Chemi-refiner mechanical pulping of flax shives: refining energy and fiber properties.

Oil-seed flax shive has been promoted as a raw material for low-end paper making because of its overall cost benefit over hardwood and groundwood pulp and increasing demand for low-cost pulp in rigid packaging applications. We have made refiner mechanical pulp from oil-seed shives by using a 300 mm Sprout-Bauer pilot refiner. The factors controlled during refining were: consistency, multi-pass refining, temperature, spacing between the plates and polyol-anhydride reactant concentration. Based on the results in this study it is apparent that unmodified shives develop low mechanical strength, shorter fibers and large amount of fines. Chemical modification of shives with a pre-reacted mixture of polyol-anhydride reduces refining energy consumption, improves strength performance but decreases scattering coefficient. From the results of investigation it is suggested that chemically modified refiner pulp from shives cannot be used for high-grade paper manufacture but it can be used as a low-cost filler for low-end applications in packaging or low-performance decorative papers.     

Biokraft pulping of European black pine with Ceriporiopsis subvermispora

European black pine (Pinus nigra Arn.) chips were treated with the white-rot fungus Ceriporiopsis subvermispora for periods ranging from 20 to 100 days. The effects of pretreatment on the chemical composition of wood and kraft pulping were investigated. The results showed that fungal pretreatment reduced the lignin and extractive content of wood chips. Also, weight losses occurred. Kappa number, viscosity, and reject ratio of biokraft pulps decreased. Biokraft pulps gave better response to beating, which led to significant energy saving during refining. The tear index, burst index, and tensile index of biokraft pulps were found to be lower than those of kraft pulps. However, the tensile index and burst index of 20-day biotreated and unbeaten pulp was higher than those of kraft pulp. Also, the tear index of 20-day biotreated and beaten pulp was higher than that of kraft pulp. The brightness of biokraft pulps decreased irregularly with increasing incubation time.     

Extracting hemicelluloses prior to aspen chemi-thermomechanical pulping: Effects of pre-extraction on pulp properties

Pre-extraction of hemicelluloses prior to pulping and conversion of the extracted hemicelluloses to other by-products will provide additional revenues to traditional pulp and paper industry. The effects of hemicelluloses pre-extraction with sulfuric acid on aspen (Populus tremuloides) chemi-thermomechanical pulp (CTMP) properties were investigated in this study. The sulfuric acid pre-extraction resulted in a release of 11% of hemicelluloses (determined as xylan) and acetic acid, especially at the second press-impregnation stage. Compared with CTMP without acid pre-extraction, the acid pre-extraction significantly reduced refining energy to a given freeness, and the pulps produced from acid pre-extracted chips have lower shives, higher strength properties except zero-span breaking length, lower bulk, but lower brightness at a similar specific refining energy. This study provides useful information for integration of biorefinery in mechanical pulp mills in the future.     

A comparative study of the effect of refining on organosolv pulp from olive trimmings and kraft pulp from eucalyptus wood

This paper examines the influence of the degree of refining of different pulps, produced from olive trimmings and eucalyptus wood, on various physical properties. Corresponding pulps were obtained by means of different cooking processes. Pulp from olive trimmings was obtained by means of an organosolv process and pulp from eucalyptus was obtained by means of a kraft process. Pulp from olive trimmings exhibited a lower specific surface area, water retention volume, breaking length, stretch and burst index, but a higher porosity, than eucalyptus pulp. On the other hand, the same degree of refining was achieved with less energy for olive pulp than for eucalyptus pulp. Mixed pulp from olive trimmings and eucalyptus provided paper sheets with acceptable physical properties but with reduced refining energy costs relative to eucalyptus pulp alone.     

Comparative study of paper sheets from olive tree wood pulp obtained by soda,sulphite or kraft pulping

Paper sheets from olive tree wood pulp obtained by soda, sulphite or kraft pulping were studied to examine the influence of pulp beating on properties of the paper sheets.Paper sheets from kraft and sulphite pulps exhibited the highest resistance, and sulphite pulp the highest brightness. Soda pulp required more intensive beating than did kraft or sulphite pulps; in fact, the PFI beater had be operated at a 40–50% higher number of beating revolutions to obtain soda pulp with 70–80° SR.The breaking length, stretch, burst index and tear index of paper sheets obtained from kraft pulp, beaten to a Shopper–Riegler index of 70–80° SR were 20–30%, 30–50%, 50–60% and 15–35% higher, respectively, than those of sheets obtained from soda pulp.     

