Treated Kraft Pulp Extenders for Reactive, Lower-Cost Rayon
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Solution Overview
Problem
The production of rayon fibers from high-quality wood pulps that have been extensively processed to remove non-cellulose components like lignin and hemicellulose is costly, and there is a need for pulp compositions that offer the advantageous properties of high alpha pulps without the associated costs.
Innovation Solution
Development of treated Kraft pulps with increased reactivity, natural cellulose I structure, high xylan and hemicellulose content, and low viscosity, which can be blended with dissolving grade pulp to increase yield and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-quality wood pulps are extensively processed to remove non-cellulose components like lignin and hemicellulose to produce high alpha pulp, then the cellulose purity is improved, but the production cost significantly increases
Solution Approach 1:
The patent changes the chemical parameters of Kraft pulp by controlling the cooking process to achieve a specific hemicellulose content range (4-12%) and R18 value (85-95%), transforming low-quality Kraft pulp into a suitable extender for viscose production without requiring extensive additional processing
Solution Approach 2:
The patent utilizes low-cost Kraft pulp, which would otherwise be unsuitable for dissolving applications, as a disposable extender material that can be blended with dissolving grade pulp to reduce the amount of expensive high-alpha pulp required while still achieving acceptable viscose production
2Productivity
If Kraft pulp is used as a pulp extender in viscose production, then the production yield is improved and cost is reduced, but the reactivity and filterability may deteriorate
Solution Approach 1:
The patent optimizes specific parameters of Kraft pulp including hemicellulose content (4-12%), R18 value (85-95%), and viscosity ratios to achieve the desired balance between reactivity, filterability, and cost-effectiveness for viscose production
Solution Approach 2:
The patent applies different quality requirements to different components of the pulp blend, allowing Kraft pulp to serve as an extender with specific hemicellulose content ranges while maintaining overall blend performance through controlled blending ratios with dissolving grade pulp
Data Source
AI summary
Compositions including treated Kraft pulp, useful for making rayon fibers, having a lower degree of polymerization, a high R18, a low hemicellulose content, and high reactivity, are described. Methods of making the compositions are also described.