Technical field

[0001 ] The present invention relates to a process for improving the

manufacture of cellulose derivatives including regenerated cellulose. A cellulose derivative is included as an intermediate in the manufacture process.

Background

[0002] Cellulose is an important constituent in plants and comprises anhydrous glucose units. Unmodified cellulose is often difficult to use in applications due to limited solubility and complex crystalline structure. To overcome this problem cellulose is derivatized, and then it ^' s physical properties are changed and it can be used in many materials, medical and food applications.

[0003] The derivatization of cellulose is complicated due to the resistibility of the material. When cellulose is derivatized it is difficult to control the degree of substitution and the yield in the process. Groups may also be uneven distributed along the cellulose chain which may give quality problems (Kamide K (2005) "Cellulose and Cellulose Derivatives" Elsevier ISBN 1 0: 0 - 444- 82254-2).

[0004] There are several known ways to dissolve cellulose for various

applications including manufacture regenerated cellulosic fiber. Often expensive chemicals are used in such processes. (Ohno H and Fukaya Y (2009)Task specific ionic liquids for cellulose technology Chemistry Letters V38)

[0005] Zhao et al, in Biotechnology and Bioengineering, pp. 1 320-1 328, Vol.

99, No. 6, 2008 discloses treatment of wood fiber bundles with NaOH and NaOH/Urea. There is disclosed treatment with cold NaOH. The treated pulp is neutralized. Any cellulose which is dissolved in the NaOH solution is apparently not used further. It is disclosed that treatment with cold NaOH is advantageous. The yield is improved with pretreatment.

[0006] WO 2008/095098 discloses a process for the manufacture of sugar from biomass, where the biomass is pretreated with alkali solution to improve the following hydrolysis. The temperature is increased and is 50-150°C, preferably 80-1 40°C.

[0007] Jeihanipour et al, in Biorecource Technology, pp. 1 007-1 01 0, Vol.

1 00, 2009 discloses alkali pretreatment of cotton linter followed by enzymatic hydrolysis. It is disclosed that low temperatures improves the process. The cellulose material which is used is not dissolved or suspended in the alkali solution, it remains solid. A problem in this technology is that some of the cellulose material dissolves and is discarded, which reduces the yield.

[0008] EP 0 344 371 Al discloses a method for the production of

monosaccharides by hydrolysis of lignocellulosic materials. There is no dissolution of the cellulose, where the dissolved cellulose is recovered. The cellulose is washed, but cellulose that is dissolved is apparently not recovered.

[0009] US 4,089,745 discloses a process for enzymatic conversion of corn hull cellulose to glucose. Again there is no dissolution of the cellulose, where the dissolved cellulose is recovered. The cellulose is washed, but cellulose that is dissolved is apparently not recovered.

[0001 0] US 2008/01 02502 Al concerns recovery of inorganic salt during processing of lignocellulosic feedstocks. It is mentioned that carbon dioxide can be used to adjust pH.

[0001 1 ] There is a need for an improved process for the derivatization of

cellulose. Summary

[0001 2] It is an object of the present invention to obviate at least some of the disadvantages in the prior art and to provide an improved process for the treatment of cellulose before the derivatization stage.

[0001 3] In a first aspect there is provided a process for the derivatization of cellulose comprising the sequential steps: (a) mixing cellulose with a viscosity below 900 ml/g with an aqueous solution to obtain a liquid, wherein particles comprising cellulose in said liquid have a diameter of maximum 200 nm, wherein the temperature of the aqueous solution is below 20°C _/ and wherein the pH of the aqueous solution is above 1 2, (b) subjecting the liquid to at least one of the steps: (i) decreasing the pH of the liquid with at least 1 pH unit and (ii) increasing the temperature by at least 20°C _/ and (c) derivatization of the cellulose.

[0001 4] Further aspects and embodiments are defined in the appended claims, which are specifically incorporated herein by reference.

[0001 5] Advantages include that there is provided the possibility to derivatize cellulose faster and to a greater extent after the treatment. Further the yield is improved.

[0001 6] This can lead to cheaper and easier manufacture and improved

product quality for instance regarding an even distribution of substitutes.

[0001 7] One advantage is that the yield is increased compared to methods which discard an alkali treatment solution. In the present method the cellulose material is treated with an alkali solution, and the alkali solution, which inevitably comprises cellulose is not discarded. [0001 8] Another advantage is that the liquid is possible to pump since it is a solution and/or a colloidal system with particles not larger than 200 nm.

