Microfibrillated Cellulose Production via Conical Extrusion
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Solution Overview
Problem
Current methods for producing microfibrillated cellulose are energy-intensive and often require separate process steps for defibrillation and chemical modification, leading to inefficiencies and varying quality in the final product.
Innovation Solution
A process using a conical extruder to defibrillate cellulose fibers while simultaneously adding modifying chemicals, allowing for energy-efficient production of modified microfibrillated cellulose in a single step, with the ability to control fiber length and increase dry content, and enabling simultaneous modification of both surface and inner regions of the fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical treatment is used to produce MFC, then microfibrils are formed, but the process is very energy consuming
Solution Approach 1:
The patent combines mechanical defibrillation and chemical modification into a single extrusion process step. The extruder simultaneously performs mechanical treatment to separate microfibrils and chemical treatment through added modifying agents, eliminating the need for separate energy-intensive mechanical refining steps while achieving both defibrillation and modification in one operation.
Solution Approach 2:
The patent changes the physical and chemical parameters during extrusion by controlling temperature, pressure, and residence time to optimize both defibrillation and chemical modification. By adjusting these parameters, the process achieves efficient microfibril formation with reduced energy consumption compared to conventional mechanical treatment.
2Manufacturing precision
If separate process steps are used for defibrillation and chemical modification, then each step can be optimized, but the process becomes less efficient and produces varying quality
Solution Approach 1:
The patent merges defibrillation and chemical modification into a single integrated extrusion process. This combination ensures uniform quality throughout the product since all treatment occurs simultaneously under controlled conditions, eliminating the variability that arises from sequential processing steps.
Solution Approach 2:
The extrusion process provides continuous simultaneous action of mechanical defibrillation and chemical modification throughout the material flow. This continuous treatment ensures consistent quality and higher productivity compared to intermittent separate steps, as the useful actions occur continuously without interruption or quality variation.
3Manufacturing precision
If modifying chemical is added after defibrillation, then chemical modification can be controlled, but an additional process step is required
Solution Approach 1:
The patent combines the addition of modifying chemical with the defibrillation process in a single extrusion step. The chemical is introduced into the extruder where it simultaneously performs defibrillation and modification, reducing device complexity by eliminating separate process steps while maintaining modification uniformity through controlled addition and mixing.
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 approach results in a more energy-efficient and cost-effective production of modified microfibrillated cellulose with improved properties, such as increased dry content and uniform modification, reducing the need for separate process steps and minimizing energy consumption.
Implementation Method 1
treating the slurry in the extruder so that the fibers are defibrillated and microfribrillated cellulose is formed
Implementation Method 2
the addition of a chemical will thus react with the fibers either by modifying the fibers on the surface or by being incorporated into the softened and/or expanded fibers
Data Source
AI summary
The present invention relates to a process for the production of microfibrillated cellulose wherein the process comprises the steps of, providing a slurry comprising fibers, adding the slurry to an extruder, treating the slurry in the extruder so that the fibers are defibrillated and microfibrillated cellulose is formed. The invention further relates to a microfibrillated cellulose produced.