High-purity cellulose production from birch wood by γ-valerolactone/water fractionation and IONCELL-P process

Molecular-level design of alternative media for energy-saving pilot-scale fibrillation of nanocellulose

The outstanding mechanical properties, light weight, and biodegradability of cellulose nanofibrils (CNFs) make them promising components of renewable and sustainable next-generation reinforced composite biomaterials and bioplastics. Manufacturing CNFs at a pilot scale requires disc-refining fibrillation of dilute cellulose fibers in aqueous pulp suspensions to shear the fibers apart into their nanodimensional forms, which is, however, an energy-intensive process. Here, we used atomistic molecular dynamics (MD) simulation to examine media that might facilitate the reduction of interactions between cellulose fibers, thereby reducing energy consumption in fibrillation. The most suitable medium found by the simulations was an aqueous solution with 0.007:0.012 wt.% NaOH:urea, and indeed this was found in pilot-scale experiments to reduce the fibrillation energy by ~21% on average relative to water alone. The NaOH:urea-mediated CNFs have similar crystallinity, morphology, and mechanical strength to those formed in water. The NaOH and urea act synergistically on CNFs to aid fibrillation but at different length scales. NaOH deprotonates hydroxyl groups leading to mesoscale electrostatic repulsion between fibrils, whereas urea forms hydrogen bonds with protonated hydroxyl groups thus disrupting interfibril hydrogen bonds. This suggests a general mechanism in which an aqueous medium that contains a strong base and a small organic molecule acting as a hydrogen-bond acceptor and/or donor may be effectively employed in materials processes where dispersion of deprotonable polymers is required. The study demonstrates how atomic-detail computer simulation can be integrated with pilot-scale experiments in the rational design of materials processes for the circular bioeconomy.

Sustainable All-Cellulose Biocomposites from Renewable Biomass Resources Fabricated in a Water-Based Processing System by the Vacuum-Filtration-Assisted Impregnation Method

The increasing awareness of global ecological concerns and the rising sustainability consciousness associated with the manufacturing of non-renewable and non-biodegradable composite materials have led to extensive research on product and process developments of more sustainable, environmentally friendly, and fully biodegradable biocomposites for higher-value end-use applications. All-cellulose composites (ACCs) are an emerging class of biocomposites, which are produced utilizing solely cellulose as a raw material that is derived from various renewable biomass resources, such as trees and plants, and are assessed as fully biodegradable. In this study, sustainable ACCs were fabricated for the first time based on the full dissolution of commercially available sulfite dissolving (D) pulps as a matrix with concentrations of 1.5 wt.% and 2.0 wt.% in an aqueous NaOH-urea solvent, and they were then impregnated on/into the pre-fabricated birch (B), abaca (A), and northern softwood (N) fiber sheets as reinforcements by the vacuum-filtration-assisted impregnation approach. This research aimed to investigate the effects of the impregnated cellulose matrix concentrations and types of the utilized cellulose fiber reinforcements (B, A, N) on the morphological, crystalline, structural, and physio-mechanical properties of the ACCs. The highest degrees of improvements were achieved for tensile strength (+532%, i.e., from 9.24 MPa to 58.04 MPa) and strain at break of the B fiber-reinforced ACC B1.5 (+446%, i.e., from 1.36% to 4.62%) fabricated with vacuum impregnation of the 1.5 wt.% cellulose matrix. Noticeably, the greatest improvements were attained in strain at break of the A and N fiber-reinforced ACCs A2.0 (+218%, i.e., from 4.44 % to 14.11%) and N2.0 (+466%, i.e., 2.59% to 14.65%), respectively, produced with vacuum impregnation of the 2.0 wt.% cellulose matrix. The study highlights the diverse properties of the all-cellulose biocomposite materials that could, expectedly, lead to further development and research for upscaled production of the ACCs.

Efficient preparation of high-purity cellulose from moso bamboo by p-toluenesulfonic acid pretreatment

This work proposed a promising biorefinery method for the deconstruction of moso bamboo by using p-toluenesulfonic acid (P-TsOH) pretreatment to product high-purity cellulose (dissolving pulp). The cellulose pulp with high α-cellulose content (82.36 %) was successfully prepared for 60 min at low pretreatment temperature (90 °C) and atmospheric pressure. After the simple bleaching and cold caustic extraction (CCE) processes, the properties of cellulose pulp, such as α-cellulose content, polymerization, ISO brightness, all met the standard of dissolving pulp. In general, the cooking method through P-TsOH pretreatment can shorten the preparation time, which can effectively reduce energy consumption and chemical consumption. Therefore, this work may provide a new perspective for the green preparation of dissolving pulp that can be used to produce lyocell fiber after ash and metal ion treatment.

