Integrating phosphotungstic acid-assisted prerefining with cellulase treatment for enhancing the reactivity of kraft-based dissolving pulp

Viscosity control and reactivity enhancement are of practical importance for high-quality dissolving pulp manufacturing. In this work, we demonstrate a two-step activating process consisting of a phosphotungstic acid (PTA)-assisted prerefining (PTA/R pretreatment), followed by cellulase treatment for this purpose. The cellulase adsorption can increase from 29.1% to 49.7% as a result of PTA/R pretreatment (8000 r at 90 °C). The viscosity of the resultant pulp decreases from 665 to 430 mL/g, while its Fock reactivity increases from 31.5% to 74.4% under a low-loading cellulase treatment (0.5 mg cellulase /g odp), which mainly due to the fact that the PTA/R pretreatment can increase fiber accessibility and viscosity control, thus facilitating cellulase adsorption and reaction efficiency. Moreover, PTA also shows a high recyclability/ reusability (more than 86%) during the PTA/R pretreatment. Therefore, the new proposed two-step activating process provides a green, and efficient pathway for large-scale manufacturing of high-quality dissolving pulp.

Improving enzymatic hydrolysis of mechanically refined poplar branches with assistance of hydrothermal and Fenton pretreatment

The combination of different pretreatment methods can effectively overcome recalcitrance of lignocellulosic biomass to ensure its highly efficient conversion into bio-based products. In this study, the combined pretreatments of chemical methods (hydrothermal treatment and Fenton treatment) with mechanical refining were used to improve the enzymatic hydrolysis efficiency of poplar branches. The results indicated that hydrothermal pretreatment and Fenton pretreatment can effectively improve the enzymatic hydrolysis of poplar substrates, e.g., the maximum glucose conversion yield and glucose concentration reached 92.4% and 20.8 g/L, respectively. The pre-hydrolysates contained some valuable components such as monosaccharides, oligosaccharides, acetic acid, furfural, and hydroxymethylfurfural. The main characteristics (specific surface area, water retention value, fines content, and surface lignin concentration) of poplar substrates were obviously changed by the combined pretreatment, which benefit the enzymatic hydrolysis.

Two-stage autohydrolysis and mechanical treatment to maximize sugar recovery from sweet sorghum bagasse

Modified autohydrolysis combined with mechanical refining has been suggested to recover free sugars from sweet sorghum bagasse and facilitates enzyme access to cellulose in bagasse for enhancing its conversion to fermentable sugars. The amount of total available sugars in sweet sorghum bagasse was found to be 76.1% and this value was used to evaluate the efficiency of the process suggested. Total sugar recovery was achieved up to 68.1% through the single-stage autohydrolysis at 170 °C for 60 min, followed by mechanical refining and enzymatic hydrolysis; however, the sugar recovery through partial degradation of free sugars induced by high-temperature autohydrolysis was lower than expected. A modified two-stage autohydrolysis was suggested to prevent sugar degradation and the total sugar recovery using this process reached 83.9% of total available sugars in sweet sorghum bagasse.

Toward an understanding of the increase in enzymatic hydrolysis by mechanical refining

BACKGROUND

Mechanical refining is a low-capital and well-established technology used in pulp and paper industry to improve fiber bonding for product strength. Refining can also be applied in a biorefinery context to overcome the recalcitrance of pretreated biomass by opening up the biomass structure and modifying substrate properties (e.g., morphology, particle size, porosity, crystallinity), which increases enzyme accessibility to substrate and improves carbohydrate conversion. Although several characterization methods have been used to identify the changes in substrate properties, there is no systematic approach to evaluate the extent of fiber cell wall disruption and what physical properties can explain the improvement in enzymatic digestibility when pretreated lignocellulosic biomass is mechanically refined. This is because the fiber cell wall is complex across multiple scales, including the molecular scale, nano- and meso-scale (microfibril), and microscale (tissue level). A combination of advanced characterization tools is used in this study to better understand the effect of mechanical refining on the meso-scale microfibril assembly and the relationship between those meso-scale modifications and enzymatic hydrolysis.

RESULTS

Enzymatic conversion of autohydrolysis sugarcane bagasse was improved from 69.6 to 77.2% (11% relative increase) after applying mechanical refining and an increase in enzymatic digestibility is observed with an increase in refining intensity. Based on a combination of advanced characterizations employed in this study, it was found that the refining action caused fiber size reduction, internal delamination, and increase in pores and swellability.

CONCLUSIONS

A higher level of delamination and higher increase in porosity, analyzed by TEM and DSC, were clearly demonstrated, which explain the faster digestibility rate during the first 72 h of enzymatic hydrolysis for disc-refined samples when compared to the PFI-refined samples. In addition, an increased inter-fibrillar distance between cellulose microfibrils at the nano-meso-scale was also revealed by SFG analysis, while no evidence was found for a change in crystalline structure by XRD and solid-state NMR analysis.

