Microcellulose Production via High-Consistency Acid Hydrolysis
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Solution Overview
Problem
Existing methods for producing microcellulose require high amounts of chemicals and energy due to harsh acid hydrolysis conditions and mechanical treatment, making them inefficient and costly.
Innovation Solution
A process involving mild acid hydrolysis at high consistency (at least 8% on dry weight) and temperatures below 140°C, with controlled particle size distribution, eliminating the need for subsequent mechanical disintegration and reducing energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If harsh acid hydrolysis conditions (high acid concentration, high temperature) are used, then microcellulose production yield is improved, but chemical usage and energy consumption increase
Solution Approach 1:
The patent changes the parameters of acid hydrolysis by using lower acid concentrations (0.5-5% instead of conventional higher concentrations) and moderate temperatures (80-140°C instead of higher temperatures), while maintaining high consistency (30-70% instead of low consistency). This parameter optimization achieves satisfactory microcellulose yield while significantly reducing chemical and energy consumption.
2Productivity
If harsh acid hydrolysis conditions (high acid concentration, high temperature) are used, then microcellulose production yield is improved, but energy consumption increases
Solution Approach 1:
The patent optimizes hydrolysis parameters by using moderate temperatures (80-140°C) combined with high consistency (30-70%), which reduces the energy required for heating while maintaining effective hydrolysis and achieving satisfactory microcellulose yield.
3Manufacturing precision
If mechanical disintegration treatment is applied after acid hydrolysis, then particle size control is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent replaces the mechanical disintegration system with a chemical hydrolysis process optimized at high consistency. The acid hydrolysis under these specific conditions directly produces microcellulose with satisfactory particle size distribution, eliminating the need for separate mechanical disintegration equipment and operations.
4Manufacturing precision
If mechanical disintegration treatment is applied after acid hydrolysis, then particle size control is improved, but energy consumption increases
Solution Approach 1:
The patent substitutes mechanical disintegration energy with optimized chemical hydrolysis energy. By conducting acid hydrolysis at high consistency (30-70%) with controlled acid concentration and temperature, the process achieves acceptable particle size control without requiring additional mechanical energy input for disintegration.
5Ease of operation
If low consistency pulp is used in acid hydrolysis, then acid and cellulose contact is improved, but heating demand and acid amount increase
Solution Approach 1:
The patent changes the consistency parameter to high levels (30-70%), which reduces the volume of acid solution required and lowers heating demand. The high consistency ensures sufficient contact between acid and cellulose while minimizing the energy and chemical quantities needed for effective hydrolysis.
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 achieves high yields of microcellulose with narrow particle size distribution, reducing chemical usage and energy consumption, and allowing for efficient production without extensive mechanical treatment.
Implementation Method 1
cellulose undergoes acid hydrolysis and forms microcrystalline cellulose
Implementation Method 2
the temperature of the extruder barrel during the hydrolysis is from 80 to 200° C. Due to the temperature of the extruder and the pressure created by the die or screw of the extruder, the cellulose melts in the extruder
Implementation Method 3
the temperature of the extruder barrel during the hydrolysis is from 80 to 200° C.
Data Source
AI summary
The present invention relates to a process for producing microcellulose comprising subjecting fibrous cellulosic material to acid hydrolysis at a temperature from 10° C. to less than 140° C. and at a consistency of at least 8% on dry weight of the cellulose, wherein the amount of added acid is from 0.2 to 2%, preferably from 0.3 to 1.9%, more preferably from 0.5 to 1.5% on dry weight of the cellulose.