A HIGH YIELD COOKING METHOD

Abstract

A cooking method and a digester system wherein partly digested cellulosic fiber source is compressed during cooking to provide high molecular weight xylan, high molecular weight lignin and pulp.

Claims

1. A cooking method comprising: a) providing wood based cellulosic raw material comprising chips, pin chips, shavings, saw dust, or a combination thereof; b) optionally pre-treating the wood based cellulosic raw material by steaming at 80-120° C. to provide pre-treated material comprising cellulosic solid fraction; c) optionally pre-hydrolyzing the pre-treated material with steam or water to provide pre-hydrolyzed material; d) cooking in cooking conditions comprising a cooking liquor comprising a chemical charge selected from the range between 1-200 g/l of acidic sulfite or an organic acid selected from lactic acid, acetic acid, formic acid, citric acid, oxalic acid, uric acid and malic acid, to provide cooked cellulosic material in a spent liquor; e) grinding and compressing the cooked cellulosic material in the cooking conditions to release HMW lignin from the cooked material into the spent cooking liquor, and to provide a compressed cellulose fraction; f) recovering the HMW lignin from the spent cooking liquor; g) displacing the spent cooking liquor with a displacing liquor containing cooking liquor having 1-200 g/l of acid sulfite or organic acid; h) recovering the HMW lignin from the displacing liquor; and i) recovering pulp from the compressed cellulose fraction.

2. The method of claim 1 wherein the method comprises the pre-hydrolyzing step and wherein the grinding and compressing is carried out at the pre-hydrolyzing temperature, and to a consistency of at least 10 % by weight.

3. The method of claim 1, wherein the method comprises the pre-hydrolyzing step, and wherein grinding and compressing is carried out to a consistency of at least 60% by weight.

4. The method of claim 1, wherein the method comprises the pre-hydrolyzing step, and cooking is continued to a kappa number selected from the range between 100 and 3, at a cooking temperature selected from the range between 120 and 180° C.

5. The method of claim 1 wherein the method comprises the pre-hydrolyzing step, and the pre-hydrolyzed material and/or the cooked cellulosic material is treated by grinding and compressing preferably by grinding and compressing through a gap, and a size of the gap is selected such that: for wood chips the gap is selected from the range 50 mm - 8 mm, for pin chips the gap is selected from the range 35 mm - 6 mm, and for saw dust the gap is selected from the range 20 mm - 4 mm.

6. The method of claim 1, wherein grinding and compressing is carried out at the cooking temperature, and to a consistency of at least 10% by weight.

7. The method of claim 1, wherein in the step e) the compressive pressure is selected from the range between 35 kPa and 1000 kPa.

8. The method of claim 1, wherein the compressing is carried out to a density selected from the range between 350 kg/m3 and 2000 kg/m.sup.3, preferably between 350 kg/m.sup.3 and 1525 kg/m.sup.3.

9. The method of claim 1, wherein the step e) is carried out to increase porosity of the fiber cell wall.

10. The method of claim 1, wherein the step e) comprises pressing with a pressure selected from the range between 1 kPa and 250 kPa to form a column having a consistency of at least 5% by weight.

11. The method of claim 1, wherein the displacing is carried out at a temperature selected from the range between 70° C. and 200° C.

12. The method of claim 1, wherein after step i) the pulp is dewatered to remove 90% or more of the sulfite, alkali, lignin and dissolved xylan and other organic and inorganic material as a liquor flow from the pulp, and to provide dewatered pulp.

13. The method of claim 12 comprising delignifying the dewatered pulp by oxygen to provide delignified pulp, optionally followed by washing and pressing.

14. The method of claim 1, wherein the temperature and cooking liquor chemical charges are not changed between cooking and grinding compressing steps.

15. A high molecular weight xylan fraction obtainable using the method of claim 1.

16. A high molecular weight lignin fraction obtainable using the method of claim 1.

17. Pulp obtainable using the method of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 schematically illustrates an embodiment of the present method involving optional pre--steaming and optional pre-hydrolyzing of the wood based cellulosic raw material, and a digester system for grinding and/or compressing condensate liquors out of wood chips after cooking. The process parameters mentioned in FIG. 1 are exemplary only, and other process parameters can be used, as described in this disclosure.

