U.S. patent application number 09/835365 was filed with the patent office on 2003-01-30 for metal substituted xerogels for improved peroxide bleaching of kraft pulps.
Invention is credited to Kim, Dong Ho, Ragauskas, Arthur J..
Application Number | 20030019596 09/835365 |
Document ID | / |
Family ID | 25269319 |
Filed Date | 2003-01-30 |
United States Patent
Application |
20030019596 |
Kind Code |
A1 |
Ragauskas, Arthur J. ; et
al. |
January 30, 2003 |
Metal substituted xerogels for improved peroxide bleaching of kraft
pulps
Abstract
A novel process for bleaching cellulosic pulp is disclosed which
provides improvements in pulp brightness and delignification
without negatively impacting physical properties of the pulp.
Specifically, a process is disclosed in which kraft pulp is treated
with at least one of each of an oxidizing agent, an alkaline agent,
and a metal substituted xerogel in a bleaching stage to improve
brightness and delignification of softwood, hardwood, or recycled
pulp. In a preferred embodiment, a process is disclosed which uses
at least one metal substituted xerogel as a catalyst in an alkaline
peroxide bleaching stage to improve kraft pulp brightness and
delignification. Pulps bleached according to the process of the
present invention are also disclosed.
Inventors: |
Ragauskas, Arthur J.;
(Lawrenceville, GA) ; Kim, Dong Ho; (Tucker,
GA) |
Correspondence
Address: |
FINNEGAN, HENDERSON, FARABOW, GARRETT &
DUNNER LLP
1300 I STREET, NW
WASHINGTON
DC
20005
US
|
Family ID: |
25269319 |
Appl. No.: |
09/835365 |
Filed: |
April 17, 2001 |
Current U.S.
Class: |
162/72 ; 162/78;
162/80 |
Current CPC
Class: |
D21C 9/163 20130101;
D21C 9/1036 20130101 |
Class at
Publication: |
162/72 ; 162/78;
162/80 |
International
Class: |
D21C 003/20; D21C
003/00 |
Claims
We claim:
1. A process for bleaching cellulosic pulp comprising treating said
pulp with at least one oxidizing agent, at least one alkaline agent
and at least one metal substituted xerogel, in amounts effective to
improve brightness and delignification of said pulp.
2. The process of claim 1 wherein said pulp is a kraft pulp.
3. The process of claim 1 wherein said pulp has a consistency of
from about 10% to about 20%.
4. The process of claim 3 wherein said pulp has a consistency of
from about 10% to about 15%.
5. The process of claim 4 wherein said pulp has a consistency of
about 10%.
6. The process of claim 1 wherein said treatment is practiced at a
temperature of from about 60.degree. C. to about 90.degree. C.
7. The process of claim 6 wherein said temperature is from about
70.degree. C. to about 90.degree. C.
8. The process of claim 7 wherein said temperature is about
70.degree. C.
9. The process of claim 1 wherein said treatment is practiced for a
time of from about 60 minutes to about 180 minutes.
10. The process of claim 9 wherein said time is about 90
minutes.
11. The process of claim 1 wherein said treatment is practiced at a
pH of from about 9 to about 12.5.
12. The process of claim 11 wherein said pH is about 12.2.
13. The process of claim 1 wherein said at least one alkaline agent
is selected from NaOH, KOH, Na.sub.2CO.sub.3, Mg(OH).sub.2 and
mixtures thereof.
14. The process of claim 11 wherein said alkaline agent is
NaOH.
15. The process of claim 1 wherein said at least one metal
substituted xerogel is an alkyl metal substituted xerogel.
16. The process of claim 15 wherein said alkyl metal substituted
xerogel is selected from Al-Xgel, W-Xgel, Mn-Xgel, V-Xgel, Mn-Xgel,
Li-Xgel, and Mo-Xgel, and mixtures thereof.
17. The process of claim 16 wherein said alkyl metal substituted
xerogel is W-Xgel.
18. The process of claim 16 wherein said alkyl metal substituted
xerogel is Al-Xgel.
19. The process of claim 16 wherein said alkyl metal substituted
xerogel is Mn-Xgel.
20. The pulp of claim 1 wherein said pulp is selected from hardwood
pulp, softwood pulp, and recycled pulp, and mixtures thereof.
21. The process of claim 20 wherein said pulp is softwood pulp.
22. The process of claim 1 wherein said at least one oxidizing
agent is selected from oxygen, ozone, hydrogen peroxide, peracetic
acid, peroxo monosulfate and mixtures thereof.
23. The process of claim 22 wherein said at least one oxidizing
agent is hydrogen peroxide.
24. The process of claim 1 wherein the initial kappa number of said
pulp is from about 20 to about 35.
25. The process of claim 24 wherein the initial kappa number of
said pulp is from about 20 to about 30.
26. The process of claim 25 wherein the initial kappa number of
said pulp is about 28.5.
