INLINE DILUTION OF MICROFIBRILLATED CELLULOSE

Abstract

The present invention relates a process and a system for the point-of-use dilution of microfibrillated cellulose (MFC) from a higher solids content to a lower solids content, for example from a solids content in the range of 5% weight by weight (w/w)-50% w/w, preferably 5% w/w-30% w/w, further preferably 5% w/w-15% w/w, down to a solids content of below 7% w/w, preferably below 5% w/w, preferably to a solids content of 0.01% w/w-5% w/w, further preferably to a solids content of 0.1% w/w-3% w/w. The process at least comprises the following steps: (i) providing microfibrillated cellulose in a solvent, wherein the solids content is in the range of 5% weight by weight (w/w)-50% w/w, preferably 5% w/w-30% w/w, further preferably 5 w/w-15% w/w; (ii) subjecting said microfibrillated cellulose from step (i) to a dilution step in a rotor-stator mixer; (iii) simultaneously to step (ii): injecting solvent into the rotor-stator mixer, or into a volume segment upstream of the rotor-stator mixer, in order to lower the solids content of the microfibrillated cellulose in the rotor-stator mixer.

Claims

1. A process for the dilution of microfibrillated cellulose, from a solids content in the range of 5% weight by weight (w/w)-50% w/w, preferably 5% w/w-30% w/w, further preferably 5% w/w-15% w/w, down to a solids content of below 7% w/w, preferably below 5% w/w, preferably to a solids content of 0.01% w/w-5% w/w, further preferably to a solids content of 0.1% w/w-3% w/w, wherein said process at least comprises the following steps: (i) providing microfibrillated cellulose in a solvent, wherein the solids content is in the range of 5% weight by weight (w/w)-50% w/w, preferably 5% w/w-30% w/w, further preferably 5% w/w-15% w/w; (ii) subjecting said microfibrillated cellulose from step (i) to a dilution step in a rotor-stator mixer; (iii) simultaneously to step (ii): injecting solvent into the rotor-stator mixer, or into a volume segment upstream of the rotor-stator mixer, in order to lower the solids content of the microfibrillated cellulose in the rotor-stator mixer.

2. The process according to claim 1 wherein the dilution process of step (ii) occurs in the volume segment defined between at least one stator and at least one rotor.

3. The process according to claim 1 or claim 2 wherein, in step (ii), the microfibrillated cellulose is subjected to an energy input of from 1 kWh/ton dry MFC-1000 kWh/ton dry MFC, preferably from 10 kWh/ton dry MFC-700 kWh/ton dry MFC, further preferably from 100 kWh/ton dry MFC-400 kWh/ton dry MFC.

4. The process according to any one of the preceding claims, wherein, in step (ii), the retention time of the MFC in the rotor-stator mixer is from 0.01 to 30 sec, preferably from 0.02 to 1 sec, further preferably from 0.02 to 0.2 sec.

5. The process according to any one of the preceding claims, wherein the tip speed of the rotors in the rotor-stator mixer is from 10 m/s to 100 m/s, preferably from 30 m/s to 60 m/s.

6. The process according to any one of the preceding claims, wherein step (ii) leads to an increase in PEG viscosity, in particular an enhanced thickening effect in a PEG-water-MFC suspension.

7. The process according to any one of the preceding claims, wherein the water retention capacity of the microfibrillated cellulose after step (ii) is higher than the water retention capacity of the microfibrillated cellulose as initially provided in step (i).

8. The process according to any one of the preceding claims, wherein said microfibrillated cellulose comprises fibrils having a diameter in the nanometer range and a length in the micrometer range, preferably wherein the microfibrillated cellulose is not physically modified.

9. The process according to any one of the preceding claims, wherein the solvent essentially consists of water, i.e. comprises at least 90%, preferably at least 95%, further preferably at least 99% of water.

10. A system for the dilution of microfibrillated cellulose, from a solids content in the range of 5% weight by weight (w/w)-50% w/w, preferably 5% w/w-30% w/w, further preferably 5% w/w-15% w/w, down to a solids content of below 7% w/w, preferably below 5% w/w, preferably to a solids content of 0.01% w/w-5% w/w, further preferably to a solids content of 0.1% w/w-3% w/w, wherein said system at least comprises the following components: at least one rotor-stator mixer (2); at least one line (1) for feeding microfibrillated cellulose into at least one volume segment of said rotor-stator mixer; at least one process line (3) for injecting solvent into said at least one volume segment of said rotor-stator mixer, or into a volume segment upstream of the rotor-stator mixer.