Integrated microwave and alkaline treatment for the separation between hemicelluloses and cellulose from cellulosic fibers

In this study, the microwave was employed during the alkaline treatment process, in order to separate the hemicelluloses and cellulose from a delignified hardwood kraft pulp. In relation to hemicelluloses yield, the integrated microwave and alkaline treatment resulted in 9.25% and 12.05% at 50°C and 80°C, respectively. Correspondingly, the resultant pulp fibers presented the increased cellulose content, which was desirable for manufacturing dissolving pulp. Additionally, the effect from mechanical refining pretreatment followed microwave and alkaline treatment, on the separation of hemicelluloses and cellulose, was also investigated.

Impact of disk milling on corn stover pretreated at commercial scale

In cellulosic biofuel production, chemical pretreatment performed at laboratory or pilot scale, followed by mechanical refining, has been demonstrated to be effective to increase feedstock enzyme digestibility. To take the combined pretreatment process one step closer to commercialization, disk milling was performed with commercially pretreated corn stover. Dilute acid pretreated samples with combined severity factors (cSF) of 0.09 (DA09) and 0.43 (DA43) were obtained from a commercial plant. Effects of pretreatment conditions (DA09 and DA43), milling cycles (0, 3, 9, and 15) and enzyme dosages (7.8, 15.6 and 31.2mgcellulase/g dry biomass) were evaluated. Milling improved glucose yields by 0.7 to 1.2-fold. Higher enzyme dosages enhanced sugar yields. Milling was more effective to improve glucose yields, while enzyme dosage was more effective to improve xylose yields. However, dilute acid pretreatment condition was the most important factor to increase final sugar yields compared to milling cycles and enzyme dosages.

Surface lignin change pertaining to the integrated process of dilute acid pre-extraction and mechanical refining of poplar wood chips and its impact on enzymatic hydrolysis

Dilute acid pre-extraction enhanced the mechanically refined poplar pulp substrates' enzymatic hydrolysis efficiency obviously. The results showed that the surface lignin distribution was changed significantly in residual wood chips and pulp substrates, and the surface lignin distribution showed important impact on the following enzymatic hydrolysis. Acid pre-extraction can lead to a redistribution of lignin in fiber cell walls, i.e., the lignin was degraded and migrated to fiber surface in the form of re-deposited lignin and pseudo-lignin. However, higher pre-extraction intensity was not desired due to the formation of redeposited lignin and pseudo-lignin. This study will help to reach a deeper understanding on the lignin distribution in the view of molecular and ultrastructure, and promote the development of a cost-efficient pretreatment strategy for biomass processing.

Increasing efficiency of enzymatic hemicellulose removal from bamboo for production of high-grade dissolving pulp

To improve the efficiency of enzymatic hemicellulose removal from bamboo pre-hydrolysis kraft pulp, mechanical refining was conducted prior to enzyme treatment. Refining significantly improved the subsequent hemicellulose removal efficiency by xylanase treatment. Results showed that when PFI refining was followed by 3h xylanase treatment, the xylan content of the bamboo pre-hydrolysis kraft pulp (after first stage oxygen delignification) could be decreased to 2.72% (w/w). After bleaching of enzyme treated pulp, the alpha-cellulose content was 93.4% (w/w) while the xylan content was only 2.38%. The effect of refining on fibre properties was investigated in terms of freeness, water retention value, fibre length and fibrillation characteristics. The brightness, reactivity and viscosity were also determined to characterize the quality of final pulp. Results demonstrated the feasibility of combining refining and xylanase treatment to produce high quality bamboo dissolving pulp.

Post-treatment mechanical refining as a method to improve overall sugar recovery of steam pretreated hybrid poplar

This study investigates the effect of mechanical refining to improve the sugar yield from biomass processed under a wide range of steam pretreatment conditions. Hybrid poplar chips were steam pretreated using six different conditions with or without SO2. The resulting water insoluble fractions were subjected to mechanical refining. After refining, poplar pretreated at 205°C for 10min without SO2 obtained a 32% improvement in enzymatic hydrolysis and achieved similar overall monomeric sugar recovery (539kg/tonne) to samples pretreated with SO2. Refining did not improve hydrolyzability of samples pretreated at more severe conditions, nor did it improve the overall sugar recovery. By maximizing overall sugar recovery, refining could partially decouple the pretreatment from other unit operations, and enable the use of low temperature, non-sulfur pretreatment conditions. The study demonstrates the possibility of using post-treatment refining to accommodate potential pretreatment process upsets without sacrificing sugar yields.

