Fiber-Based Biopolymer Processing as a Route toward Sustainability

Some of the most abundant biomass on earth is sequestered in fibrous biopolymers like cellulose, chitin, and silk. These types of natural materials offer unique and striking mechanical and functional features that have driven strong interest in their utility for a range of applications, while also matching environmental sustainability needs. However, these material systems are challenging to process in cost-competitive ways to compete with synthetic plastics due to the limited options for thermal processing. This results in the dominance of solution-based processing for fibrous biopolymers, which presents challenges for scaling, cost, and consistency in outcomes. However, new opportunities to utilize thermal processing with these types of biopolymers, as well as fibrillation approaches, can drive renewed opportunities to bridge this gap between synthetic plastic processing and fibrous biopolymers, while also holding sustainability goals as critical to long-term successful outcomes.

The Relationship between Crystal Structure and Mechanical Performance for Fabrication of Regenerated Cellulose Film through Coagulation Conditions

Cellulose films regenerated from aqueous alkali–urea solution possess different properties depending on coagulation conditions. However, the correlation between coagulant species and properties of regenerated cellulose (RC) films has not been clarified yet. In this study, RC films were prepared from cellulose nanofiber (CNF) and microcrystalline cellulose (MCC) under several coagulation conditions. Cellulose dissolved in aqueous LiOH–urea solution was regenerated using various solvents at ambient temperature to investigate the effects of their dielectric constant on the properties of RC film. The crystal structure, mechanical properties, and surface morphology of prepared RC films were analyzed using X-ray diffraction (XRD), tensile tester, and atomic probe microscopy (AFM), respectively. It is revealed that the preferential orientation of (110) and (020) crystal planes, which are formed by inter- and intramolecular hydrogen bonding in cellulose crystal regions, changed depending on coagulant species. Furthermore, we found out that tensile strength, elongation at break, and crystal structure properties of RC films strongly correlate to the dielectric constant of solvents used for the coagulation process. This work, therefore, would be able to provide an indicator to control the mechanical performance of RC film depending on its application and to develop detailed researches on controlling the crystal structure of cellulose.

Relaxation phenomenon and swelling behavior of regenerated cellulose fibers affected by organic solvents

Regenerated cellulose fibers are extremely sensitive to water. In particular, their mechanical properties are greatly affected by water. Recently, it was clarified that the glass transition temperatures of regenerated cellulose over 500 K can be shifted to room temperature, and small-angle X-ray scattering (SAXS) showed the maxima and shoulders on the equator line in the wet state. In this study, glass transition caused by organic solvents was observed, although the peak heights of tangent δ (tan δ) were low, which suggested the regions affected by organic solvents were small. SAXS showed the maxima and shoulders, suggesting that organic solvents decreased the density of the amorphous region, i.e., widened space between cellulose molecules, creating sufficient space for the micro-Brownian motion of cellulose main chains. However, alkanes with molecular weight larger than n-nonane did not show tan δ peaks, which suggests that the solvent is hard to enter between microfibrils.

Relaxation phenomenon and swelling behavior of regenerated cellulose fibers affected by water

Regenerated cellulose fibers are extremely sensitive to water; particularly, the mechanical properties are greatly affected by water. We examined the effect of water on regenerated cellulose fibers in respect of the relaxation phenomenon and swelling behavior. The peaks and shoulder of mechanical loss tangent δ were observed at room temperature and water regains of 56-78%. At the same time, the storage modulus markedly decreased around these water regains. Small angle X-ray scattering showed the maxima and shoulders in the wet state, which suggested that water decreased the density of the amorphous region and made space for the movement of polymer segments. It is possible that the glass transition temperatures of 510-550 K shift to room temperature at specific water regains. It is reasonable to suppose that water can penetrate into the amorphous region, loosening the interactions between cellulose molecules and widening the region, and in consequence decreasing the glass transition temperature.