[0001 9] Another advantage is that the waste of cellulose material is reduced or even eliminated.

[00020] Compared to known methods the present process is easy to perform in a large scale set up.

Detailed Description

[00021 ] Before the invention is disclosed and described in detail, it is to be

understood that this invention is not limited to particular compounds,

configurations, method steps, substrates, and materials disclosed herein as such compounds, configurations, method steps, substrates, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present invention is limited only by the appended claims and equivalents thereof.

[00022] It must be noted that, as used in this specification and the appended claims, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise.

[00023] If nothing else is defined, any terms and scientific terminology used herein are intended to have the meanings commonly understood by those of skill in the art to which this invention pertains.

[00024] Unless clearly indicated, all percentages are calculated by weight.

[00025] The term "about" as used in connection with a numerical value

throughout the description and the claims denotes an interval of accuracy, familiar and acceptable to a person skilled in the art. Said interval is ± 1 0 %. [00026] "Colloid system" is used herein to denote a system comprising two separate phases, a dispersed phase and a continuous phase. The dispersed phase comprises particles with an average diameter of between 5-200 nm. In the present invention a colloidal system comprises particles comprising cellulose with an average diameter of between 5-200 nm in a continuous aqueous phase, where the aqueous phase may comprise dissolved cellulose and other dissolved substances.

[00027] "Diameter" of an irregular particle as used herein is the longest

distance between two points on its surface.

[00028] "Fluid" is used herein to denote a substance that continually deforms (flows) under an applied shear stress. Fluid comprises all liquids and all gases.

[00029] "Liquid" is used herein to denote a fluid that can freely form a distinct surface at the boundaries of its bulk material. The term liquid encompasses both solutions as well as colloidal systems such as a colloidal suspension.

[00030] "Solution" is used herein to denote a homogeneous mixture comprising at least one substance dissolved in a solvent.

[00031 ] The term "viscosity" for an aqueous cellulose mixture is a standard term within in pulp and paper industry. The term is well known by persons skilled in the art of cellulose including pulp and paper making. Its value is related to the average degree of polymerization of the cellulose, i.e. how long the individual cellulose chains are. A high value indicates that the cellulose has long chains and high degree of polymerization, whereas a low value indicates that the cellulose have low degree of polymerization. The viscosity value is proportional to the average molecular weight of the cellulose molecules. The limiting viscosity number ("viscosity") in the present description and in the appended claims is determined according to ISO 5351 . "Pulps - Determination of limiting viscosity number in cupri-ethylenediamine (CED) solution Reference number 5351 :2004(E), International Organization for Standardization, Geneva , Switzerland.

[00032] Fock-test: A simulation of viscose method, where an alkaline soluble cellulose derivatives cellulose xanthate is formed, which subsequently is precipitated to regenerated cellulose, by an acid treatment that removes the xanthate groups. The yield of the process is a measurement of the reactivity of the cellulose (Fock vW. (1 956) Eine modifizierte Methode zur Bestimmung der Reaktivitat von Zellstoffen fur die Viskosherstellung. Das Papier, 92-96). Another way to measure chemical reactivity (i.e., easiness to make cellulose derivatives) is to measure the rate of acid or enzymatic hydrolysis.)

[00033] There is provided a process for the derivatization of cellulose

comprising the sequential steps: (a) mixing cellulose with a viscosity below 900 ml/g with an aqueous solution to obtain a liquid, wherein particles comprising cellulose in said liquid have a diameter of maximum 200 nm, wherein the temperature of the aqueous solution is below 20°C, and wherein the pH of the aqueous solution is above 1 2, (b) subjecting the liquid to at least one of the steps: (i) decreasing the pH of the liquid with at least 1 pH unit and (ii) increasing the temperature by at least 20°C, and (c) derivatization of the cellulose. The latter can be a step in a process for making regenerated cellulose.

[00034] The cellulose is mixed with the aqueous solution so that a liquid is

obtained. The liquid which is obtained is either a solution of cellulose in the aqueous solution or a combination of a solution of cellulose and a colloidal system with dispersed particles comprising cellulose in the aqueous solution. The particles comprising cellulose have a diameter of 200 nm or less. In one embodiment the particle diameter is from about 5 nm to about 200 nm. [00035] In one embodiment the viscosity of the cellulose is below 900 ml/g. In one embodiment the viscosity of the cellulose is below 700 ml/g.