11. The system according to claim 10, wherein the at least one rotor-stator mixer (2) comprises a restriction element, preferably an adjustable valve downstream of the mixing volume segment of the rotor-stator mixer to establish a counter-pressure.

12. The system according to any one of the preceding claims, wherein the rotor-stator mixer includes at least one rotor which rotates at high speed inside at least one stationary stator, which stator is interchangeable.

13. The system according to any one of the preceding claims, wherein the at least one stator comprises cylindrical screens.

14. Use of diluted microfibrillated cellulose obtained or obtainable according to any one of claims 1-9 or obtained with a system according to any one of claims 10-13 in or as coatings, adhesives, (surface) sizes, paints, inks, de-icing fluids or additives, thixotropic additives, emulsifier/emulsion aid; viscosity adjustment, additive in oil field applications, in particular drilling fluids, in home care/personal care/personal hygiene applications, cosmetics and pharmaceutical applications, in particular in ointments, emulsions or high viscosity liquids, as an additive or aid in medical devices or medical applications, in particular scar and wound care, agrochemicals, food applications, for example as thickener, dietary supplement, non-caloric additive, emulsifier etc., in printing applications, including 3-D printing, in composite materials, for example plastics, rubber or paper-based materials, cardboards etc., in or as porous material, foam or aerogel/hydrogel; in separation technologies, including filter elements, membranes, separators etc., in film forming applications, in battery technology and/or flexible electronics, in textile application and/or as filaments, including yarns, non-wovens, meshes etc., as an additive or adjuvant in construction commodities, including cement, concrete, gypsum boards, and the like.

15. Process according to any one of claims 1-13, wherein the microfibrillated cellulose is prepared by a process, which comprises at least the following steps: (a) subjecting a cellulose pulp to at least one mechanical pretreatment step; (b) subjecting the mechanically pretreated cellulose pulp of step (a) to a homogenizing step, which results in fibrils and fibril bundles of reduced length and diameter vis--vis the cellulose fibers present in the mechanically pretreated cellulose pulp of step (a), said step (b) resulting in microfibrillated cellulose; wherein the homogenizing step (b) involves compressing the cellulose pulp from step (a) and subjecting the cellulose pulp to a pressure drop.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0040] The invention is described in more detail in the following, with reference to the enclosed figures, which are only meant to be illustrative, wherein:

[0041] FIG. 1 shows microfibrillated cellulose at a dry matter content of approx. 8% to 10%; the paste-like structure of MFC is apparent.

[0042] FIG. 2 shows a schematic representation of the rotor-stator-principle.

[0043] FIG. 3 shows a further exemplary embodiment for a rotor and stator as implemented in a rotor-stator mixer that is exemplary for the present invention.

[0044] FIG. 4 shows an exemplary flow diagram of the process, including various components of the system, in accordance with the present invention.

[0045] FIG. 5 shows a comparison of performance parameters for one batch of Exilva as obtained after dilution in a laboratory mixer (reference) compared to dilution using a process in accordance with the present invention.

[0046] FIG. 6 shows the respective comparison of performance parameters for a higher viscosity Exilva batch as obtained after dilution in a laboratory mixer (reference) compared to dilution using a process in accordance with the present invention.

[0047] In accordance with the present invention, a rotor-stator mixer is any device that comprises at least one rotor that turns at a predetermined speed relative to at least one stationary stator. As the rotating blades pass the stator, they mechanically shear the content, here the MFC as dispersed in a solvent.

[0048] Conventionally, a rotor-stator mixer, for example a high-intensity Cavitron inline mixer is not used for dilution processes, but rather for homogenizing, emulsifying and/or mixing additives into a suspension, in particular a high viscosity suspension. Surprisingly, the inventors have found that not only is inline dilution of high viscosity paste-like MFC possible with such a high intensity rotor-stator mixer, but that such inline dilution also results in improved properties of the resulting diluted MFC, in particular increased water retention capabilities and increased homogeneity, respectively vis-{acute over (b)}-vis MFC diluted with conventional laboratory equipment used for stirring, as will be shown in more detail below, in particular in the Examples-Section.