New Insights on the Role of Urea on the Dissolution and Thermally-Induced Gelation of Cellulose in Aqueous Alkali

The gelation of cellulose in alkali solutions is quite relevant, but still a poorly understood process. Moreover, the role of certain additives, such as urea, is not consensual among the community. Therefore, in this work, an unusual set of characterization methods for cellulose solutions, such as cryo-transmission electronic microscopy (cryo-TEM), polarization transfer solid-state nuclear magnetic resonance (PTssNMR) and diffusion wave spectroscopy (DWS) were employed to study the role of urea on the dissolution and gelation processes of cellulose in aqueous alkali. Cryo-TEM reveals that the addition of urea generally reduces the presence of undissolved cellulose fibrils in solution. These results are consistent with PTssNMR data, which show the reduction and in some cases the absence of crystalline portions of cellulose in solution, suggesting a pronounced positive effect of the urea on the dissolution efficiency of cellulose. Both conventional mechanical macrorheology and microrheology (DWS) indicate a significant delay of gelation induced by urea, being absent until ca. 60 °C for a system containing 5 wt % cellulose, while a system without urea gels at a lower temperature. For higher cellulose concentrations, the samples containing urea form gels even at room temperature. It is argued that since urea facilitates cellulose dissolution, the high entanglement of the cellulose chains in solution (above the critical concentration, C*) results in a strong three-dimensional network.

Effects of coagulation conditions on structure and properties of cellulose-based fibers from aqueous NaOH solvent

Hydroxyethyl cellulose (HEC) fibers with low degree of substitution were prepared by wet spinning of solutions in 8wt% NaOH solvent, and H₂SO₄/Na₂SO₄/ZnSO₄ solution was chosen as coagulants. The influence of coagulation temperature and H₂SO₄ concentration on structure and mechanical properties of resultant HEC fibers was examined by synchrotron X-ray measurements, scanning electron microscope and tensile tests. The results were analyzed from the perspective of coagulation kinetics by determining coagulation rate and mass transfer rate difference. It is shown that the increase of either coagulation temperature or H₂SO₄ concentration would accelerate the diffusion and coagulation process. The lowest coagulation temperature of 20°C or moderate H₂SO₄ concentration around 10-15wt%, which provided a gentle solidification process, favored the development of regular crystal and oriented structure, uniform and dense inner structure as well as cross sections closer to circular, resulting in HEC fibers with better tensile properties.

Side-chain motion of components in wood samples partially non-crystallized using NaOH-water solution

Wood samples (Picea jezoensis Carr.) were treated with solutions of aqueous NaOH (0-0.20 concentration fraction) and each treated samples evaluated by dynamic mechanical analyses (DMA). NaOH treatment was shown to affect the interactions between microfibrils and the surrounding matrix and, in particular, the dynamics of methylol groups in the microfibrils. The former is not dependent on the degree of crystallization but rather on the eluviation of the matrix. The latter depends on the degree of crystallization. Alkali treatment induces changes in the polymer domains as a result of matrix eluviation. This decreases the dynamics of methylol groups at NaOH concentrations less than 0.11. On the other hand, alkali treatment causes non-crystallization at concentrations greater than 0.11, which quantitatively increases the flexibility of methylol groups. Crystallinity decreased, and main-chain dynamics increased, following treatment with highly concentrated NaOH solutions. The dynamics of lignin also increased due to weakened interactions with microfibrils due to non-crystallization.

Rheological behaviors in the regimes from dilute to concentrated in cellulose solutions dissolved at low temperature

Cellulose was dissolved rapidly in 9.5 wt.-% NaOH/4.5 wt.-% thiourea aqueous solution pre-cooled to -5 degrees C to prepare cellulose solution with different concentrations. The rheological properties of the cellulose solutions in wide concentration regimes from dilute (0.008 wt.-%) to concentrated (4.0 wt.-%) at 25 degrees C were investigated. On the basis of data from the steady-shear flow test, the critical overlap (c*), the entanglement (c(e)) and the gel (c(g)) concentrations of the cellulose solution at 25 degrees C were determined, respectively, to be 0.10 wt.-%, 0.53 wt.-% and 2.50 wt.-%, in accordance with the results of storage modulus (G') versus c by dynamic test. Moreover, the Cox-Merz deviation at relatively low concentrations was in good agreement with the micro-gel particles in dilute regime. As the cellulose concentration increased, a homogeneous 3-dimensional network formed in the cellulose solution in the concentrated regime, and further increasing of the concentration led to micro-phase separation as determined by the time-temperature superposition (tTS). So far, this complex cellulose solution has been successfully described by the concentration regime theory for the first time, and the relatively molecular morphologies in each regime have been determined, providing useful information for the applications of the cellulose solution systems.