Influence of the holm oak soda pulping conditions on the properties of the resulting paper sheets

This paper reports on the influence of independent variables in the pulping of holm oak wood [viz. temperature (135-195 degrees C), cooking time (30-90 min) and soda concentration (10-20%)] on the properties of the resulting paper sheets. By using a central composite factorial design and a fuzzy neural model, equations relating each dependent variable to the different independent variables were derived that reproduced the experimental results for the dependent variables with errors less than 14%. Using a soda concentration of 17.5% at 195 degrees C for 30 min, it is possible to reduce the working capital (cost of chemical) and the capital investment, because it is operated with smaller values of the soda concentration and cooking time that maximum considered (20% of soda concentration and 90 min). The pulp yield thus obtained differed by less than 31.3% from the highest possible value; also, the resulting pulp and paper sheets had acceptable properties that differed by less than 21.10% from their optimum values.     

Influence of dimethyl formamide pulping of wheat straw on cellulose degradation and comparison with Kraft process

The pulping of wheat straw with dimethyl formamide was studied in order to investigate the effects of the cooking variables (temperature (190 degrees C, 200 degrees C, and 210 degrees C) and time (120 min, 150 min, and 180 min) and organic solvent ratio (30%, 50%, and 70%) dimethyl formamide (DMF+water) value) on the degradation of cellulose and degree of polymerization (DP) of organosolv pulp. The SCAN viscosity was applied to estimating the extent of cellulose degradation produced by cooking condition and then, it was compared with Kraft pulp at equal Kappa number. Response of pulp and handsheets properties to the process variables were analyzed using statistical software (MINITAB 14). The process variables (cooking temperature and cooking time) must be set at low variables with high DMF ratio in order to ensure a high yield and high SCAN viscosity. Also, pulps with high mechanical properties can be acceptably obtained at 210 degrees C for 150 min with 50% DMF. Generally, the cooking temperature was a significant factor while the cooking time and DMF ratio had a smaller role. By the comparison of Kraft and organosolv pulp, it can be resulted that DMF basically had improvement role on reducing of cellulose degradation by reason of high SCAN viscosity of organosolv pulp than Kraft pulp under equal kappa number and, scanning electron microscopy (SEM) of obtained pulp. Consequently, the protective action of organic solvent on non-cellulosic polysaccharides of wheat straw against degradation under Kraft pulping conditions was pointed as a main reason of the fairly high yield of organosolv pulps.     

Optimization of pulping conditions of abaca. An alternative raw material for producing cellulose pulp

The influence of temperature (150-170 degrees C), pulping time (15-45 min) and soda concentration (5-10%) in the pulping of abaca on the yield, kappa, viscosity, breaking length, stretch and tear index of pulp and paper sheets, was studied. Using a factorial design to identify the optimum operating conditions, equations relating the dependent variables to the operational variables of the pulping process were derived that reproduced the former with errors lower than 25%. Using a high temperature, and a medium time and soda concentration, led to pulp that was difficult to bleach (kappa 28.34) but provided acceptable strength-related properties (breaking length 4728 m; stretch 4.76%; tear index 18.25 mN m2/g), with good yield (77.33%) and potential savings on capital equipment costs. Obtaining pulp amenable to bleaching would entail using more drastic conditions than those employed in this work.     

Assessment of wood-inhabiting Basidiomycetes for biokraft pulping of softwood chips

Wood-inhabiting Basidiomycetes have been screened for various applications in the pulp and paper industry and it is evident that different fungi need to be used to suit the specific requirements of each application. This study assessed the suitability of 278 strains of South African wood-decay fungi for the pre-treatment of softwood chips for kraft pulping. The influence of these fungi on kappa number, yield and strength properties of pulp was evaluated. A number of these strains were more efficient in reducing kappa number than the frequently used strains of Phanerochaete chrysosporium and Ceriporiopsis subvermispora. Six strains of Stereum hirsutum and a strain of an unidentified species were able to reduce the kappa number significantly without a significant influence on the pulp yield. Treatment of wood with two strains of S. hirsutum, one strain of Peniophora sp. and a strain of an unidentified species resulted in paper with improved strength properties.     