Gamma-valerolactone biorefinery: Catalyzed birch fractionation and valorization of pulping streams with solvent recovery

In this study, we propose a full gamma-valerolactone (GVL) organosolv biorefinery concept including the utilization of all pulping streams, solvent recovery, and preliminary material and energy balances. GVL is a renewable and non-toxic solvent that fractionates woody biomass. The silver birch chips were pulped (45-65 wt% GVL, 150 °C, 2 h) under a series of acid-catalyzed conditions (5-12 kg H₂SO₄/t), and the fully bleached pulp was spun into fibers by the IONCELL® process and knitted into the fabric. The dissolved lignin was precipitated by water from spent liquor (1:1) and processed into polyhydroxyurethane. Most of the dissolved hemicelluloses were in the form of xylose, therefore, the crystallization efficiency of xylose from spent liquor in the presence of residual GVL was studied. The GVL recovery rate in the lab column was 66%, however by increasing the number of equilibrium stages, 99% recovery could be achieved.

Efficient Fractionation and Catalytic Valorization of Raw Biomass in ϵ-Caprolactone and Water

Efficient fractionation and utilization of the whole biomass is particularly attractive but remains a great challenge, owing to the recalcitrance of biomass. In this study, a simple and efficient approach is developed to obtain high-purity cellulose with a delignification degree of 97.5 % in ϵ-caprolactone and water. FTIR spectroscopy reveals that ϵ-caprolactone and water act in synergy to remove lignin from raw biomass and afford cellulose with clear macrofibrils. A linear positive correlation between the contents of hemicellulose and lignin is observed for the separated cellulose pulp. This mixed solvent exhibits good performance for the removal of lignin from various agricultural and forestry wastes. Moreover, nearly complete transformation of the whole biomass constituents is achieved with Ni-Al catalyst.

Simultaneous microwave-assisted phosphotungstic acid catalysis for rapid improvements on the accessibility and reactivity of Kraft-based dissolving pulp

Improving the cellulose accessibility and reactivity in an efficient and convenient way has become the focused issue in the field of dissolving pulp manufacturing. We herein demonstrate a simple yet efficient strategy, namely a simultaneous microwave (MW)-assisted phosphotungstic acid (PTA) catalysis (MW-PTA_sim). The MW-PTA_sim treatment was efficient to improve Fock reactivity from 49.1 % to 85.8 % and decrease viscosity from 561 to 360 mL/g within 10 min, which was superior to the single MW treatment and the sequential MW-PTA_seq treatment. Besides, the MW-PTA_sim treated fiber had rougher and more fibrillated surfaces with an enhanced fiber accessibility, showing increased specific surface area (SSA) from 1.43 to 6.31 m²/g, mean pore diameter (MPD) from 6.92 to 11.20 nm and water retention value (WRV) from 101 % to 172 %. These positive enhancements are mainly due to a synergy that MW-enhanced rotation of PTA mediums was served as "spinning cutters" to attack the fibers, plus MW-accelerated PTA transfer and catalytic hydrolysis further improved the fiber accessibility. Moreover, PTA also demonstrates a high reusability and chemical stability. This process offers an effective and sustainable alternative for manufacturing a premium dissolving pulp.

Nypa fruticans Frond Waste for Pure Cellulose Utilizing Sulphur-Free and Totally Chlorine-Free Processes

The search for alternative methods for the production of new materials or fuel from renewable and sustainable biomass feedstocks has gained increasing attention. In this study, Nypa fruticans (nipa palm) fronds from agricultural residues were evaluated to produce pure cellulose by combining prehydrolysis for 1–3 h at 150 °C, sulfur-free soda cooking for 1–1.5 h at 160 °C with 13–25% active alkali (AA), 0.1% soluble anthraquinone (SAQ) catalyst, and three-stage totally chlorine-free (TCF) bleaching, namely oxygen, peroxymonosulfuric acid, and alkaline hydrogen peroxide stages. The optimal conditions were 3 h prehydrolysis and 1.5 h cooking with 20% AA. Soda cooking with SAQ was better than the kraft and soda process without SAQ. The method decreased the kappa number as a residual lignin content index of pulp from 13.4 to 9.9–10.2 and improved the yields by approximately 6%. The TCF bleaching application produced pure cellulose with a brightness of 92.2% ISO, 94.8% α-cellulose, viscosity of 7.9 cP, and 0.2% ash content. These findings show that nipa palm fronds can be used to produce pure cellulose, serving as a dissolving pulp grade for viscose rayon and cellulose derivatives.