[00036] In one embodiment there is a step before step a), wherein the viscosity of cellulose with a viscosity above 900 ml/g is lowered to below 900, preferably below 700 ml/g. This is particularly useful when cellulose with a viscosity above 900 ml/g is to be treated. In one embodiment treatment with acid is used to reduce the viscosity of the cellulose.

[00037] In alternative embodiments the degradation is performed using a

radical generating system. Examples include the Fenton reaction, (i.e. transition metal ions and hydrogen peroxide), hypochlorite, and alkaline hydrolysis at high temperature. More precise Fenton's reagent is a solution of hydro hydrogen peroxide and an iron catalyst. In one embodiment the viscosity is lowered before step a) by treatment with at least one method selected from treatment with Fenton's reagent and treatment with an alkaline solution.

[00038] In one embodiment the aqueous solution in step a) comprises at least one strong base. In one embodiment the aqueous solution in step a) comprises NaOH. NaOH is a suitable and economical way of achieving a high pH in this method. In one embodiment the aqueous solution comprises at least 2wt% NaOH. In one embodiment the aqueous solution comprises at least 5wt%

NaOH. In one embodiment the aqueous solution comprises at least 8wt%

NaOH. In one embodiment the aqueous solution comprises at least 1 0wt% NaOH.

[00039] In one embodiment the liquid is filtered between step a) and step b). In another embodiment the liquid if centrifuged between step a) and step b) in order to remove impurities. It is an advantage that the process provides this possibility to remove impurities which have not dissolved in the liquid. [00040] In one embodiment the pH is decreased in step b) by addition of an acid. This has the effect of precipitating the cellulose from the liquid. In one embodiment the acid is sulphuric acid.

[00041 ] In an alternative embodiment the pH is decreased in step b) by addition of C0 ₂ . Also H ₂ C0 ₃ may be employed particularly in combination with C0 ₂ . Thus there is disclosed an embodiment where the pH is decreased in step b) by addition of at least one chemical entity selected from C0 _2/ and H ₂ C0 ₃ . This is advantageous for use in an industrial scale, where C0 ₂ can be recycled in the process according to methods well known to a person skilled in the art of papermaking.

[00042] In one embodiment the temperature is below 20°C in step a). In one embodiment the temperature is below 1 5°C in step a). In one embodiment the temperature is below 1 0°C in step a). In one embodiment the temperature is below 4°C in step a). A lower temperature is beneficial although the process can be carried out at room temperature, i.e. at about 20°C. In one embodiment the temperature is below ambient temperature in step a). In one embodiment the temperature is below 1 7°C in step a).

[00043] In one embodiment cellulose which has not been dissolved and/or suspended to a particle size below 200 nm in step a) is recycled to step a). In this way any waste of cellulose can be minimized. In one embodiment fibers which are larger than 200 nm are removed in step a).

[00044] The derivatization is carried out introducing groups including but not limited to at least one group from methoxy, acetyl, methyl, carboxy methyl, ethyl, sulfate, phosphate and quaternary ammonia groups. The groups are introduced in at least one of the C2-, C3- and Composition of the anhydroglucose unit of cellulose. [00045] In one embodiment step c) comprises chemical derivatization of cellulose using acid catalysis. Manufacture of cellulose derivatives with acid catalysis is used mainly for making cellulose esters, including but not limited to cellulose acetate. The cellulose is mixed with a target molecule, such as an acetic acid anhydride. In one embodiment the mixing is performed under water free conditions. Strong acid, such as sulphuric acid, is added, and the hydroxyl groups of the cellulose perform nucleophilic attacks on the target molecule, which have been made more reactive by the strong acid, causing a chemical coupling on the cellulose. (Gellerstedt G (2009) "Cellulose Products and

Chemicals from wood" In "Wood Chemistry and Wood Biotechnology" Eds: M Ek, G Gellerstedt and G Henriksson. De Gruyter ISBN 978-3-1 1 -021 339-3 ppl 73 - 1 93)

[00046] In one embodiment step c) comprises chemical derivatization of

cellulose using alkaline catalysis. Manufacture of cellulose derivative by alkaline catalysis is used mainly for making cellulose ethers, including but not limited to carboxymethyl cellulose. The cellulose is mixed with a target molecule, such as chlorine acetic acid. In one embodiment the mixing is performed under water free conditions. Strong base, such as sodium hydroxide, is added and the hydroxyls of the cellulose is partly deprotonated by the strong base, which make them reactive and able to perform nucleophilic attacks on the target molecules causing a chemical coupling on the cellulose.

