Fibrillated Cellulose High-Consistency Dispersion Process
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Solution Overview
Problem
The production of fibrillated cellulose compositions with high dry content is challenging due to their shear-thinning characteristics, which makes processing and distribution difficult, and existing methods to address this, such as drying, are energy-intensive and can cause structural changes in microfibrillated cellulose.
Innovation Solution
A process involving pre-treating cellulosic fibers mechanically, chemically, and/or enzymatically, then mixing them with pigments to form a dispersion at high consistency, which increases the final composition's consistency and rheology properties, allowing for the production of fibrillated cellulose with pigments in a cost-efficient manner without requiring additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fibrillated cellulose is produced with high dry content, then transportation costs and energy consumption are reduced, but the material exhibits gel-like character with very high viscosity making it difficult to process and distribute
Solution Approach 1:
The patent applies parameter changes by controlling the degree of fibrillation and solid content during production. By adjusting these parameters, the process produces fibrillated cellulose with high dry content (up to 50% or more) that maintains acceptable viscosity and processability, avoiding the gel-like state that would occur with conventional high-solid-content materials.
2Ease of operation
If a dispersion with low solid content is used, then processability is improved, but energy consumption increases due to the need to remove large amounts of water during drying
Solution Approach 1:
The patent applies preliminary action by producing fibrillated cellulose at high solid content (high dry content) before distribution and application. This preliminary concentration step eliminates the need for subsequent drying operations, as the material can be directly applied to substrates like paper or board without requiring energy-intensive water removal.
3Quantity of substance
If fibrillated cellulose is dried before addition to composition, then solid content is increased, but significant irreversible chemical and physical structural changes occur on the microfibrillated cellulose
Solution Approach 1:
The patent replaces the thermal drying process (which causes structural damage) with a mechanical/chemical fibrillation process that directly produces high-solid-content material in a wet state. The fibrillation mechanism (using refiners, homogenizers, or chemical treatments) converts intact cellulose fibers into fibrillated cellulose with high solid content without requiring heat-induced drying, thus preserving the structural integrity of the microfibrils.
4Ease of operation
If wetting agent is added to facilitate re-dispersion of dried MFC, then processability is improved, but additional chemicals and process complexity are required
Solution Approach 1:
The patent extracts the need for wetting agents and re-dispersion processes by producing fibrillated cellulose directly at high solid content in a usable wet state. By eliminating the drying step entirely, the material maintains its inherent dispersibility and can be directly incorporated into compositions or applied to substrates without requiring additional wetting agents or complex re-dispersion procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enables the production of fibrillated cellulose compositions with high consistency and improved rheology properties, reducing energy consumption and avoiding structural changes, while allowing for on-site production and efficient transportation, thus addressing the challenges of processing and distribution.
Implementation Method 1
The friction between the fibers and the pigments which occur during the dispersing
Implementation Method 2
mechanically treat cellulosic fibers so that microfibrils are formed
Implementation Method 3
produce fibrils from cellulose by the aid of different chemicals and/or enzymes which will break interfibrillar bonds
Data Source
AI summary
The present invention relates to a process for the production of a composition wherein the process comprises pre-treating cellulosic fibers by mechanical, chemical and/or enzymatic treatment, mixing the pre-treated cellulosic fibers with pigments forming a dispersion and dispersing the dispersion of pre-treated cellulosic fibers and pigments whereby a composition comprising microfibrillated cellulose is formed. The invention further relates to a composition produced according to the process.