[0049] A schematic depiction of the basic set-up of a rotor-stator arrangement is shown in FIG. 2.

[0050] A more specific embodiment as realized in a Cavitron rotor-stator mixer is shown in FIG. 3.

[0051] A Cavitron rotor-stator mixer typically consists of a series of concentric rings, or chambers. As the MFC paste to be diluted enters the center chamber, it is compressed at a rate of up to 10 bar. One one-thousandth of a second later, the chamber opens, and the medium inside the head of the mixer explodes outward into the next chamber. A series of nozzles breaks down the medium as it passes from chamber to-chamber. These nozzles can be as small as 500 microns (0.5 mm), and the rotor/stator segments can meet up to 500 million times per second.

[0052] In embodiments of the invention, the rotor-stator mixer includes at least one rotor which rotates at high speed inside at least one stationary stator, which stator is interchangeable and/or adaptable to different process requirements.

[0053] In embodiments of the invention, the at least one stator comprises cylindrical screens, preferably having a clearance from the rotor of 1 mm or less, preferably 0.5 mm or less.

[0054] In embodiments of the invention, the at least one stator has holes or slots through which the fluid is forced.

[0055] The kinetic energy generated by the rotor which is dissipated in the stator region creates comparatively high energy dissipation rates due to the relatively small volume segment present between stator and rotor. Fluid undergoes shear when one area of fluid travels with a different velocity relative to an adjacent area (see FIG. 2).

[0056] In embodiments of the invention, the at least one rotor is or comprises a rotating impeller or high-speed rotor, or a series of such impellers or inline rotors (see FIG. 3), preferably powered by an electric motor.

[0057] In embodiments of the invention, the speed of the MFC as dispersed in the solvent at the outside diameter of the rotor is higher than the velocity at the center of the rotor, and it is this velocity difference that creates shear.

[0058] Relevant parameters describing the performance of the rotor-stator mixer of the present invention include the diameter of the rotor and its rotational speed (tip speed).

[0059] In accordance with the present invention, at least a subset of the above-stated problems is solved by a system for the dilution of microfibrillated cellulose, from a solids content in the range of 5% weight by weight (w/w)-50% w/w, preferably 5% w/w-30% w/w, further preferably 5% w/w-15% w/w, down to a solids content of below 7% w/w, preferably below 5% w/w, preferably to a solids content of 0.01% w/w-5% w/w, further preferably to a solids content of 0.1% w/w-3% w/w, wherein said system at least comprises the following components: [0060] at least one rotor-stator mixer (2); [0061] at least one line (1) for feeding microfibrillated cellulose into at least one volume segment of said rotor-stator mixer; [0062] at least one process line (3) for injecting solvent into said at least one volume segment of said rotor-stator mixer or into a volume segment upstream of the rotor-stator mixer.

[0063] The overall system is schematically and exemplarily illustrated in FIG. 4.

[0064] In embodiments of the invention, process solvent, preferably water (S1 or S2 or both) is loaded into the system, preferably through a manual valve and a flowmeter (FM) with a control valve. In front of the inlet, a check valve is preferably located prior to the entry into tubing of the system.

[0065] In embodiments the present invention, the at least one rotor-stator mixer (2) comprises a restriction element, preferably an adjustable valve downstream of the mixing volume segment of the rotor-stator mixer

[0066] Microfibrillated cellulose (MFC) in accordance with the present invention is to be understood as relating to cellulose fibers that have been subjected to a mechanical treatment resulting in an increase of the specific surface and a reduction of the size of cellulose fibers, in terms of cross-section (diameter) and/or length, wherein said size reduction preferably leads to fibrils having a diameter in the nanometer range and a length in the micrometer range.

[0067] In cellulose, which is the starting product for producing microfibrillated cellulose (typically present as a cellulose pulp), no, or at least not a significant or not even a noticeable portion of individualized and separated cellulose fibrils can be found. The cellulose in wood fibres is an aggregation of fibrils. In cellulose (pulp), elementary fibrils are aggregated into microfibrils which are further aggregated into larger fibril bundles and finally into cellulosic fibres. The diameter of wood based fibres is typically in the range 10-50 m (with the length of these fibres being even greater). When the cellulose fibres are microfibrillated, a heterogeneous mixture of released fibrils with cross-sectional dimensions and lengths from nm to m may result. Fibrils and bundles of fibrils may co-exist in the resulting microfibrillated cellulose.