[00047] In one embodiment step c) comprises chemical derivatization of

cellulose using oxidation. Manufacture of cellulose derivatives by oxidation convert cellulose alcohols to aldehydes or carboxylic acids. These reactions can be done in water using for instance TEMPO as catalysist and sodium

hypochlorite as oxidant (Isogai A and Kato Y (1 998) "Preparation of polyuronic acid from cellulose by TEMPO-mediated oxidation" Cellulose 5, 1 53 - 1 64). [00048] In a second aspect there is provided cellulose derivate manufactured by derivatization according to the above process. The cellulose derivate can be used in many material applications, food applications and medical applications.

[00049] Examples of cellulose derivatives include but are not limited to cellulose ethers, cellulose esters and inorganic cellulose derivatives. Example of cellulose ethers include but are not limited to carboxymethyl cellulose, methyl cellulose, and ethyl cellulose. One example of cellulose esters includes cellulose acetate. In one embodiment the cellulose derivative is at least one selected from

carboxymethyl cellulose, methyl cellulose, ethyl cellulose, and cellulose acetate.

[00050] Other features and uses of the invention and their associated

advantages will be evident to a person skilled in the art upon reading this description and the appended examples.

[00051 ] It is to be understood that this invention is not limited to the particular embodiments shown here. The following examples are provided for illustrative purposes and are not intended to limit the scope of the invention since the scope of the present invention is limited only by the appended claims and equivalents thereof.

Examples

Example 1 Dissolution of different celluloses at 4°C

[00052] Cellulose quality: Avicel (Microcrystalline cellulose), cotton linter,

sulphite pulp, birch kraft pulp. Viscosities of the samples were measured according to ISO 5351 . This is a method to get a viscosity value that is dependent on the degree of polymerization of mainly the cellulose in the samples; the higher the viscosity, the higher the average degree of

polymerization of the samples. [00053] Treatment conditions: Every 1 g sample was added to 50 ml 1 0% NaOH at 4°C, and subjected to magnetic stirring for approx 1 h.

[00054] The solutions were evaluated for how clear they appeared.

[00055] Only Avicel is totally dissolved. The other one are not totally in one phase. The Avicel has shorter cellulose chains. The non transparent samples indicate that the cellulose has not dissolved completely.

Example 2 Dissolution in varying concentration of cellulose

[00056] Cellulose quality: Avicel (Microcrystalline cellulose)

[00057] Treatment conditions: 1 g or 2 g cellulose were added to 50 ml 1 0% NaOH at varying temperature, and subjected to magnetic stirring for approx 1 h.

Appearance

Temperature 1 g sample 2g sample

One phase and One phase, not so transparent, a

4°C

transparent little bit milky One phase and

1 0°C One phase, milky

transparent

Room One phase, not so

One phase, light yellow color

Temperature transparent

Two phases, some

40°C - precipitate

Example 3 Dissolution at varying concentration

[00058] Cellulose quality: Avicel (Microcrystalline cellulose)

[00059] Treatment conditions: Samples 0.05g, O. l g, 0.25g, 0.5g, I g Avicel in 50ml 1 %, 5%, 8%, 1 0% NaOH respectively. All experiments were done at 4°C.

[00060] The solutions were evaluated for if the Avicel dissolved.

[00061 ] Along with the increase of the concentration of NaOH, more Avicel will be dissolved (as a reference a solution of 2% NaOH has a pH of about 1 2.8 at 25°C). Example 4 Dissolution at varying concentration

[00062] Cellulose quality: Avicel (Microcrystalline cellulose)

[00063] Treatment conditions: 0.05 g, 0.25g, 0.5g, I g, 2.5g, 5g cellulose

were added to 50 ml 1 0% NaOH at 4°C , and subjected to magnetic stirring for approx 1 h.

[00065] When the Avicel concentration reached a certain point, the sample will become a colloid, and not a true solution. During the dissolving stage, stirring is very important, strong stirring can dissolve the Avicel easily and fast.

Example 5 Dissolution at varying temperature

[00066] Cellulose quality: Avicel (Microcrystalline cellulose)

[00067] Treatment conditions: 1 g cellulose were added to 50 ml 1 0% NaOH at varying temperature, and subjected to magnetic stirring for approx 1 h. The effect was mostly done within 1 0 minutes. [00068] The solutions were evaluated for how clear they were. Photos were taken in some cases.