[0035] FIG. 2 schematically illustrates an embodiment of a digester system for compressing cooking liquors out of wood chips when using organic acid or sulphite cooking. The process parameters mentioned in FIG. 2 are exemplary only, and other process parameters can be used, as described in this disclosure.

[0036] FIG. 3 illustrates an embodiment of a schematic process to compress the wood chips to press out the cooking liquors. The process parameters mentioned in FIG. 3 are exemplary only, and other process parameters can be used, as described in this disclosure.

[0037] FIG. 4 schematically represents an embodiment of a displacing process for spent liquors from compressed wood chips. The process parameters mentioned in FIG. 4 are exemplary only, and other process parameters can be used, as described in this disclosure.

DETAILED DESCRIPTION

[0038] As used herein, the term “comprising” includes the broader meanings of “including”, “containing”, and “comprehending”, as well as the narrower expressions “consisting of” and “consisting only of”.

[0039] In an embodiment the process steps are carried out in the sequence identified in any aspect, embodiment or claim. In another embodiment any process step specified to be carried out to a product or intermediate obtained in a preceding process step is carried out directly to said product, i.e. without additional, optional or auxiliary processing steps that may chemically or physically alter the product between said two steps.

[0040] In an embodiment the wood based cellulosic raw material used in the present cooking method is in the form of chips, pin chips, shavings, saw dust or any combination thereof. Preferably wood chips are used, more preferably softwood or hardwood chips, such as chips of eucalyptus, pine or spruce. However, when using wood chips as the primary raw material, the raw material may contain smaller amount of e.g. pin chips and/or saw dust.

[0041] Unless otherwise indicated, all percentage values refer to dry weight-% expressed as wt-%.

[0042] The present process is suitable for use in a plant or a mill, i.e. in industrial (large) scale processes.

[0043] In an embodiment the wood based cellulosic raw material has a xylan content of 4 weight-% or more. In an embodiment the wood based cellulosic raw material comprises wood chips.

[0044] The term high molecular weight xylan (HMW xylan) means xylan, which has an average weight molecular weight (Mw) of 45000 g/mol or more.

[0045] The term high molecular weight lignin (HMW lignin) means lignin which has an average weight molecular weight (Mw) of 4500 g/mol or more for hardwood and for softwood 4980 g/mol or more.

[0046] In an embodiment molecular weight is measured by Size-Exclusion Chromatography and is presented as average weight molecular weight (MW).

[0047] Wood chips typically have a generally rectangular shape with a height, length, and width. However, the geometry of a wood chip may vary depending e.g. on its manufacturing process. The length (longest dimension) and width (second longest dimension) of a chip can be considered to determine the general “flat side” of a chip, and the thickness is the smallest dimension of the chip. For pin chips the width and thickness can be close to each other, thereby forming a match-like elongated object. The exact dimensions of the chip may vary.

[0048] In an embodiment the cellulosic raw material serving as a fiber source of the wood based cellulosic raw material comprises or consists of wood chips, and the grinding and compressing is applied to the largest area of surface of the wood chip. Preferably the grinding and compressing is carried out to achieve a density between 250-2000 kg/m.sup.3, preferably between 350-1525 kg/m.sup.3, to release at least HMW xylan and/or HMW lignin. Grinding and compressing to the largest area of surface can be achieved by using a gap which allows the chips to enter their smallest dimension, or “a side” first. Equipment used for this purpose can be between segmented plates, feeding screws with blades with decreasing distance, plug feeding screws feeding against rotating segment plates, rotors and stators with segmented plates, modified pump where the stator and the rotor of the pump have segmented plates enabling pressing and feeding action, drum presses with gap and segmented surfaces, modified stator and rotor systems. The solutions are not limited to above mentioned and can be applied by person skilled in the art.

[0049] In an embodiment the wood-based cellulosic raw material is pre-treated by steaming before cooking and/or before pre-hydrolyzation.

