Nanofibrillar Cellulose Production via Segmented Homogenization
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Solution Overview
Problem
Current methods for producing nanofibrillar cellulose, such as homogenization, face challenges in scalability and energy efficiency, and are prone to clogging due to high input power requirements and fiber material susceptibility.
Innovation Solution
A two-step method involving a disperser and a homogenizer, where the fiber material is subjected to shear and impact forces in the disperser at high consistency, followed by homogenization under pressure to achieve nanofibrillar cellulose production without clogging, allowing for higher consistency processing and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If homogenization is used to produce nanofibrillar cellulose, then fibrillation is achieved, but the process is prone to clogging and has poor scalability
Solution Approach 1:
The patent divides the homogenization process into multiple sequential stages with progressively narrower gaps. The homogenizer includes a first homogenization stage with a first gap, a second homogenization stage with a second gap narrower than the first, and a third homogenization stage with a third gap narrower than the second. This segmentation allows gradual fibrillation while maintaining scalability and reducing clogging risk.
2Manufacturing precision
If high input power is applied in homogenization to achieve good fibrillation, then fibrillation quality improves, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by progressively preparing the fiber material through staged homogenization with gradually narrowing gaps. The first homogenization stage prepares the material for the second stage, which in turn prepares it for the third stage. This preliminary action at each stage reduces the energy required in subsequent stages while achieving the same fibrillation quality.
3Productivity
If fiber material is processed at high consistency, then productivity improves, but clogging susceptibility increases
Solution Approach 1:
The patent segments the homogenization process into multiple stages with progressively narrower gaps, allowing high consistency processing without clogging. Each stage handles a specific portion of the fibrillation task, enabling the system to process high consistency fiber material reliably while maintaining productivity.
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 method enables efficient production of nanofibrillar cellulose with improved scalability and energy efficiency, reducing the risk of clogging and achieving a uniform gel-like dispersion with high viscosity and low turbidity.
Implementation Method 1
the material is repeatedly subjected to shear and impact forces by the effect of the different counter-rotating rotors
Implementation Method 2
the material is repeatedly subjected to shear and impact forces by the effect of the different counter-rotating rotors
Implementation Method 3
the fiber material obtained from the first step is supplied to a homogenizer, where it is subjected to homogenization by the effect of pressure
Data Source
AI summary
In a method for producing nanofibrillar cellulose, cellulose based fiber material in dispersion is processed for separating fibrils. The method includes a first step where the fiber material is supplied to a disperser, where it flows through several counter-rotating rotors in such a way that the material is repeatedly subjected to shear and impact forces by the effect of the different counter-rotating rotors, and a second step, where the fiber material obtained from the first step is supplied to a homogenizer, where it is subjected to homogenization by the effect of pressure.