[00069] All of the celluloses were dissolved in 4°C, 1 0°C and room

temperature, but at 40°C when the magnetic stir is stopped, some precipitate occurred. At room temperature a stable suspension is obtained, which can be treated as a fluid from a technical point of view.

Example 6 Precipitation of cellulose with carbon dioxide.

[00070] Cellulose quality: Avicel (Microcrystalline cellulose)

[00071 ] Treatment conditions: I g Avicel was dissolved in 50ml 1 0% NaOH solution at 4°C, and then either precipitate it with sulphuric acid (pH adjusted to pH 7) or by flushing carbon dioxide gas. A beaker with the solution was flushed with carbon dioxide gas meanwhile the solution was stilled by magnetic stirring. The precipitate come quick, but the flushing was continued for 1 h. The pH was then 1 0. A continuous 30 min of flushing did not change the pH.

[00072] The precipitates were collected and weight. [00073] The yield of the carbon dioxide precipitation was 86.1 %, and the acid precipitation was close to 1 00%

[00074] The results show that adjustment of pH with carbon dioxide (that forms carbonic acid) can be used for precipitating cellulose, although the yield was lower than in the case of pH adjustment with sulphuric acid. The results also show that the precipitate comes at higher pH than 7.

[00075] It has several advantages to perform cellulose precipitation with carbon dioxide, since this make closing of process streams in a pulp mill, easier. This since the sodium carbonate formed during the precipitation can be reconverted to sodium hydroxide with a lime cycle. In this process carbon dioxide is formed that can be used for the precipitation.

Short chained cellulose

Cellulose Example 7 Dissolution at varying concentration

[00076] Cellulose quality: Avicel (Microcrystalline cellulose) Treatment

conditions: Samples 0.05g, O. l g, 0.25g, 0.5g, I g Avicel in 50ml 1 %, 5%, 8%, 1 0% NaOH respectively. All experiments were done at 4°C.

[00077] The solutions were evaluated regarding dissolution of Avicel.

[00078] Along with the increasing of the concentration of NaOH, more Avicel will be dissolved.

[00079] It is possible to perform dissolution of short chain cellulose to at least 4% in 8% and 1 0% NaOH respectively. 1 0% is too high a cellulose

concentration. Lower concentrations of alkali can dissolve low concentrations of cellulose. Example 8 Precipitation with varying temperature or pH

[00080] Cellulose quality: Avicel (Microcrystalline cellulose) pretreated with NaOH, the pretreatment was done by dissolving I g Avicel in 50ml 1 0% NaOH at 4 °C

[00081 ] Treatment conditions: Attempts to precipitate the solution were

performed according to two different strategies; Neutralizing the solution with sulphuric acid to pH approx 7, 9, and 1 1 (pH was determined) at 4°C, or increasing the temperature which is done by putting the solution into 1 00°C water bath for 1 .5 hours.

[00082] The evaluation was done by measuring the yield of the precipitation. A filtration method was used. The pH before precipitation was 1 4 - 14.6

[00083] In the previous examples the precipitation was performed by a

combined increase of the temperature and decrease of pH to approximately neutral. Here the effects of lowering the pH lowering and increasing the temperature were investigated separately. The results show clearly that the most of the effect is achieved by lowering the pH. This implies that it is possible to run the process at constant temperature, which is advantageous since the sample does not have to undergo energy consuming temperature changes. The pH lowering can also be much smaller than what we have used earlier; a decrease to a pH around 1 1 seems to be enough, which is beneficial from an economical point of view. To use the same pH and only increase the temperature is an option, but seems to be less preferred for most applications. The yield of the precipitation at an increase of temperature to close to 1 00°C was only around 35%, and the formation of yellow color indicates that the cellulose has undergone structural changes. Something that is likely under this very high temperature and alkalinity.

Example 9 Fock test of pretreated samples

[00084] The example comprising the steps of dissolution of cellulose with a

viscosity below 900 ml/g in alkali at a temperature below 20°C followed by precipitation leads to a considerably increased reactivity measured by the Fock test. Indicating suitability for derivatization.

Reference sample Pretreated sample

Pulp

Fock test Reactivity, % Fock test Reactivity, %

Bleached Hardwood 22 74

Bleached Hardwood 23 71

Bleached Hardwood 21 72

Bleached Softwood 38 69

Bleached Softwood 38 68

Bleached Softwood 38 74