[0050] According to an embodiment the pre-treatment by steaming is preferably carried out to achieve air evacuation of the air inside the wood chips in order to improve liquor penetration to the porous wood material. Pre-steaming can be carried out in separate steaming vessel or in chips silo. In an embodiment the steaming is carried out by using low pressure steam with an approximate pressure of 3.5 bar for at least 10 min, preferably more than 20 min. In an embodiment pre-steaming comprises pre-steaming with low pressure steam at 1-4 bar for 1-100 min to provide pre-treated material. In an embodiment the temperature is more than 100° C., preferably more than 120° C.

[0051] After the optional pre-treatment, the raw material can be taken to the optional pre-hydrolyzing step or directly to the cooking step.

[0052] In an embodiment the optionally pre-treated wood-based cellulosic raw material is pre-hydrolyzed before cooking.

[0053] In an embodiment the pre-hydrolysis is carried out by steam or water at a temperature selected from the range 150-220° C. In an embodiment the pre-hydrolyzing step comprises pre-hydrolyzing with steam at 8-15 bar at a temperature selected from the range 150-220° C. for 1 to 150 min.

[0054] In an embodiment the grinding and compressing step is carried out by a plug feeding screw in a separate screw, with segmented plates, or the material is pressed through a rotating gap. The gap allows the chip to enter so that the shortest dimension enters first, however without being limited to these embodiments.

[0055] In a preferable embodiment the chips are forced to enter the gap such that their flat side with the largest surface area does not enter the gap first. This can be achieved by directing the chip to a gap to which the chip does not fit its flat side ahead.

[0056] In an embodiment grinding and compressing is carried out by taking the material through the gap in the cooking conditions to release HMW lignin into the spent cooking liquor, thereby providing HMW lignin in spent cooking liquor.

[0057] In an embodiment the grinding and compressing is carried out to consistency of more than 10 wt-%, preferably more than 20% or more preferably more than 30%, preferably more than 65%. Consistency can be measured using standard TAPPl T 240 Consistency (Concentration) of Pulp Suspensions or corresponding ISO 4119 standard.

[0058] In an embodiment the grinding and compressing is carried out at the cooking temperature and to a consistency of at least 10 wt-%.

[0059] In an embodiment the grinding and compressing is carried out by taking the wood chips through a gap in the range 50 mm - 8 mm, so that wood porosity decreases inside the gap at least 20%, 30%, 40%, 50%, 60%, 70% or more, and at least HMW lignin is released.

[0060] In an embodiment the grinding and compressing is carried out by taking the pin chips through a gap in the range 35 mm - 6 mm, so that wood porosity decreases inside the gap at least 20%, 30%, 40%, 50%, 60%, 70% or more, and at least HMW lignin is released.

[0061] In an embodiment the grinding and compressing is carried out by taking the saw dust through a gap in the range 20 mm - 4 mm, so that wood porosity decreases inside the gap at least 20%, 30%, 40%, 50% 60%, 70% or more, and at least HMW lignin is released.

[0062] Ina an embodiment the grinding and compressing is carried out by pressing the optionally pre-hydrolyzed material and/or the cooked cellulosic material through a gap, and a size of the gap is selected such that: [0063] for wood chips the gap is selected from the range 50 mm - 8 mm, [0064] for pin chips the gap is selected from the range 35 mm - 6 mm, and [0065] for saw dust the gap is selected from the range 20 mm - 4 mm.

[0066] The wood material porosity is calculated by 1-amount wood inside the gap (kg/m.sup.3) / 1500 kg/m.sup.3.

[0067] Grinding and compressing to the largest area of surface can be achieved by using a gap which allows the chips to enter their smallest dimension first. Equipment used for this purpose can be segmented plates, screws, modified pumps, drum presses, modified screws, modified stator and rotor systems.

[0068] According to an embodiment the cooking liquor comprises sulfite acids (acidic sulfite) or organic acids.

[0069] In an embodiment the cooking method is a sulfite pulping process. Chemicals in a cooking liquor of the sulfite pulping process are either sulfites (SO.sub.3.sup.2-), or bisulfites (HSO.sup.3-), depending on the pH. The counter ion can be sodium (Na.sup.+), calcium (Ca.sup.2+), potassium (K.sup.+), magnesium (Mg.sup.2+) or ammonium (NH.sub.4.sup.+).