High-strength cellulose/poly(ethylene glycol) gels

Cellulose gel membranes have been prepared by a pre-gelation method employing cellulose solutions in aqueous NaOH-thiourea obtained at low temperature. The cellulose gels were then swollen by low-molecular-weight polyethylene glycol (PEG; MW<1000 g mol(-1)), and the morphology, structure and mechanical properties of the cellulose/PEG gels were studied by various techniques. The gels exhibit high mechanical performance, and the tensile strength of the gel membranes increases sharply with an increase in the molecular weight of PEG from 200 to 800 g mol(-1). Moreover, their elongation at break remains stable at 100 %. PEG800 efficiently improves the optical transmittance of the gel membranes at ambient temperature, which is about five times greater than that of a normal cellulose hydrogel membrane. A strong hydrogen-bonding interaction occurs between PEG and cellulose leading to a homogeneous structure, high mechanical strength and good transparency of the gel membranes.

Solid-State 13C NMR Study of Na−Cellulose Complexes

The interaction of microcrystalline cellulose from cotton and aqueous sodium hydroxide was investigated by 13C NMR solid-state spectroscopy as a function of temperature and sodium hydroxide concentration. When the concentration of NaOH was increased, the initial cellulose spectrum was replaced successively by that of Na-cellulose I followed by that of Na-cellulose II. In Na-cellulose I, each carbon atom occurred as a singlet, thus implying that one glucosyl moiety was the independent magnetic residue in the structure of this allomorph. In addition, the occurrence of the C6 near 62 ppm is an indication of a gt conformation for the hydroxymethyl group of Na-cellulose I. In Na-cellulose II, the analysis of the resonances of C1 and C6 points toward a structure based on a cellotriosyl moiety as the independent magnetic residue, in agreement with the established X-ray analysis that has shown that for this allomorph, the fiber repeat was also that of a cellotriosyl residue. For Na-cellulose II, the occurrence of the C6 in the 60 ppm region indicates an overall gg conformation for the hydroxymethyl groups. A comparison of the spectra recorded at 268 K and at room temperature confirms the stronger interaction of NaOH with cellulose when the temperature is lowered. In the Q region, corresponding to NaOH concentrations of around 9% and temperatures below 277 K, most of the sample was dissolved and no specific solid-state 13C NMR spectrum could be recorded, except for that of a small fraction of undissolved cellulose I. The same experiment run on a wood pulp sample leads to a new spectrum, with spectral characteristics different from those of Na-cellulose I and Na-cellulose II. This new spectrum is assigned to the Q phase, which appears to result from topological constraints that are present in whole wood pulp fibers but not in microcrystalline cellulose. A spectrum recorded for samples in the Na-cellulose III conditions resembled that of Na-cellulose II but of lower resolution. Similarly, a spectrum of a sample of Na-cellulose IV was identical to that of hydrated cellulose II. These observations have allowed us to propose a simplified phase diagram of the cellulose/NaOH system in terms of temperature and NaOH concentration. This diagram, which is simpler than the one deduced from X-ray analysis, consists of only four different regions partially overlapping.