[0068] Microfibrillated cellulose consists of fibrils in constant interaction with each other in a three-dimensional network. The most important performance properties of MFChigh viscosity at rest, shear thinning (thixotropic) behavior, water holding capacityare a result of the existence of this entangled network.

[0069] In the microfibrillated cellulose (MFC) as described throughout the present disclosure, individual fibrils or fibril bundles can be identified and easily discerned by way of conventional optical microscopy, for example at a magnification of 40.

[0070] In accordance with the present invention, the term suspension is understood to mean a liquid, in which solid particles (here: fibers) are dispersed, as generally understood by the skilled person and as defined in the IUPAC Gold Book, [PAC, 1972, 31, 577 (Manual of Symbols and Terminology for Physicochemical Quantities and Units, Appendix II: Definitions, Terminology and Symbols in Colloid and Surface Chemistry); page 606].

[0071] In the present invention, the suspension of microfibrillated cellulose fibers in a solvent, has the consistence of a paste and shows non-Newtonian flow properties (see FIG. 1). Such a suspension/paste is sometimes also referred to as a gel (or hydrogel if the solvent is water).

[0072] In accordance with the present invention, the parameter solids content (sometimes also referred to as dry matter) refers to the amount of MFC that remains once all the solvent (typically water) has been removed and is provided in % weight relative to the overall weight of the suspension comprising MFC and the solvent Unless indicated otherwise, any parameter referred to in the present disclosure is measured at standard conditions, i.e. at room temperature (20 C.), ambient pressure (1 bar) and 50% ambient humidity. Unless indicated otherwise, any ratio given for an amount of component of the overall system is meant to be given in % weight relative to the overall weigh of the content of the system (i.e. excluding packaging).

[0073] No limitations exist in regard to the solvent, as long as the solvent is capable to keep the MFC fibers in suspension under conditions typical for storage and transport.

[0074] In embodiments of the invention, the solvent is a hydrophilic solvent, preferably a polar solvent, further preferably a protic solvent. Preferred solvents are water or alcohol or any mixture of such solvents. In preferred embodiments the solvent essentially consists of water, i.e. comprises at least 90%, preferably at least 95%, further preferably at least 99% of water. Water can be distilled water, processed water or tab water as commonly used in industrial applications.

[0075] In embodiments of the invention, the solvent comprises additives such as glycols, glycerols, surfactants, preservatives or others. Two different solvents can be injected upstream, as shown in FIG. 4.

[0076] As already indicated above, in principle, any type of microfibrillated cellulose (MFC) may be used in accordance with the present invention, as long as the fiber bundles as present in the original cellulose pulp are sufficiently disintegrated in the process of making MFC so that the average diameter of the resulting fibrils is in the nanometer-range and therefore more surface of the overall cellulose-based material has been created, vis-b-vis the surface available in the original cellulose material. MFC may be prepared according to any of the processes described in the art, including the prior art specifically cited in the Background-Section above.

Origin of the Cellulose Used to Prepare the MFC

[0077] In accordance with the present invention, there is no specific restriction in regard to the origin of the cellulose, and hence of the microfibrillated cellulose. In principle, the raw material for the cellulose microfibrils may be any cellulosic material, in particular wood, annual plants, cotton, flax, straw, ramie, bagasse (from sugar cane), suitable algae, jute, sugar beet, citrus fruits, waste from the food processing industry or energy crops or cellulose of bacterial origin or from animal origin, e.g. from tunicates.

[0078] In a preferred embodiment, wood-based materials are used as raw materials, either hardwood or softwood or both (in mixtures). Further preferably softwood is used as a raw material, either one kind or mixtures of different soft wood types. Bacterial microfibrillated cellulose is also preferred, due to its comparatively high purity.

Modified (Derivatized) and Non-Modified (Un-Derivatized) Cellulose/MFC

[0079] In principle, the microfibrillated cellulose in accordance with the present invention may be unmodified in respect to its functional groups or may be physically modified or chemically modified, or both.