[0070] In an embodiment the cooking liquor contains organic acids selected from lactic acid, acetic acid, formic acid, citric acid, oxalic acid, uric acid and malic acid. An organic acid is an organic compound with acidic properties.

[0071] In an embodiment the cooking liquor has a chemical charge selected from the range 1-200 g/l, preferably 1-100 g/l, of organic acid, or sulfite, or bisulfite, or an organic acid selected from lactic acid, acetic acid, formic acid, citric acid, oxalic acid, uric acid and malic acid.

[0072] In an embodiment the spent cooking liquor comprises spent sulfite liquor.

[0073] In an embodiment the spent cooking liquor comprises spent organic acid liquor.

[0074] In an embodiment the cooking is carried out at a temperature of at least 120° C., preferably more than 150° C., more preferably more than 170° C.

[0075] In an embodiment the wood based cellulosic raw material has an alfa cellulose content of more than 60 wt-%, preferably more than 70 wt-%, and more preferably more than 80 wt-% calculated from dry material.

[0076] The cooking time at cooking temperature is between 0-500 min, preferably between 0-20. Short cooking times can be achieved when the desired kappa number is reached soon, even immediately after pre-hydrolysis, depending e.g. on the raw material, pretreatment and pre-hydrolysis.

[0077] In an embodiment the ratio of the cooking liquor to the wood based cellulosic raw material is selected from 2-10 as dry mass of the wood based cellulosic material.

[0078] In an embodiment the grinding and compressing releases at least one of xylan and lignin into the cooking liquor, thereby forming spent cooking liquor containing at least one of HMW lignin and HMW xylan, and a solid fraction comprising compressed material. The HMW xylan can be recovered from the spent liquor. The HMW lignin can be recovered from the spent liquor.

[0079] In an embodiment grinding and compressing is started before the wood chip has reached a porosity level of 0.35-0.9, preferably 0.35-0.85.

[0080] In an embodiment during grinding and compressing the wood based cellulosic raw material particles, such as wood chips, are directed through a gap to which e.g. the chip fits only on its flat side. In an embodiment this treatment results into a consistency of more than 10%, preferably more than 20%, more preferably more than 30%, and even more preferably more than 65%.

[0081] In an embodiment the grinding and compressing is carried out by taking the wood chips through a gap in the range 50 mm - 8 mm, so that wood porosity decreases inside the gap at least 20%, 30%, 40%, 50%, 60%, 70% or more. The increased porosity and pressure releases HMW lignin.

[0082] In an embodiment the grinding and compressing is carried out by taking the pin chips through a gap in the range 35 mm - 6 mm, so that wood porosity decreases inside the gap at least 20%, 30%, 40%, 50%, 60%, 70% or more. The increased porosity and pressure releases HMW lignin.

[0083] In an embodiment the grinding and compressing is carried out by taking the saw dust through a gap in the range 20 mm - 4 mm, so that wood porosity decreases inside the gap at least 20%, 30%, 40%, 50% 60%, 70% or more. The increased porosity and pressure releases HMW lignin.

[0084] In an embodiment the grinding and compressing is carried out by pressing the cooked cellulosic material through a gap, and a size of the gap is selected such that: [0085] for wood chips the gap is selected from the range 50 mm - 8 mm, [0086] for pin chips the gap is selected from the range 35 mm - 6 mm, and [0087] for saw dust the gap is selected from the range 20 mm - 4 mm.

[0088] The wood material porosity is calculated by 1-amount wood inside the gap (kg/m.sup.3)/ 1500 kg/m.sup.3.

[0089] The term black liquor in the present invention means used cooking liquor, i.e. spent cooking liquor, or spent liquor.

[0090] In an embodiment the recovered HMW lignin has an average weight molecular weight (MW) more than 4500 g/mol when using hardwood raw material, and more than 4580 g/mol when using softwood raw material.

[0091] In an embodiment the compressed cellulose fraction has an alpha cellulose content of more than 65%, preferably more than 85%, more preferably more than 90%, and even more preferably more than 95%.

[0092] In an embodiment the cooked material is compressed in the spent liquor with a pressure selected from the range between 1 and 250 kPa to form a column of solids having a consistency of at least 5 % by weight. After compressing the spent cooking liquor is displaced with a displacing liquor having a lignin content lower than in the black liquor.

