Changes in lignin and cellulose by irradiation

The effect of high-energy radiation on wood and cellulose was investigated. By irradiation of beech wood, changes in lignin, in carbohydrates and in wood structure take place. Furthermore, new lignin carbohydrate complexes are formed. A way is shown to prevent undesirable reactions. Irradiated pulp possesses a lower degree of polymerization and a higher accessibility for chemical reactions. Processing irradiated pulp to viscose fibres will be more efficient.     

Evaluation of new organosolv dissolving pulps. Part I: Preparation, analytical characterization and viscose processability

New acidic organosolv pulping processes, such as Acetosolv, Formacell and Milox, promise to have superior potential in terms of purification selectivity and specific investment costs. Consequently, a thorough investigation of these new acidic pulping processes in comparison to state-of-the-art acidic magnesium sulfite technology was conducted. The impact of pulping and bleaching parameters on the physical and chemical characteristics was studied to compare process efficiency and selectivity for each type of pulp made from Eucalypt wood. In addition to a detailed analysis of the chemical composition and physical properties on a molecular and supramolecular level, the TCF-bleached dissolving pulps were tested for their applicability in viscose fiber production. The influence of pulp properties as determined by standard and advanced analytical methods on process performance and selected fiber properties is emphasized.     

SO2–ethanol–water (SEW) fractionation process: production of dissolving pulp from spruce

SO₂–ethanol–water (SEW) fractionation process is a highly attractive platform for future lignocellulosic Biorefineries. Its governing advantages include high flexibility in the selection of the raw material, simple and efficient recovery of fractionation chemicals, absence of carbohydrate degradation (both cellulose and hemicelluloses), and high reaction rates. The process is suitable for production of various carbohydrate- and lignin-based products including papermaking pulp, glucose, bioalcohols and lignosulfonates. The present paper addresses the possibility of producing dissolving pulp from spruce using SEW fractionation followed by ECF bleaching with and without hot caustic extraction. Comprehensive characterisation of chemical and macromolecular properties of the SEW dissolving pulps was complemented by determining the quality of viscose. The comparison with conventional viscose-grade acid sulfite pulps revealed close proximity in all properties. Therefore, considering the advantages of SEW process, it is suggested as a possible replacement for acid sulfite process in dissolving pulp manufacturing.     

Ionic liquid extraction method for upgrading eucalyptus kraft pulp to high purity dissolving pulp

High purity cellulose from wood is an important raw material for many applications such as cellulosic fibers, films or the manufacture of various cellulose acetate products. Hitherto, multi-step refining processes are needed for an efficient hemicellulose removal, most of them suffering from severe cellulose losses. Recently, a novel method for producing high purity cellulose from bleached paper grade birch kraft pulp was presented. In this so called IONCELL process, hemicelluloses are extracted by an ionic liquid–water mixture and both fractions can be recovered without yield losses or polymer degradation. Herein, it is demonstrated that bleached Eucalyptus urograndis kraft pulp can be refined to high purity acetate grade pulp via the IONCELL process. The hemicellulose content could be reduced from initial 16.6 to 2.4 wt% while persevering the cellulose I crystal form by using an optimized 1-ethyl-3-methylimidazolium dimethylphosphate-water mixture as the extraction medium. The degree of polymerization was then reduced by a sulfuric acid treatment for subsequent acetylation of the pulp, resulting in a final hemicellulose content of 2.2 wt%. When pre-treating the pulp enzymatically with endoxylanase, the final hemicellulose content could be reduced even to 1.7 wt%. For comparison, the eucalyptus kraft pulp was also subjected to cold caustic extraction and the same subsequent acid treatment which led to 3.9 wt% of residual hemicelluloses. The performance in acetylation of all produced pulps was tested and compared to commercial acetate grade pulp. The endoxylanase-IONCELL-treated pulp showed superior properties. Thus, an ecologically and economically efficient alternative for the production of highest value cellulose pulp is presented.     