Effects of fibrillation on the wood fibers' enzymatic hydrolysis enhanced by mechanical refining

The hardwood bleached kraft pulp (HBKP) fibers were pretreated by PFI mill to obtain the substrates, the effects of fibrillation on HBKP fibers' enzymatic hydrolysis was studied. The results showed that the enzymatic hydrolysis efficiency was enhanced obviously by mechanical refining. The mechanical refining alterated the fibers' characteristics such as fibrillation degree, specific surface area, swelling ability, crystallinity, fiber length and fines content. All these factors correlating to the enzymatic hydrolysis were evaluated through mathematical analysis. Among these factors, the fibrillation degree has the profoundest impact on the enzymatic hydrolysis of wood fibers. Consequently, the mechanical refining aiming for a high fibrillation degree was feasible to enhance the enzymatic hydrolysis of lignocellulosic biomass.

Use of mechanical refining to improve the production of low-cost sugars from lignocellulosic biomass

Mechanical refining is widely used in the pulp and paper industry to enhance the end-use properties of products by creating external fibrillation and internal delamination. This technology can be directly applied to biochemical conversion processes. By implementing mechanical refining technology, biomass recalcitrance to enzyme hydrolysis can be overcome and carbohydrate conversion can be enhanced with commercially attractive levels of enzymes. In addition, chemical and thermal pretreatment severity can be reduced to achieve the same level of carbohydrate conversion, which reduces pretreatment cost and results in lower concentrations of inhibitors. Refining is versatile and a commercially proven technology that can be operated at process flows of ∼ 1500 dry tons per day of biomass. This paper reviews the utilization of mechanical refining in the pulp and paper industry and summarizes the recent development in applications for biochemical conversion, which potentially make an overall biorefinery process more economically viable.

Promise of combined hydrothermal/chemical and mechanical refining for pretreatment of woody and herbaceous biomass

Production of advanced biofuels from woody and herbaceous feedstocks is moving into commercialization. Biomass needs to be pretreated to overcome the physicochemical properties of biomass that hinder enzyme accessibility, impeding the conversion of the plant cell walls to fermentable sugars. Pretreatment also remains one of the most costly unit operations in the process and among the most critical because it is the source of chemicals that inhibit enzymes and microorganisms and largely determines enzyme loading and sugar yields. Pretreatments are categorized into hydrothermal (aqueous)/chemical, physical, and biological pretreatments, and the mechanistic details of which are briefly outlined in this review. To leverage the synergistic effects of different pretreatment methods, conducting two or more pretreatments consecutively has gained attention. Especially, combining hydrothermal/chemical pretreatment and mechanical refining, a type of physical pretreatment, has the potential to be applied to an industrial plant. Here, the effects of the combined pretreatment (combined hydrothermal/chemical pretreatment and mechanical refining) on energy consumption, physical structure, sugar yields, and enzyme dosage are summarized.

Combination of mechanical, alkaline and enzymatic treatments to upgrade paper-grade pulp to dissolving pulp with high reactivity

A modified process consisting of an initial mechanical refining (R) followed by a low-alkali (5.5% NaOH) cold caustic extraction (CCE) and finally an endoglucanase (EG) treatment (R-5.5%CCE-EG) was investigated for upgrading paper-grade pulp to dissolving pulp. Results showed that compared to the conventional process (9%CCE-EG), the modified process can decrease the alkali concentration (from 9% to 5.5%) to achieve a similar hemicelluloses removal while simultaneously enhancing the Fock reactivity (from 62.2% to 81.0%). The improved results were due to the fact that the mechanical refining resulted in favorable fiber morphological changes, including increased pore volume/size, water retention value and specific surface area. Consequently, the hemicelluloses removal was enhanced even under the subsequent low-alkali CCE condition. A synergic effect of refining, low alkali concentration and enzymatic activation was responsible for the higher reactivity of resulting dissolving pulp.

Mechanical pretreatment improving hemicelluloses removal from cellulosic fibers during cold caustic extraction

Hemicelluloses removal is a prerequisite for the production of high-quality cellulose (also known as dissolving pulp), and further recovery and utilization of hemicelluloses, which can be considered as a typical Integrated Forest Biorefinery concept. In this paper, a process of combined mechanical refining and cold caustic extraction (CCE), which was applied to a softwood sulfite sample, was investigated. The results showed that the hemicelluloses removal efficiency and selectivity were higher for the combined treatment than that for the CCE alone. The combined treatment can thus decrease the alkali concentration (from 8% to 4%) to achieve a similar hemicelluloses removal. The improved results were due to the fact that the mechanical refining resulted in increases in pore volume and diameter, water retention value (WRV) and specific surface area (SSA), all of which can make positive contributions to the hemicelluloses removal in the subsequent CCE process.