[0093] Non-limiting examples of suitable pressures to reach the selected target consistency value are 1 kPa, 2 kPa, 3 kPa, 4 kPa, 5 kPa, 6 kPa, 7 kPa, 8 kPa, 9 kPa, 10 kPa, 20 kPa, 30 kPa, 40 kPa, 50 kPa, 60 kPa, 70 kPa, 80 kPa, 90 kPa, 100 kPa, 110 kPa, 120 kPa, 130 kPa, 140 kPa, 150 kPa, 160 kPa, 170 kPa, 180 kPa, 190 kPa, 200 kPa, 210 kPa, 220 kPa, 230 kPa, 240 kPa, and 250 kPa. Non-limiting examples of suitable consistency values are 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% and 50 % by weight based on dry matter.

[0094] The compressed column of the material at the end of step e) can be diluted to a consistency selected from the range between 2 and 35% by weight, such as 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, 30%, or 35% by weight based on dry matter.

[0095] In the embodiment a HMW lignin fraction and/or a HMW xylan fraction is recovered from the spent cooking liquor. Optionally a lignin and/or xylan containing smaller molecular weight species is also recovered.

[0096] In an embodiment the dissolving pulp is dewatered to remove 90% lignin and dissolved xylan and other organic and inorganic material as a liquor flow from the pulp and to provide dewatered pulp.

[0097] In the embodiment in the step e) the compressive pressure is selected from the range between 35 kPa and 1000 kPa.

[0098] In the embodiment the compressing is carried out to a density selected from the range between 350 kg/m.sup.3 and 2000 kg/m.sup.3, preferably between 350 kg/m.sup.3 and 1525 kg/m.sup.3.

[0099] In the embodiment step e) is carried out to increase porosity of the fiber cell wall.

[0100] In the embodiment the step e) comprises pressing with a pressure selected from the range between 1 kPa and 250 kPa to form a column having a consistency of at least 5% by weight.

[0101] In the embodiment the displacement liquor has a chemical charge selected from the range between 1-200 g/l organic acid or acid sulfite cooking liquor, preferably 1-100 g/l.

[0102] In the embodiment the displacing is carried out at a temperature selected from the range between 70° C. and 200° C.

[0103] In the embodiment after step i) the pulp is dewatered to remove 90% or more of the sulfite, alkali, lignin and dissolved xylan and other organic and inorganic material as a liquor flow from the pulp, and to provide dewatered pulp.

[0104] In the embodiment the method comprises delignifying the dewatered pulp by oxygen to provide delignified pulp, optionally followed by washing and pressing.

[0105] In the embodiment the temperature and alkali or acid sulfite cooking liquor charges are not changed between cooking and grinding compressing steps.

[0106] In an embodiment the method comprises the pre-hydolyzing step and wherein the grinding and compressing is carried out at the pre-hydrolyzing temperature, and to a consistency of at least 10 % by weight.

[0107] In an embodiment the method comprises the pre-hydrolyzing step, and wherein grinding and compressing is carried out to a consistency of at least 60% by weight.

[0108] In an embodiment the method comprises the pre-hydrolyzing step, and cooking is continued to a kappa number selected from the range between 100 and 3, at a cooking temperature selected from the range between 120 and 180° C.

[0109] In an embodiment the method comprises the pre-hydrolyzing step, and pre-hydrolyzed material and/or the cooked cellulosic material is treated by grinding and compressing preferably by pressing through a gap, and a size of the gap is selected such that: [0110] for wood chips the gap is selected from the range 50 mm - 8 mm, [0111] for pin chips the gap is selected from the range 35 mm - 6 mm, and [0112] for saw dust the gap is selected from the range 20 mm - 4 mm.

[0113] In an embodiment the grinding and compressing is carried out at the cooking temperature, and to a consistency of at least 10 % by weight.

[0114] In an embodiment in the step e) the compressive pressure is selected from the range between 35 kPa and 1000 kPa.

[0115] In an embodiment the compressing is carried out to a density selected from the range between 350 kg/m.sup.3 and 2000 kg/m.sup.3, preferably between 350 kg/m.sup.3 and 1525 kg/m.sup.3.