Dissolving-grade birch pulps produced under various prehydrolysis intensities: quality,structure and applications

Aqueous-phase prehydrolysis followed by alkaline pulping is a viable process to produce wood-based dissolving pulps. However, detailed characterisation of the achievable pulp quality, performance and cellulose structure is yet lacking. In this study, the production of hemicellulose-lean birch soda-anthraquinone pulps after prehydrolysis under various intensities was investigated. Increasing prehydrolysis intensity resulted in pulps of higher purity but lower cellulose yield and degree of polymerisation. Higher cellulose yield by using sodium borohydride during pulping was achieved at the expense of reducing pulp purity. Cellulose crystallinity was similar in all pulps indicating simultaneous degradation of both crystalline and amorphous cellulose regions. Reinforced prehydrolysis seemingly increased the cellulose crystal size and the interfibrillar distances. Moderate intensity prehydrolysis (170 °C) resulted in a pulp well suited for viscose application, whereas reinforced prehydrolysis favoured the production of acceptable cellulose triacetate dope. The performance of the pulps in viscose and acetate applications was strongly related to the chemical and structural properties.     

13C CPMAS NMR investigations of cellulose polymorphs in different pulps

In order to obtain information about the crystallinity and polymorphs of cellulose, and the occurrence of hemicelluloses in pulp fibers, wood cellulose, bacterial cellulose, cotton linters, viscose, and celluloses in different pulps were investigated by solid state ¹³C CPMAS NMR spectroscopy. A mixed softwood kraft pulp and a dissolving-grade pulp were treated under strongly alkaline and acidic conditions and the effect on cellulose crystallinity was studied. The presence of different crystalline polymorphs of cellulose and the amounts of hemicelluloses are considered.     

Sulfur-free dissolving pulps and their application for viscose and lyocell

In this study, the concept of multifunctional alkaline pulping has been approved to produce high-purity and high-yield dissolving pulps. The selective removal of hemicelluloses was achieved by either water autohydrolysis (PH) or alkaline extraction (E) both applied as pre-treatments prior to cooking. Alternatively, hemicelluloses were isolated after oxygen delignification in a process step denoted as cold caustic extraction (CCE). Eucalyptus globulus wood chips were used as the raw material for kraft and soda-AQ pulping. In all process modifications sulfur was successfully replaced by anthraquinone. By these modifications purified dissolving pulps were subjected to TCF bleaching and comprehensive viscose and lyocell application tests. All pulps met the specifications for dissolving pulps. Further more, CCE-pulps showed a significantly higher yield after final bleaching. Morphological changes such as ultrastructure of the preserved outer cell wall layers, specific surface area and lateral fibril aggregate dimension correlated with the reduced reactivity towards regular viscose processing. The residual xylan after alkali purification depicted a lower content of functional groups and a higher molecular weight and was obviously entrapped in the cellulose fibril aggregates which render the hemicelluloses more resistant to steeping in the standard viscose process. Simultaneously, the supramolecular structure of the cellulose is partly converted from cellulose I to cellulose II by the alkaline purification step which did not influence the pulps reactivity significantly. Nevertheless, these differences in pulp parameters did not affect the lyocell process due to the outstanding solubility of the pulps in NMMO. Laboratory spinning revealed good fiber strength for both, regular viscose and lyocell fibers. The high molecular weight xylan of the CCE-treated pulps even took part in fiber forming.     

Monitoring the polymerization process of polypyrrole films by thermogravimetric and X-ray analysis

Bio-composite fibers were developed from wood pulp and polypropylene (PP) by an extrusion process. The thermo-physical and mechanical properties of wood pulp-PP composite fibers, neat PP and wood pulp were studied using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic mechanical analysis (DMA). The thermal stability of bio-composite fibers was found to be significantly higher than pure wood pulp. An understanding into the melting behaviour of the composite system was obtained which would assist in selecting a suitable temperature profile for the extruder during processing. The visco-elastic properties of bio-composite fibers were also revealed from the study. The generated bio-composite fibers were also characterized using Fourier transform infrared spectroscopy (FTIR) to understand the nature of chemical interaction between wood pulp reinforcement and PP matrix. The use of maleated polypropylene (MAPP) as a compatibilizer was investigated in relation to the fiber microstructure. Changes in absorption peaks were observed in FTIR spectra of bio-composite fibers as compared to the pure wood pulp which indicated possible chemical linkages between the fiber and polymer matrix.     

