Abstract:
Some variations provide a new nanolignocellulose composition comprising, on a bone-dry, ash-free, and acetyl-free basis, from 35 wt% to 80 wt% cellulose nanofibrils, cellulose microfibrils, or a combination thereof, from 15 wt% to 45 wt% lignin, and from 5 wt% to 20 wt% hemicelluloses. The hemicelluloses may contain xylan or mannan as the major component. Novel properties arise from the hemicellulose content that is intermediate between high hemicellulose content of raw biomass and low hemicellulose content of conventional nanocellulose. The nanolignocellulose composition is hydrophobic due to the presence of lignin. Processes for making and using the nanolignocellulose compositions are also described.
Abstract:
In some variations, OCC is screened, cleaned, deinked, and mechanically refined to generate cellulose nanofibrils. The OCC may be subjected to further chemical, physical, or thermal processing, prior to mechanical refining. For example, the OCC may be subjected to hot-water extraction, or fractionation with an acid catalyst, a solvent for lignin, and water. In certain embodiments to produce cellulose nanocrystals, OCC is exposed to AVAP® digestor conditions. The resulting pulp is optionally bleached and is mechanically refined to generate cellulose nanocrystals. In certain embodiments to produce cellulose nanofibrils, OCC is exposed to GreenBox+® digestor conditions. The resulting pulp is mechanically refined to generate cellulose nanofibrils. The site of a system to convert OCC to nanocellulose may be co-located with an existing OCC processing site. The nanocellulose line may be a bolt-on retrofit system to existing infrastructure. In other embodiments, a dedicated plant for converting OCC to nanocellulose is used.
Abstract:
The present invention provides a pulp product (e.g., paper) comprising cellulose and nanocellulose, wherein the nanocellulose is derived from the cellulose in a mechanical and/or chemical step that is separate from the main pulping process. The pulping process may be thermomechanical pulping or hydrothermal-mechanical pulping, for example. The pulp product is stronger and smoother with the presence of the nanocellulose. The nanocellulose further can function as a retention aid, for a step of forming the pulp product (e.g., in a paper machine). Other embodiments provide a corrugated medium pulp composition comprising cellulose pulp and nanocellulose, wherein the nanocellulose includes cellulose nanofibrils and/or cellulose nanocrystals and the nanocellulose may be hydrophobic. The nanocellulose improves the strength properties of the corrugated medium. In some embodiments, the cellulose pulp is a GreenBox+® pulp and the nanocellulose is derived from the AVAP® process.
Abstract:
A composition comprising nanocellulose is disclosed, wherein the nanocellulose contains very low or essentially no sulfur content. The nanocellulose may be in the form of cellulose nanocrystals, cellulose nanofibrils, or both. The nanocellulose is characterized by a crystallinity of at least 80%, an onset of thermal decomposition of 300F or higher, and a low light transmittance over the range 400-700 nm. Other variations provide a composition comprising lignin-coated hydrophobic nanocellulose, wherein the nanocellulose contains very low or essentially no sulfur content. Some variations provide a composition comprising nanocellulose, wherein the nanocellulose contains about 0.1 wt% equivalent sulfur content, or less, as SO4 groups chemically or physically bound to the nanocellulose. In some embodiments, the nanocellulose contains essentially no hydrogen atoms (apart from hydrogen structurally contained in nanocellulose itself) bound to the nanocellulose. Various compositions, materials, and products may incorporate the nanocellulose compositions disclosed herein.
Abstract:
In some variations, the invention provides a process for fractionating biomass, comprising: fractionating the biomass in the presence of a solvent for lignin, sulfur dioxide, and water, to produce a liquor containing hemicellulose, cellulose-rich solids, and lignin; hydrolyzing the hemicellulose contained in the liquor, to produce hemicellulosic monomers; hydrolyzing the cellulose-rich solids to produce glucose; and recovering the hemicellulosic monomers and the glucose, as fermentable sugars, wherein a metal sulfite or metal bisulfite additive is introduced to react directly or indirectly with lignin to produce sulfonated lignin. The disclosed processes may enhance lignin separations as well as promote the co-product potential of lignin.
Abstract:
Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with surprisingly low mechanical energy input. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and mechanically treating the cellulose-rich solids to form nanofibrils and/or nanocrystals. The total mechanical energy may be less than 500 kilowatt-hours per ton. The crystallinity of the nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites.
Abstract:
This disclosure provides a polymer composite including a polymer, nanocellulose, and a compatibilizer, wherein the nanocellulose comprises cellulose nanocrystals and/or cellulose nanofibrils, and wherein the compatibilizer comprises a maleated polymer. In some embodiments, the nanocellulose includes lignin-coated nanocellulose. The polymer may be selected from polyethylene, polypropylene, polystyrene, polylactide, or poly(ethylene terephthalate). The maleated polymer may be selected from maleated polyethylene, maleated polypropylene, maleated polystyrene, maleated polylactide, or maleated poly(ethylene terephthalate. Other variations provide a process for compatibilizing a polymer with nanocellulose, comprising: providing a polymer; providing nanocellulose comprising cellulose nanocrystals and/or cellulose nanofibrils; providing a maleated polymer; and combining the polymer, the nanocellulose, and the maleated polymer, wherein the maleated polymer functions as a compatibilizer between the polymer and the nanocellulose.
Abstract:
Some variations provide a process for producing a nanocellulose material, comprising: providing a biomass feedstock comprising a bleached or unbleached pulp material; fractionating the feedstock in the presence of an acid, a solvent for lignin, and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and mechanically treating the cellulose-rich solids to form cellulose fibrils and/or cellulose crystals, thereby generating a nanocellulose material. The process is preferably co-located with, or adjacent to, a mill that generates the pulp material. There are several advantages of a bolt-on AVAP® nanocellulose plant to an existing pulp mill, as disclosed herein.
Abstract:
In some variations, the invention provides a process for producing a microcrystalline cellulose material, comprising: fractionating lignocellulosic biomass feedstock in the presence of an acid, a solvent for lignin, and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; chemically and/or mechanically treating the cellulose-rich solids to form microcrystalline cellulose having an average crystallinity of at least 60%; and recovering the microcrystalline cellulose as a pharmaceutical excipient. The pharmaceutical excipient may function as an antiadherent, a binder, a coating, or a disintegrant. In some embodiments, the pharmaceutical excipient further comprises a lignin-derived lubricant, glidant, sorbent, preservative, or other component. The pharmaceutical excipient may be present in a pill, tablet, capsule, powder, slurry, or other pharmaceutically effective and acceptable form.
Abstract:
A polymer-nanocellulose-lignin composite as disclosed comprises a polymer, nanocellulose, and lignin, wherein lignin forms a hydrophobic interface between the polymer and the nanocellulose. In some variations, a process is disclosed for producing a polymer-nanocellulose-lignin composite material, comprising: fractionating lignocellulosic biomass in the presence of an acid, a solvent for lignin, and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin, wherein lignin deposits onto fiber surfaces or into fiber pores; mechanically treating the cellulose-rich solids to form a hydrophobic nanocellulose material comprising cellulose fibrils and/or cellulose crystals; hydrolyzing the hemicellulose to generate fermentable hemicellulosic sugars; fermenting the fermentable hemicellulosic sugars to generate a monomer or monomer precursor; polymerizing the monomer to produce a polymer; and combining the polymer with the lignin-coated nanocellulose to generate a polymer-nanocellulose-lignin composite material for use in a wide variety of products.