Processes disclosed are capable of converting
biomass into high-
crystallinity nanocellulose with surprisingly low
mechanical energy input. In some variations, the process includes fractionating
biomass with an acid (such as
sulfur dioxide), a
solvent (such as
ethanol), and water, to generate
cellulose-rich solids and a liquid containing
hemicellulose and
lignin; and mechanically treating the
cellulose-rich solids to form nanofibrils and / or nanocrystals. The
total mechanical energy may be less than 500 kilowatt-hours per
ton. The
crystallinity of the
nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites. The
nanocellulose material may include nanofibrillated
cellulose, nanocrystalline cellulose, or both. In some embodiments, the nanocellulose material is hydrophobic via deposition of some
lignin onto the cellulose surface. Optionally, sugars derived from amorphous cellulose and
hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the nanocellulose to form completely renewable composites.