Techno-economic analysis of the deacetylation and disk refining process: characterizing the effect of refining energy and enzyme usage on minimum sugar selling price and minimum ethanol selling price

BACKGROUND

A novel, highly efficient deacetylation and disk refining (DDR) process to liberate fermentable sugars from biomass was recently developed at the National Renewable Energy Laboratory (NREL). The DDR process consists of a mild, dilute alkaline deacetylation step followed by low-energy-consumption disk refining. The DDR corn stover substrates achieved high process sugar conversion yields, at low to modest enzyme loadings, and also produced high sugar concentration syrups at high initial insoluble solid loadings. The sugar syrups derived from corn stover are highly fermentable due to low concentrations of fermentation inhibitors. The objective of this work is to evaluate the economic feasibility of the DDR process through a techno-economic analysis (TEA).

RESULTS

A large array of experiments designed using a response surface methodology was carried out to investigate the two major cost-driven operational parameters of the novel DDR process: refining energy and enzyme loadings. The boundary conditions for refining energy (128-468 kWh/ODMT), cellulase (Novozyme's CTec3) loading (11.6-28.4 mg total protein/g of cellulose), and hemicellulase (Novozyme's HTec3) loading (0-5 mg total protein/g of cellulose) were chosen to cover the most commercially practical operating conditions. The sugar and ethanol yields were modeled with good adequacy, showing a positive linear correlation between those yields and refining energy and enzyme loadings. The ethanol yields ranged from 77 to 89 gallons/ODMT of corn stover. The minimum sugar selling price (MSSP) ranged from $0.191 to $0.212 per lb of 50 % concentrated monomeric sugars, while the minimum ethanol selling price (MESP) ranged from $2.24 to $2.54 per gallon of ethanol.

CONCLUSIONS

The DDR process concept is evaluated for economic feasibility through TEA. The MSSP and MESP of the DDR process falls within a range similar to that found with the deacetylation/dilute acid pretreatment process modeled in NREL's 2011 design report. The DDR process is a much simpler process that requires less capital and maintenance costs when compared to conventional chemical pretreatments with pressure vessels. As a result, we feel the DDR process should be considered as an option for future biorefineries with great potential to be more cost-effective.

Comparison of lab, pilot, and industrial scale low consistency mechanical refining for improvements in enzymatic digestibility of pretreated hardwood

Mechanical refining has been shown to improve biomass enzymatic digestibility. In this study industrial high-yield sodium carbonate hardwood pulp was subjected to lab, pilot and industrial refining to determine if the mechanical refining improves the enzymatic hydrolysis sugar conversion efficiency differently at different refining scales. Lab, pilot and industrial refining increased the biomass digestibility for lignocellulosic biomass relative to the unrefined material. The sugar conversion was increased from 36% to 65% at 5 FPU/g of biomass with industrial refining at 67.0 kWh/t, which was more energy efficient than lab and pilot scale refining. There is a maximum in the sugar conversion with respect to the amount of refining energy. Water retention value is a good predictor of improvements in sugar conversion for a given fiber source and composition. Improvements in biomass digestibility with refining due to lab, pilot plant and industrial refining were similar with respect to water retention value.

Comparison of different mechanical refining technologies on the enzymatic digestibility of low severity acid pretreated corn stover

The effect of mechanical refining on the enzymatic digestibility of pretreated corn stover (PCS) was investigated. Low severity, dilute sulfuric acid PCS was subjected to mechanical refining using a bench-scale food processor blender, a PFI mill, a 12-inch laboratory disk refiner, and a 25 mm co-rotating twin-screw extruder. Glucose yields from enzymatic hydrolysis were improved by 10-15% after blending and disk refining, while PFI refining and twin-screw extrusion showed a glucose yield improvement of 16-20%. A pilot scale refining test using a Szego mill was performed and showed approximately 10% improvements in biomass digestibility. This suggests the possibility to scale up a mechanical refining technique to obtain similar enzymatic digestibility glucose yield enhancement as achieved by PFI milling and extrusion technologies. Proposed mechanisms of each mechanical refining technology are presented and reasons for improvements in biomass digestibility are discussed in this paper.

Enhancement in enzymatic hydrolysis by mechanical refining for pretreated hardwood lignocellulosics

This study investigated the effectiveness of mechanical refining to overcome the biomass recalcitrance barrier. Laboratory scale refining was conducted via PFI mill and valley beater refiners using green liquor and Kraft hardwood pulps. A strong positive correlation was determined between sugar recovery and water retention value. Refining produced significant improvements in enzymatic hydrolysis yield relative to unrefined substrates (e.g., sugar recovery increase from 67% to 90%, for 15% lignin Kraft pulp). A maximum absolute enzymatic hydrolysis improvement with refining was observed at enzymatic hydrolysis conditions that produced intermediate conversion levels. For a 91% target sugar conversion, PFI refining at 4000 revolutions allowed for a 32% reduction in enzyme charge for 15% lignin content hardwood Kraft pulp and 96 h hydrolysis time, compared to the unrefined material.