A precise study on the feasibility of enzyme treatments of a kraft pulp for viscose application

The development of efficient process steps to convert paper-grade to dissolving pulps was investigated as part of the work programme to improve the process economics. The challenge of pulp refinement comprises the selective removal of hemicelluloses and the precise adjustment of the pulp viscosity, while maintaining the reactivity of the pulp as required for viscose application. The purpose of this study was to investigate the effects of various enzyme treatments on a commercial oxygen-delignified Eucalyptus globulus paper-grade kraft pulp in the course of a total chlorine free bleaching sequence in combination with refining techniques following the principle of Modified Kraft Cooking (Sixta et al. 2007). The objectives were to assess its applicability as viscose pulp besides the reduction of chemical consumption in alkaline and ozone bleaching steps by means of xylanase pre-treatment and the controlled adjustment of final pulp viscosity utilizing endoglucanase post-treatment. Xylanase pre-treatment combined with cold caustic extraction at reduced alkalinity efficiently removed the hemicelluloses from the pulp and clearly increased the pulp brightness by extensive removal of hexenuronic acid side chains. The xylanase pre-treated pulp showed increased reactivity towards xanthation and high viscose dope quality in terms of particle content. The dependence of cellulose chain scission on the applied endoglucanase concentration was analyzed in detail, and this allowed precise viscosity reduction as well as reactivity increase. The differently treated pulps, with and without xylanase pre-treatment, were of very narrow molecular weight distribution and the quality of the spun fibers were very similar to those viscose fibers from commercial dissolving pulps.     

Reactivity of Dissolving Pulp for Processing Viscose

Summary : Pulp reactivity is a kinetic term and is always connected with a certain derivatization process. The quality and hence the market value of the pulp is determined by such characteristics as α- cellulose content, solubility, brightness, ash content, as well as the amount of soluble material in dichloromethane. However, solubility data, especially S₁₈ and S₁₀ values do not characterise dissolving pulp reactivity. These are indicative of pulp solubility and provide some information regarding losses of material during pulp processing. One way by which the pulp reactivity for viscose making can be characterised is the investigation of the mercerisation step. Following the mercerisation kinetics by help of the molecular weight distribution of cellulose II the behaviour especially of the high molecular weight cellulose gives information regarding the accessibility and therefore, about the reactivity of the pulp aside from losses in low molecular weight cellulose. This behaviour will be shown on different pulps and the physicochemical background will be discussed in relation to results obtained from wide angle X-ray scattering and Raman investigations. The influence of the behaviour of the pulp during mercerising on the viscose process, and the molecular weight distribution of the viscose including the distribution of the xanthogenate groups along the chain was investigated and will also be discussed.     

Decontamination of food packaging using electron beam—status and prospects

In this paper the status of food packaging disinfection decontamination using electron beam at Mediscan GmbH is presented. The first section of the paper describes the activities at the service center, where food packaging materials, e.g. yoghurt cups are decontaminated in their final shipment containers. As important step in the hazard analysis and critical control point of food processing, microbiological uncontaminated food packaging material is of public interest and attracts a lot of attention from packaging material producers and food processors.The dose ranges for different sterility assurance levels are discussed and results from microbiological test are presented. Studies at Mediscan have demonstrated, that an electron beam treatment at a dose of 5–7 kGy is most effective against yeast and mold, which are mainly responsible for spoilage and short shelf-life of a variety of products.The second section is devoted to the field of inline decontamination of food packaging and sterilization of pharmaceutical packaging material and the research currently conducted at Mediscan. The requirements for industrial inline electron beam systems are summarized and design concepts discussed in terms of beam energy, beam current, irradiation topology, product handling and shielding.     

Switchable ionic liquids enable efficient nanofibrillation of wood pulp

Use of switchable ionic liquid (SIL) pulp offers an efficient and greener technology to produce nanofibers via ultrafine grinding. In this study, we demonstrate that SIL pulp opens up a mechanically efficient route to the nanofibrillation of wood pulp, thus providing both a low cost and chemically benign route to the production of cellulose nanofibers. The degree of fibrillation during the process was evaluated by viscosity and optical microscopy of SIL treated, bleached SIL treated and a reference pulp. Furthermore, films were prepared from the fibrillated material for characterization and tensile testing. It was observed that substantially improved mechanical properties were attained as a result of the grinding process, thus signifying nanofibrillation. Both SIL treated and bleached SIL treated pulps were fibrillated into nanofibers with fiber diameters below 15 nm thus forming networks of hydrophilic nature with an intact crystalline structure. Notably, it was found that the SIL pulp could be fibrillated more efficiently than traditional pulp since nanofibers could be produced with more than 30% less energy when compared to the reference pulp. Additionally, bleaching reduced the energy demand by further 16%. The study demonstrated that this switchable ionic liquid treatment has considerable potential in the commercial production of nanofibers due to the increased efficiency in fibrillation.     