Soda-anthraquinone pulping of palm oil empty fruit bunches and beating of the resulting pulp

The influence of soda-anthraquinone pulping variables (temperature, time and soda concentration) and beating (number of PFI beating revolution) of palm oil empty fruit bunches (EFB) on the resulting paper sheets was studied, with a view to identifying the optimum operating conditions. Equations were derived that reproduced the properties of the paper sheets with errors less than 10-12% in 90-95% of cases. An optimum compromise was found as regards operating conditions (15% soda, 170 degrees C, 70 min and 2400 number of PFI beating revolutions) that provided paper properties departing by less than 12% from their optimum values (59.63 Nm/g tensile index, 4.48% stretch, 4.17 kN/g burst index and 7.20 m Nm(2)/g tear index), and a beating grade of 47.5 degrees SR, acceptable to obtain paper sheets. Because these conditions involve a lower soda, temperature, time and beating than those required to maximize the studied paper properties, they can save chemical reagents, energy and immobilized capital for industrial facilities. On the other hand, the stretch properties of these pulp beaten are higher than those of others non-wood pulps, as wheat straw and olive wood.     

Feasibility of utilizing Rhizoclonium in pulping and papermaking

Material of Rhizoclonium from brackish water in Taiwan was investigated for its possible use in pulping and papermaking. After beating, this filamentous alga produced a pulp with a length to width ratio of about 10, much less than that of a typical wood pulp. Handsheets made from this pulp had a moderate breaking length of 4.02 km. Cooking pre-beaten pulp with a low chemical charge (5–25%NaOH) at a low cooking temperature (100 ^°C), and for a short time (30–120 min) gave high algal pulp yields (70–80%). This cooking process was sulfur-free, but the water requirement was high. After cooking and further caustic soda and bleaching treatments, wide-angle X-ray diffraction and FTIR spectroscopy showed that the crystallinity of the algal pulp increased substantially, but type I cellulose conformation was retained. The best pulp mechanical strengths (breaking length 5.23 km,zero-span tensile strength 79.2 Nm g^-1, bursting index of 2.2 kpa m² g^-1) were obtained after cooking for 1 h with 20% NaOH. Because of the morphological characteristics of the algal strands, the pulp generally lacked bursting, tearing and folding strengths, but proper blending with softwood pulp increased the tensile breaking length to8.40 km, the tearing index to 14.5 mNm² g^-1, the bursting index to 6.42 kpam² g^-1 and the folding endurance to 4299 double folds, i.e. levels comparable to a typical kraft pulp. The algal pulp thus showed clear potential as a supplement for traditional medium strength wood pulps. This revised version was published online in August 2006 with corrections to the Cover Date.     

Fiber fractionation to understand the effect of mechanical refining on fiber structure and resulting enzymatic digestibility of biomass

Mechanical refining results in fiber deconstruction and modifications that enhance enzyme accessibility to carbohydrates. Further understanding of the morphological changes occurring to biomass during mechanical refining and the impacts of these changes on enzymatic digestibility is necessary to maximize yields and reduce energy consumption. Although the degree of fiber length reduction relative to fibrillation/delamination can be impacted by manipulating refining variables, mechanical refining of any type (PFI, disk, and valley beater) typically results in both phenomena. Separating the two is not straightforward. In this study, fiber fractionation based on particle size performed after mechanical refining of high-lignin pulp was utilized to successfully elucidate the relative impact of fibrillation/delamination and fiber cutting phenomena during mechanical refining. Compositional analysis showed that fines contain significantly more lignin than larger size fractions. Enzymatic hydrolysis results indicated that within fractions of uniform fiber length, fibrillation/delamination due to mechanical refining increased enzymatic conversion by 20–30 percentage points. Changes in fiber length had little effect on digestibility for fibers longer than ~0.5 mm. However, the digestibility of the fines fractions was high for all levels of refining even with the high-lignin content.     

