for carbon fiber production

Herein we investigate the stabilization behavior of a cellulose-lignin composite fibre towards application as a new bio derived precursor for carbon fibres. Carbon fibre materials are in high demand as we move towards a lower emission high-efficiency society. However, the most prominent current carbon fibre precursor is an expensive fossil-based polymer. Over the past decade significant research has focused on using renewable and bio derived alternatives. By blending cellulose and lignin and spinning a fibre with a continuous bi-component matrix a new approach to overcome the current limitations of both these precursors is proposed. A thorough study is conducted here on understanding the stabilization of the new precursors which is a critical step in the carbon fibre process. We show that stabilization times of the composite fibre are significantly reduced in comparison to pure lignin and improvements in mass yield compared to pure cellulose fibres are observed.

Cellulose modification and shaping – a review

This review aims to present cellulose as a versatile resource for the production of a variety of materials, other than pulp and paper. These products include fibers, nonwovens, films, composites, and novel derivatized materials. This article will briefly introduce the structure of cellulose and some common cellulose derivatives, as well as the formation of cellulosic materials in the micro- and nanoscale range. The challenge with dissolution of cellulose will be discussed and both derivatizing and nonderivatizing solvents for cellulose will be described. The focus of the article is the critical discussion of different shaping processes to obtain a variety of cellulose products, from commercially available viscose fibers to advanced and functionalized materials still at the research level.

Filament spinning of unbleached birch kraft pulps: Effect of pulping intensity on the processability and the fiber properties

Man-made lignocellulosic fibres were successfully prepared from unbleached birch kraft pulps by using the Ioncell-F technology. Pulps with different lignin content were produced by tailored kraft pulping with varying intensity. The degree of polymerization of the pulps was adjusted by acid-catalyzed hydrolysis and electron beam treatment. All substrates were completely soluble in 1,5-diazabicyclo[4.3.0]non-5-enium acetate ([DBNH]OAc) and the respective solutions were spinnable to yield fibres with good to excellent mechanical properties despite the use of only mildly refined wood pulp. The tensile properties decreased gradually as the lignin concentration in the fibres increased. Changes in the chemical composition also affected the structure and morphology of the fibres. Both the molecular orientation and the crystallinity decreased while the presence of lignin enhanced the water accessibility. The effects of the crystallite size and lignin content on monolayer water adsorption are discussed.

Effect of Ionic Liquids on Zebrafish (Danio rerio) Viability, Behavior, and Histology; Correlation between Toxicity and Ionic Liquid Aggregation

The effect of 11 common amidinium, imidazolium, and phosphonium based ionic liquids (ILs) on zebrafish (Danio rerio) and Chinese hamster ovary cells (CHO) was investigated with specific emphasis on the effect of anion and cation chain length and aggregation of phosphonium based ILs. Viability and behavioral alteration in the locomotor activity and place preference, after IL treatment of 5 days postfertilization larvae, was recorded. Behavior and histological damage evaluation was performed for adult fish in order to get insight into the long-term effects of two potential biomass-dissolving ILs, [DBNH][OAc] and [P4441][OAc]. To get an understanding of how IL aggregation is linked to the toxicity of ILs, median effective concentrations (EC50) and critical micelle concentrations (CMC) were determined. The long-chain ILs were significantly more toxic than the short-chain ones, and the anion chain length was shown to be less significant than the cation chain length when assessing the impact of ILs on the viability of the organisms. Furthermore, most of the ILs were as monomers when the EC50 was reached. In addition, the ILs used in the long-term tests showed no significant effect on the zebrafish behavior, breeding, or histology, within the used concentration range.