The potential in bioethanol production from waste fiber sludges in pulp mill-based biorefineries

Industrial production of bioethanol from fibers that are unusable for pulp production in pulp mills offers an approach to product diversification and more efficient exploitation of the raw material. In an attempt to utilize fibers flowing to the biological waste treatment, selected fiber sludges from three different pulp mills were collected, chemically analyzed, enzymatically hydrolyzed, and fermented for bioethanol production. Another aim was to produce solid residues with higher heat values than those of the original fiber sludges to gain a better fuel for combustion. The glucan content ranged between 32 and 66% of the dry matter. The lignin content varied considerably (1-25%), as did the content of wood extractives (0.2-5.8%). Hydrolysates obtained using enzymatic hydrolysis were found to be readily fermentable using Saccharomyces cerevisiae. Hydrolysis resulted in improved heat values compared with corresponding untreated fiber sludges. Oligomeric xylan fragments in the solid residue obtained after enzymatic hydrolysis were identified using matrix-assisted laser desorption ionization-time of flight and their potential as a new product of a pulp mill-based biorefinery is discussed.     

Xylan enriched viscose fibers

In this study, a new xylan enriched viscose fiber was developed. A high molecular weight xylan with a degree of polymerization of 150–200 was added during a late stage of the viscose production process. The xylan deriving from a cold caustic extraction (CCE) of an eucalypt paper pulp was introduced to the process after xanthation and thus neither objected to any degradation conditions during alkalization nor to the xanthation step. About 90 % of the added xylan was transferred to the final fiber. A xylan content of up to 7.5 % was achieved. Fiber properties like strength showed a comparable level to the reference fibers while the water retention value was clearly raised due to the higher content of hemicelluloses. The hemicellulose distribution over the fiber cross section was investigated by enzymatic peeling. Even though a segregation of the different polysaccharides was observed, the goal of a good blending of CCE-xylan into cellulosic fibers with new interesting features was achieved.     

Alkaline steeping of dissolving pulp. Part I: cellulose degradation kinetics

The production of cellulosic man made fibres by the viscose process has been known for more than 120 years now, but still some aspects are not sufficiently understood in detail. The carbohydrates in the pulp are exposed to varying conditions during the manufacturing process. In the first production step of steeping, the strong alkaline treatment leads to undesirable loss reactions of the cellulose. In this study, a comprehensive kinetic model was developed for process simulation of cellulose degradation for the fist time comprising primary and secondary peeling, stopping and alkaline hydrolysis. A total chlorine free bleached beech sulfite pulp was treated with 18 % sodium hydroxide at 40, 50 and 60 °C for time periods up to 80 h. The corresponding reaction rates, activation energies and frequency factors for all reaction steps were calculated. The peeling-off reaction was of great significance for the cellulose yield loss, due to a contribution of the secondary peeling after random chain scission. The moderate decrease of the intrinsic viscosity and the changes in molar mass distribution indicated the validity of the assumption. Further, a reduction of the carbonyl and an increase of the carboxyl groups in the cellulose were observed due to the formation of the stable metasaccharinic acid at the reducing ends of the molecules. The fibre morphology was investigated by SEM measurements. Already short alkaline treatment times favored the dissolution of fibril fragments from the fibre surface leading to a smooth fibre surface.     

Reactivity of dissolving pulp: characterisation using chemical properties, NMR spectroscopy and multivariate data analysis

The reactivity of dissolving pulp was experimentally determined in termsof residual cellulose in viscose. The correlations between 11 chemicalproperties of pulp and filter values and residual cellulose contents of viscosewere then investigated by multivariate data analysis. Both the viscose filtervalue and the residual cellulose were well modelled from the 11 propertiesby partial least squares regression. The results show that pulps with highacetone extractable fractions, high magnesium contents, low alkali resistanceand low viscosity, gave low viscose filter values and low residual cellulosecontents. Pulps with low residual cellulose contents also had low carboxylgroupcontents and low polydispersity. The results are interpreted as that in pulpwith high reactivity, the hemicellulose content is low and that the cellulosechains are shorter and more soluble in alkali. An explanation of the positiveeffect from the high extractive content is that the extractives facilitate thediffusion of carbon disulfide. A principal component analysis of CP/MAS¹³C-NMR spectral data of six pulp samples showed that differences inreactivity between the pulps could be explained by variations in the hydrogenbonds in the cellulose and/or changes in the glucosidic bonds. In a separatestudy electron beam processing enhanced the reactivity, i.e. lowered theresidual cellulose content, of the investigated pulps. The magnitude of theelectron dose, within the tested range (5.4–23.7 kGy), didnotseem to be important, but the reactivity within pulp sheets tended to be ratherinhomogeneous.     