[0080] Chemical modification of the surface of the cellulose microfibrils may be achieved by various possible reactions of the surface functional groups of the cellulose microfibrils and more particularly of the hydroxyl functional groups, preferably by: oxidation, silylation reactions, etherification reactions, condensations with isocyanates, alkoxylation reactions with alkylene oxides, or condensation or substitution reactions with glycidyl derivatives. Chemical modification may take place before or after the defibrillation step.

[0081] The cellulose microfibrils may, in principle, also be modified by a physical route, either by adsorption at the surface, or by spraying, or by coating, or by encapsulation of the microfibril. Preferred modified microfibrils can be obtained by physical adsorption of at least one compound. The MFC may also be modified by association with an amphiphilic compound (surfactant).

[0082] However, in preferred embodiments, the microfibrillated cellulose is not physically modified.

[0083] In a preferred embodiment of the present invention, the microfibrillated cellulose is prepared by a process, which comprises at least the following steps: [0084] (a) subjecting a cellulose pulp to at least one mechanical pretreatment step; [0085] (b) subjecting the mechanically pretreated cellulose pulp of step (a) to a homogenizing step, which results in fibrils and fibril bundles of reduced length and diameter vis--vis the cellulose fibers present in the mechanically pretreated cellulose pulp of step (a), said step (b) resulting in microfibrillated cellulose; [0086] wherein the homogenizing step (b) involves compressing the cellulose pulp from step (a) and subjecting the cellulose pulp to a pressure drop.

[0087] The mechanical pretreatment step preferably is or comprises a refining step. The purpose of the mechanical pretreatment is to beat the cellulose pulp in order to increase the accessibility of the cell walls, i.e. to increase the surface area.

[0088] Prior to the mechanical pretreatment step, or in addition to the mechanical pretreatment step, enzymatic (pre)treatment of the cellulose pulp is an optional additional step that may be preferred for some applications. In regard to enzymatic pretreatment in conjunction with microfibrillating cellulose, the respective content of WO 2007/091942 is incorporated herein by reference. Any other type of pretreatment, including chemical pretreatment is also within the scope of the present invention.

[0089] In the homogenizing step (b), which is to be conducted after the (mechanical) pretreatment step, the cellulose pulp slurry from step (a) is passed through a homogenizer at least once, preferably at least two times, as described, for example, in PCT/EP2015/001103, the respective content of which is hereby incorporated by reference.

[0090] In embodiments of the invention, microfibrillated cellulose as diluted according to any one of the embodiments described above is used in a wide variety of applications, including but not limited to coatings, adhesives, (surface) sizes, paints, inks, de-icing fluids or additives, thixotropic additives, emulsifier/emulsion aid; viscosity adjustment, additive in oil field applications, in particular drilling fluids, in home care/personal care/personal hygiene applications, cosmetics and pharmaceutical applications, in particular in ointments, emulsions or high viscosity liquids, as an additive or aid in medical devices or medical applications, in particular scar and wound care, agrochemicals, food applications, for example as thickener, dietary supplement, non-caloric additive, emulsifier etc., in printing applications, including 3-D printing, in composite materials, for example plastics, rubber or paper-based materials, cardboards etc., in or as porous material, foam or aerogel/hydrogel; in separation technologies, including filter elements, membranes, separators etc., in film forming applications, in battery technology and/or flexible electronics, in textile application and/or as filaments, including yarns, non-wovens, meshes etc., as an additive or adjuvant in construction commodities, including cement, concrete, gypsum boards, and the like.

EXAMPLES

Example 1

Preparation of Microfibrillated Cellulose

[0091] MFC as diluted in accordance with the present invention is commercially available and commercialized by Borregaard as Exilva based on cellulose pulp from Norwegian spruce (softwood).

[0092] The MFC in step (i) was present as a paste, having a solids content of 10%. The solvent was water.

[0093] The MFC was provided in two different qualities, named Exilva P and Exilva F. The differences between Exilva P and Exilva F are related mainly to the size of the aggregates of microfibrils and consequently to the 3D-network properties. Exilva F has higher Brookfield viscosity, surface area (water retention) and higher tensile strength than Exilva P. While these differences have no relevance for the working of the present invention, diluting these two different microfibrillated cellulose materials shows that the method according to the present invention works for different qualities of microfibrillated cellulose (see FIGS. 5 and 6)

Example 2

Inline Dilution of 10% w/w MFC in Water to 2% w/w Using a Cavitron Reactor System

[0094] MFC from Example 1 was continually diluted in a Cavitron Reactor System as commercially available from Arde Barinco (NJ, USA).