Influence of process variables in the ethanol pulping of olive tree trimmings

A central composition design was developed to study the influence of process variables (temperature, pulping time and ethanol concentration) on the properties of the pulp produced (yield and holocellulose, alpha-cellulose and lignin contents) and the pH of the resulting wastewater, in the ethanol pulping of olive tree trimmings. The proposed equations reproduce the experimental results for the dependent variables with errors less than 5% for the holocellulose and alpha-cellulose contents, yield and wastewater pH, and less than 15% for the lignin content. Obtaining pulp with acceptably high yield (37.6%), high holocellulose and alpha-cellulose contents (above 88.8% and 46.9%, respectively), and low lignin contents (below 7.2%), entails operating at a pulping temperature of 200 degrees C, using an ethanol concentration of 75% and a pulping time of 60 min.     

Production of multi-fiber modifying enzyme from Mamillisphaeria sp. for refining of recycled paper pulp

Enzymatic modification of pulp is receiving increasing interest for energy reduction at the refining step of the paper-making process. In this study, the production of a multi-fiber modifying enzyme from Mamillisphaeria sp. BCC8893 was optimized in submerged fermentation using a response-surface methodology. Maximal production was obtained in a complex medium comprising wheat bran, soybean, and rice bran supplemented with yeast extract at pH 6.0 and a harvest time of 7 d, resulting in 9.2 IU/mL of carboxymethyl cellulase (CMCase), 14.9 IU/mL of filter paper activity (FPase), and 242.7 IU/mL of xylanase. Treatment of old corrugated container pulp at 0.2-0.3 IU of CMCase/g of pulp led to reductions in refining energy of 8.5-14.8%. The major physical properties were retained, including tensile and compression strength. Proteomic analysis showed that the enzyme was a complex composite of endo-glucanases, cellobiohydrolases, beta-1,4-xylanases, and beta-glucanases belonging to various glycosyl hydrolase families, suggestive of cooperative enzyme action in fiber modification, providing the basis for refining efficiency.     

Use of cellulases and recombinant cellulose binding domains for refining TCF kraft pulp

The modular endoglucanase Cel9B from Paenibacillus barcinonensis is a highly efficient biocatalyst, which expedites pulp refining and reduces the associated energy costs as a result. In this work, we set out to identify the specific structural domain or domains responsible for the action of this enzyme on cellulose fibre surfaces with a view to facilitating the development of new cellulases for optimum biorefining. Using the recombinant enzymes GH9–CBD3c, Fn3–CBD3b, and CBD3b, which are truncated forms of Cel9B, allowed us to assess the individual effects of the catalytic, cellulose binding, and fibronectin‐like domains of the enzyme on the refining of TCF kraft pulp from Eucalyptus globulus. Based on the physico‐mechanical properties obtained, the truncated form containing the catalytic domain (GH9–CBD3c) has a strong effect on fibre morphology. Comparing its effect with that of the whole cellulase (Cel9B) revealed that the truncated enzyme contributes to increasing paper strength through improved tensile strength and burst strength and also that the truncated form is more effective than the whole enzyme in improving tear resistance. Therefore, the catalytic domain of Cel9B has biorefining action on pulp. Although cellulose binding domains (CBDs) are less efficient toward pulp refining, evidence obtained in this work suggests that CBD3b alters fibre surfaces and influences paper properties as a result. © 2010 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

A comparative study of the effect of refining on physical and electrokinetic properties of various cellulosic fibres

The aim of this work was to study the influence of refining on various pulp properties such as freeness, specific surface area, specific volume, surface charge, total charge and elastic modulus. The results indicated that specific surface area of the pulps increased with increased refining, and at the same freeness level the pine pulp exhibited higher surface charge, surface area, and specific volume than the eucalyptus pulps. Also, the eucalypt pulps were much easier to beat than the pine pulps. The total fibre charge, as determined by conductometric titrations, was not affected by refining. However, the surface charge, as determined by titrations with poly-DADMAC, increased with refining. Increasing the specific surface area by refining resulted in a higher fibre surface charge and better fibre-fibre bonding. The change of the fibre surface charge during refining could be monitored using the FTIR characteristic bands within 1700-1300cm(-1).     