Upgrading of wood pre-hydrolysis liquor for renewable barrier design: a techno-economic consideration

A techno-economic assessment of an upgrading procedure and outtake of a pre-hydrolysate in a presumed dissolving pulp mill was performed. Pre-hydrolysis of spruce wood chips in pilot scale produced input data for energy and mass balances and was performed with and without subsequent membrane filtration to produce hydrolysate fractions rich in galactoglucomannan and with some lignin. The hydrolysate is a viable raw material for the production of renewable thin oxygen barrier films as demonstrated herein in the formulation of free standing films with very low oxygen permeability at both moderate and high relative humidities. Approximately 50,000 ton dry solid upgraded pre-hydrolysate suitable for production of oxygen barriers could be produced according to the presumed dissolving pulp mill producing about 500,000 air dry ton dissolving pulp per year and applying a liquor to wood ratio of 4:1. Utilization of the pre-hydrolysis liquor hence adds value to and realizes the dissolving plant as a biorefinery. A sensitivity analysis indicates that the market price of the upgraded pre-hydrolysate has the largest positive effect on the return on investment for separation and upgrading of a pre-hydrolysate. Increased investment cost and increased annuity factor show negative effects.     

New process for producing cellulose acetate from wood in concentrated acetic acid

To explore further potential applications of acetic acid pulp, an investigation was conducted to develop a direct method for producing cellulose acetate from wood in combination with atmospheric acetic acid pulping. The process consists of delignification, totally chlorine-free bleaching, and esterification, with the concentrated acetic acid aqueous solution being used as only solvent throughout the process. The acetic acid pulp with kappa number of 30 and ISO brightness of 16 was bleached with 5% ozone on pulp to kappa number of 1.4 and brightness of 61. The resulting bleached pulp was further bleached with peracetic acid to kappa number of less than 1.0 and brightness of 68. The final bleached acetic acid pulp was acetylated with acetic anhydride in the concentrated acetic acid for 45 min to produce cellulose acetate with an apparent degree of substitution (DS) of 2.54. Although the product was lower grade compared with commercially available cellulose diacetate because it was prepared from the chemical pulp but not dissolving pulp, the product was almost soluble in acetone. Eventually, the DS of the acetone-soluble fraction was 2.62. The acetone solubility might be attributed to the original acetic acid pulp that had been partially acetylated during the pulping.     

Defibration mechanisms of autohydrolyzed Eucalyptus wood chips

The objective of this study was to evaluate the influence of autohydrolysis on mechanical defibration of Eucalyptus wood chips. The autohydrolysis process changed notably the mechanical properties of Eucalyptus chips. The removal of mainly hemicelluloses undoubtedly decreased the overall pulp yield. Hemicellulose losses cannot be solely accounted for the changes in the wood and pulp properties, because the autohydrolysis also caused changes in lignin. When comparing the mechanical pulp fibers of the original wood chips with the fibers resulting from the autohydrolyzed wood material, it was clear that the rupture point shifted from the secondary wall to the middle lamella, confirmed by X-ray photoelectron spectroscopy measurements. This study revealed the mechanical behavior of autohydrolyzed wood chips and can provide useful information for integration of mechanical pulp mills into the biorefinery concept in the future.     

Polymers and paper as packaging materials of irradiated foodAn NMR study

Effects of γ-irradiation on synthetic polymers and paper used as packaging materials for irradiated food have been studied by NMR. Polystyrene, polybutadiene and some copolymers were studied before and after the γ-irradiation treatment and in the presence or absence of antioxidants and stabilisers. In the absence of additives, the effect of γ-irradiation on polystyrene is negligible even irradiating at high doses. In turn, the role of antioxidants and stabilisers is crucial in polybutadiene and butadiene-containing copolymers. Wood pulp paper was also studied by NMR. Preliminary measurements on γ-irradiated wood pulp sheets show a shortening in the T₂ relaxation time component due to the bound water, i.e. some of the bound water is lost.