Cellulose: fascinating biopolymer and sustainable raw material

As the most important skeletal component in plants, the polysaccharide cellulose is an almost inexhaustible polymeric raw material with fascinating structure and properties. Formed by the repeated connection of D-glucose building blocks, the highly functionalized, linear stiff-chain homopolymer is characterized by its hydrophilicity, chirality, biodegradability, broad chemical modifying capacity, and its formation of versatile semicrystalline fiber morphologies. In view of the considerable increase in interdisciplinary cellulose research and product development over the past decade worldwide, this paper assembles the current knowledge in the structure and chemistry of cellulose, and in the development of innovative cellulose esters and ethers for coatings, films, membranes, building materials, drilling techniques, pharmaceuticals, and foodstuffs. New frontiers, including environmentally friendly cellulose fiber technologies, bacterial cellulose biomaterials, and in-vitro syntheses of cellulose are highlighted together with future aims, strategies, and perspectives of cellulose research and its applications.

Structure and Properties of Novel Fibers Spun from Cellulose in NaOH/Thiourea Aqueous Solution

Cellulose was dissolved rapidly in a NaOH/thiourea aqueous solution (9.5:4.5 in wt.-%) to prepare a transparent cellulose solution, which was employed, for the first time, to spin a new class of regenerated cellulose fibers by wet spinning. The structure and mechanical properties of the resulting cellulose fibers were characterized, and compared with those of commercially available viscose rayon, cuprammonium rayon and Lyocell fibers. The results from wide angle X-ray diffraction and CP/MAS 13C NMR indicated that the novel cellulose fibers have a structure typical for a family II cellulose and possessed relatively high degrees of crystallinity. Scanning electron microscopy (SEM) and optical microscopy images revealed that the cross-section of the fibers is circular, similar to natural silk. The new fibers have higher molecular weights and better mechanical properties than those of viscose rayon. This low-cost technology is simple, different from the polluting viscose process. The dissolution and regeneration of the cellulose in the NaOH/thiourea aqueous solutions were a physical process and a sol-gel transition rather than a chemical reaction, leading to the smoothness and luster of the fibers. This work provides a potential application in the field of functional fiber manufacturing.

Production of cellulose II from native cellulose by near- and supercritical water solubilization

We explored conditions for dissolving microcrystalline cellulose in high-temperature and high-pressure water without catalyst and in order to produce cellulose II in a rapid and selective manner. For understanding reactions of microcrystalline cellulose in subcritical and supercritical water, its solubilization treatment was conducted using a continuous-flow-type microreactor. It was found that cellulose could dissolve in near- and supercritical water at short treatment times of 0.02-0.4 s, resulting in the formation of cellulose II in relatively high yield after the treatment. Next, characteristics of the cellulose II obtained were investigated. As a result, it was confirmed that the relative crystallinity index and the degree of polymerization of the cellulose II were high values ranging from 80 to 60% and from 50 to 30%, respectively. From these findings, it was suggested that this method had high potential as an alternative technique for the conventional cellulose II production method.

Structure analysis of regenerated cellulose hydrogels by small-angle and ultra-small-angle x-ray scattering

Absolute intensities Deltai(q) of small-angle x-ray scattering (SAXS) and ultra-small-angle x-ray scattering (USAXS) were measured in a wide range of scattering vector q from 2x10(-4) to 0.5 A(-1) for transparent (VI-P) and translucent (VI-L) cellulose hydrogels prepared by coagulation and regeneration of viscose in acid solutions with and without acetone, respectively. We obtained the scattering intensities at very small q conveniently by desmearing the combined data measured by SAXS and USAXS. The plot of Deltai(q)q(2) versus log(10) q showed a peak at -2.5<log(10) q<-1.0. By assuming a two-phase model with the high-density phase (phase 1) composed of only cellulose and with the low-density phase (phase 2) composed of cellulose dispersed in water, volume fractions of phase 1 in VI-P and VI-L were determined to be 0.18 and 0.09, respectively, from the mean-square fluctuation of electron density determined as integral of (Deltai(q)q(2)dq). By fitting the observed scattering profile with the theoretical particle scattering functions of spheres, the average diameter of the high-density region including crystallite was determined to be 120 A for VI-P and 80 A for VI-L. Similar analyses were applied also to freeze-dried VI-P. These results were consistent with those obtained by the wide-angle x-ray-diffraction measurement and also with the observation by scanning probe microscopy.