Cellulose Filament Refining Energy Reduction
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Solution Overview
Problem
Current methods for producing cellulose filaments with superior reinforcement ability require high energy consumption, and there is a lack of effective methods to reduce energy requirements while maintaining or improving reinforcement ability.
Innovation Solution
A method involving multi-pass high consistency refining followed by low consistency refining or non-refining mechanical treatment of wood or plant fibers, optimizing the energy percentage distribution to reduce total specific refining energy while maintaining or enhancing the aspect ratio and reinforcement ability of cellulose filaments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-pass high consistency refining is used to produce cellulose filaments with superior reinforcement ability, then the aspect ratio and reinforcement ability are improved, but the total specific refining energy consumption increases significantly
Solution Approach 1:
The refining process is divided into two distinct stages: high consistency refining (to develop aspect ratio and reinforcement ability) and low consistency refining (to reduce energy consumption). This segmentation allows each stage to be optimized independently, achieving the desired filament properties with reduced total energy input.
Solution Approach 2:
The consistency parameter is changed between refining stages. High consistency (typically 15-30%) is used in the first stage to minimize water content and energy consumption during initial fibrillation, then low consistency (typically 1-5%) is used in subsequent stages to reduce energy requirements while maintaining filament quality.
2Length of moving object
If high consistency refining is applied to maintain fiber length and aspect ratio, then fiber cutting is minimized, but energy consumption increases
Solution Approach 1:
High consistency refining is performed first to preliminarily develop the cellulose filaments and establish their aspect ratio before low consistency refining. This preliminary action at high consistency minimizes fiber cutting and establishes the structural foundation for reinforcement ability.
Solution Approach 2:
The high consistency refining is applied partially (for a limited number of passes or energy input) to achieve the necessary aspect ratio development, then the process transitions to low consistency refining. This partial application prevents excessive energy consumption while maintaining adequate fiber length.
Data Source
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AI summary
A novel method is disclosed to make cellulose filaments (CF) from wood or other plant fibers with lower energy consumption. The method consists of multi-stage, high consistency refining, followed by low consistency refining or by low consistency, non-refining mechanical treatment, of wood or other plant fibers. The total specific refining energy for the multi-stage, high consistency refining is preferably 2, 000 - 18,000 kWh/t, and more preferably 2,000 - 12,000 kWh/t. The CF produced can be used as a superior reinforcement additive in the production of paper, tissue or paperboard and in the production of plastic composites. It can also be used as a viscosity or rheology modifier in food products, coatings or drilling muds. The CF produced can also be used to make strong films for application in packaging and in composites.