[0095] The Cavitron in-line mixer was set up with a centrifugal pump for the water-supply line, and with a pump with a feeding-screw for continually feeding the Exilva paste into the head of the rotor-stator mixer (see FIG. 4 for further details).

[0096] Dilution of MFC from 10% w/w to 2% w/w in a Cavitron rotor-stator mixer was tested in two different trials. In the first trial, the maximum amount of water possible added into the system, was measured to be approximately 30 liters/min. This value was chosen to be the High flow setting. However, specification for the Cavitron rotor-stator mixture allow up to 90 liters/min. A larger water-inlet was welded onto the pipe, and an additional test was done with approximately 108 L/min.

[0097] The dilution was performed at three different flow-rates (total flow); [0098] 13 kg/min (800 kg/h) [0099] 37 kg/min (2200 kg/h) [0100] 108 kg/min (6500 kg/h)

[0101] At each flow-rate, three different settings for the Cavitron were tested; [0102] Medium intensity (35 Hz) with 3 bars counter-pressure [0103] High intensity (50 Hz) with 3 bars counter-pressure [0104] High intensity (50 Hz) with open valve. With open valve, the pressure behind the mixing-head was measured to be from 0,4 to 1 bar depending on the flow-rate.

[0105] The results of these test runs are summarized in FIGS. 5 and 6, as well as the Table given below.

TABLE-US-00001 TABLE 1 Performance Parameters of MFC diluted in High intensity Rotor-Stator system vs conventional laboratory mixer (average of different settings) increase P WRV: 20% PEG visc: 13% F WRV: 39% PEG visc: 33%

[0106] In summary, all rotor-stator mixer-diluted samples achieved similar or higher quality than the lab-diluted, respectively using the same Exilva paste. Improvements were found in regard to water retention capacity and PEG viscosity, contrary to what is usually observed in conventional dilution processes.

[0107] The mixing intensity (35-50 Hz) did not influence the quality, except for the maximum flow-rate for the high quality Exilva paste (F), where the high intensity gave best quality of the product.

[0108] More specifically, the Rotor-stator mixer diluted samples with low or medium flow (800-2200 m.sup.3/h) resulted in higher quality than the lab-diluted sample, The mixing intensity (35-50 Hz) did not noticeably influence the quality.

[0109] The Rotor-stator mixer diluted samples with high flow (6500 m.sup.3/h) resulted similar or better quality than the lab-diluted sample. The best quality was obtained with high mixing intensity (50 Hz).

Example 3

[0110] Inline Dilution of 9% w/w MFC in Water Down to 6% w/w, Using a Cavitron Reactor System

[0111] The aim of this experiment was to find a way to prepare a stable suspension of approx 6% microfibrillated cellulose (Exilva F). This experiment showed that a stable suspension with a solids content of 6% w/w can be obtained, even after 10 weeks of storage.

[0112] MFC from Example 1 was continually diluted in a Cavitron Reactor System as commercially available from Arde Barinco (NJ, USA).

[0113] The Cavitron in-line mixer was combined with a centrifugal pump for the water-supply line, and with a pump with a feeding-screw for continually feeding the MFC paste into the head of the rotor-stator mixer (see FIG. 4 for further details).

[0114] Dilution of MFC, Exilva F, from 9% w/w to 6% w/w in a Cavitron rotor-stator mixer was tested with following settings: [0115] Flow-rate (total flow); [0116] 9 kg/min (540 kg/h) [0117] Cavitron settings; [0118] High intensity (50 Hz) [0119] 3 bars counter-pressure

TABLE-US-00002 TABLE 1 Performance Parameters of MFC diluted in High intensity Rotor-Stator system vs conventional laboratory mixer (average of different settings). F increase WRV: 15% PEG visc: 0% (similar)

[0120] In summary, the rotor-stator mixer-diluted sample achieved similar or higher quality in regard to the suspension than the lab-diluted but otherwise same MFC paste. Improvements were found in regard to water retention capacity, contrary to what is usually observed in conventional dilution processes.