[0116] In an embodiment the method the step e) is carried out to increase porosity of the fiber cell wall.

[0117] In an embodiment the step e) comprises pressing with a pressure selected from the range between 1 kPa and 250 kPa to form a column having a consistency of at least 5% by weight.

[0118] In an embodiment the displacing is carried out at a temperature selected from the range between 70° C. and 200° C.

[0119] In an embodiment after step i) the pulp is dewatered to remove 90% or more of the sulfite, alkali, lignin and dissolved xylan and other organic and inorganic material as a liquor flow from the pulp, and to provide dewatered pulp.

[0120] In an embodiment the method comprises delignifying the dewatered pulp by oxygen to provide delignified pulp, optionally followed by washing and pressing.

EXAMPLES

[0121] The effects obtainable by embodiments of the method of invention are demonstrated by the following experiments, which should not be considered as limiting the scope of the invention. The abbreviation REF refers to prior art methods, i.e. cooking method without compressing step according to the present invention. The cooking conditions can be selected by the person skilled in the art to get the target kappa number at the end of the cooking stage.

Example 1

[0122] In this example eucalyptus wood pulps were produced both according to the present invention and according to a reference method (REF), by cooking at 165° C. eucalyptus acidic cooking liquor (MgSO.sub.3) with total SO.sub.2 7.8% and active MgO 0.71%. The wood chips were first impregnated at 9 bar by increasing temperature from 50° C. to 110° C. in 90 minutes at liquor to wood ratio of 5. After that in cooking phase liquor to wood ratio was decreased to 3.8 and cooking temperature 151° C. was reached after 2 hours and 10 min. At the end of cooking according to invention chips were fed through narrow gap causing pressing and shearing and the HWM-lignin containing spent liquor was displaced with washing filtrate.

[0123] In this example pine wood pulps were also produced both according to the present invention and reference method (REF). The sulphite cooking was carried out using magnesium sulphite cooking. The active MgO amount was 2% and the total SO.sub.2 was 7% and pH was 4%. The wood chips were first impregnated at 9 bar by increasing temperature from 50° C. to 110° C. in 90 minutes at liquor to wood ratio of 5. After that in cooking phase liquor to wood ratio was decreased to 3.8 and cooking temperature 160° C. was reached after 80 min. After cooking according to the invention the obtained chips were fed through a narrow gap causing pressing and shearing and the HWM-lignin containing spend liquor was displaced with washing filtrate.

[0124] The cooking results are presented the table 1 for sulphite cooking.

TABLE-US-00001 Sample Kappa number Cooking time decrease, min Cooking, yield Lignin, average MW, g/mol REF sulphite Eucalyptus 9.5 - 40.5 2300 REF sulphite Pine 25 - 49.2 4500 Sulphite Eucalyptus 10.2 47 41.7 6450 Sulphite Pine 26 40 51.3 6800

[0125] According to table 1 lignin weight average Mw molecular weight and cooking yield increases, and cooking time decreases to target kappa number when cooking is done according to the present invention. The cooking plant capacity increase because of the cooking time decrease.

[0126] In the table 2 are presented the increase in the pulp amount to the same drainage time.

TABLE-US-00002 Pulp charge to the same drainage time Sample REF sulphite Eucalyptus 1000 g/m2 REF sulphite Pine 1000 g/m2 Sulphite Eucalyptus 1550 g/m2 Sulphite Pine 1750 g/m2

[0127] As the results confirm, the present method improves also pulp drainage and therefore increase pulp mill fiber line production capacity.

[0128] The foregoing description has provided, by way of non-limiting examples of particular implementations and embodiments of the invention, a full and informative description of the best mode presently contemplated by the inventor for carrying out the invention. It is however clear to a person skilled in the art that the invention is not restricted to details of the embodiments presented in the foregoing, but that it can be implemented in other embodiments using equivalent means or in different combinations of embodiments without deviating from the characteristics of the invention.

[0129] Furthermore, some of the features of the afore-disclosed embodiments of this invention may be used to advantage without the corresponding use of other features. As such, the foregoing description shall be considered as merely illustrative of the principles of the present invention, and not in limitation thereof. Hence, the scope of the invention is only restricted by the appended patent claims.