Wavelet neural networks applied to pulping of oil palm fronds

In the organosolv pulping of the oil palm fronds, the influence of the operational variables of the pulping reactor (viz. cooking temperature and time, ethanol and NaOH concentration) on the properties of the resulting pulp (yield and kappa number) and paper sheets (tensile index and tear index) was investigated using a wavelet neural network model. The experimental results with error less than 0.0965 (in terms of MSE) were produced, and were then compared with those obtained from the response surface methodology. Performance assessment indicated that the neural network model possessed superior predictive ability than the polynomial model, since a very close agreement between the experimental and the predicted values was obtained.     

Cellulase-assisted refining of chemical pulps: Impact of enzymatic charge and refining intensity on energy consumption and pulp quality

Paper production requires fibres to be refined, meaning mechanically treated to present sufficient bonding potential. As it is a highly energy consuming stage, various charges of cellulase as a pre-treatment were investigated to reduce the energy consumption and improve paper properties. The enzyme was added during pulp slushing and conditions of treatment were chosen to be compatible with an industrial application. Results obtained after low consistency disc refining of a softwood bleached kraft pulp were compared at a given drainage index. Enzymatically-treated samples showed a better development of fibrillation leading to a stronger paper. Moreover, fibre swelling was significantly improved. The impact of cellulase charge added to the pulp was identified. However, for all cellulase charges tested, fibre intrinsic resistance was lowered. Consequently fibres became shorter and tear index dropped. A solution was found by applying a milder treatment consisting in reducing refining intensity. This was a way to limit the intense fibre cutting at high refining levels. Moreover, by treating pulp with cellulase, it became possible to reduce refining intensity by 33%, keeping breaking length similar to control.     

Hydrothermal treatment and ethanol pulping of sunflower stalks

The influence of temperature in the hydrothermal treatment of sunflower stalks on the composition of the liquid fraction obtained was examined. The remaining solid fraction was subjected to ethanol pulping in order to obtain pulp that was used to produce paper sheets. The pulp was characterized in terms of yield, kappa index, viscosity, and cellulose, hemicellulose and lignin contents; and the paper sheets in terms of breaking length, stretch, burst index and tear index. Hydrothermal treatment of the raw material at 190 degrees C provided a liquid phase with maximal hemicellulose-derived oligomers and monosaccharide (glucose, xylose and arabinose) contents (26.9 and 4.2 g/L, respectively). Pulping the solid fraction obtained by hydrothermal treatment at 180 degrees C, with 70% ethanol at a liquid/solid ratio of 8:1 at 170 degrees C for 120 min provided pulp with properties on a par with those of soda pulp from the sunflower stalks, namely: 36.3% yield, 69.1% cellulose, 12.6% hemicellulose, 18.2% lignin and 551 ml/g viscosity. Also, paper sheets obtained from the ethanol pulp were similar in breaking length (3.8 km), stretch (1.23%), burst index (1.15 kN/g) and tear index (2.04 m Nm(2)/g) to those provided by soda pulp.     

Lignin: genetic engineering and impact on pulping

Lignin is a major component of wood, the most widely used raw material for the production of pulp and paper. Although the biochemistry and molecular biology underpinning lignin production are better understood than they are for the other wood components, recent work has prompted a number of re-evaluations of the lignin biosynthetic pathway. Some of the work on which these revisions have been based involved the investigation of transgenic plants with modified lignin biosynthesis. In addition to their value in elucidating the lignin biosynthetic pathway, such transgenic plants are also being produced with the aim of improving plant raw materials for pulp and paper production. This review describes how genetic engineering has yielded new insights into how the lignin biosynthetic pathway operates and demonstrates that lignin can be improved to facilitate pulping. The current technologies used to produce paper are presented in this review, followed by a discussion of the impact of lignin modification on pulp production. Fine-tuned modification of lignin content, composition, or both is now achievable and could have important economic and environmental benefits.