27. The process of claim 1 wherein said treatment improves pulp
brightness by at least about 30% .
28. The process of claim 1 wherein said treatment improves pulp
delignification by at least about 38%.
29. The process of claim 1 wherein the amount of said at least one
metal substituted xerogel is from about 0.05% to about 0.2% by
weight of oven dry pulp.
30. The process of claim 29 wherein the amount of said at least one
metal substituted xerogel is from about 0.05% to about 0.2% by
weight of oven dry pulp.
31. The process of claim 30 wherein the amount of said at least one
metal substituted xerogel is about 0.2% by weight of oven dry
pulp.
32. The process of claim 1 wherein said pulp is recycled.
33. The process of claim 1 wherein the amount of said at least one
oxidizing agent is from about 2% to about 4% by weight of oven dry
pulp.
34. The process of claim 33 wherein the amount of said at least one
oxidizing agent is about 2% by weight of oven dry pulp.
35. The process of claim 1 wherein the amount of said at least one
alkaline agent is from about 2% to about 4% by weight of oven dry
pulp.
36. The process of claim 35 wherein the amount of said at least one
alkaline agent is about 2% by weight of oven dry pulp.
37. A pulp treated in accordance with the process of claim 1.
38. The process of claim 1 further comprising, prior to bleaching,
treating said cellulosic pulp with at least one treating agent to
remove undesirable trace metal ions.
39. The process of claim 38 wherein said at least one treating
agent is a chelating agent.
40. The process of claim 39 wherein said chelating agent is
selected from nitrogenous polycarboxylic acids, nitrogenous
polyalcohols, polycarboxylic acids and nitrogenous polyphosphonic
acids.
41. The process of claim 40 wherein said chelating agent is
selected from EDTA, DTPA, NTA, HEDTA, DTPMPA, or mixtures
thereof.
42. The process of claim 39 wherein the amount of said chelating
agent is from about 0.3% to about 0.8% per ton of oven dry
pulp.
43. The process of claim 42 wherein the amount of said chelating
agent is about 0.6% per ton of oven dry pulp.
44. The process of claim 39 wherein said chelating treatment is
practiced at a pH of about 5.
45. The process of claim 38 wherein said treating agent is an
acid.
46. The process of claim 38 wherein said pulp is washed between
said chelating treatment and said bleaching treatment.
47. A process for bleaching kraft pulp in an alkaline hydroxide
stage comprising treating said pulp with hydrogen peroxide, sodium
hydroxide, and at least one metal substituted xerogel in amounts
effective to improve brightness and delignification of said
pulp.
48. The process of claim 47 wherein said at least one metal
substituted xerogel is selected from W-Xgel, Al-Xgel, Mn-Xgel, and
mixtures thereof.
49. The process of claim 47 wherein said at least one metal
substituted xerogel includes at least one recycled metal
substituted xerogel.
50. The process of claim 1 wherein said at least one metal
substituted xerogel includes at least one recycled metal
substituted xerogel.
51. The process of claim 47 wherein said pulp is washed after said
treatment.
52. The process of claim 47 wherein the amount of hydrogen peroxide
is from about 2% to about 4%, the amount of sodium hydroxide is
from about 2% to about 4%, and the amount of metal substituted
xerogel is from about 0.05% to about 0.2%, all by weight of oven
dry pulp.
53. The process of claim 52 wherein the amount of hydrogen peroxide
is about 2%, the amount of sodium hydroxide is about 2%, and the
amount of metal substituted xerogel is about 0.2%, all by weight of
oven dry pulp.
54. The process of claim 1 wherein said process comprises at least
one stage in a multistage bleaching sequence.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of cellulosic
pulp treatment. More particularly, the present invention relates to
activated alkaline peroxide processes for bleaching kraft pulps to
improve brightness and delignification without negatively impacting
physical properties of the pulp.
[0003] 2. Description of the Related Art
[0004] Bleaching is a chemical process applied to cellulosic
materials, such as pulp, to increase their brightness by
decolorizing and/or removing lignin. Brightness is the reflectance
of visible light from cellulosic cloth or pulp fibers formed into
sheets.
[0005] The absorbence of visible light by cellulosic pulp fibers is
mainly caused by the presence of lignin, a principal constituent of
wood. Lignin-removing bleaching, or delignification, not only
increases brightness, but also improves brightness stability
because lignin is known to darken with age.
[0006] The bleaching of chemical pulp is typically a multi-stage
process, with bleaching chemicals applied sequentially, often with
intermediate washing between treatments (stages). In chemical pulp,
the wood chips are cooked with appropriate chemicals in an aqueous
solution at elevated temperature and pressure. The objective is to
degrade and dissolve away the lignin and leave behind most of the
cellulose and hemicellulose in the form of intact fibers. See G.
Smook, Handbook for Pulp and Paper Technologists, Angus Wilde
Publications, p. 38 (2nd Ed. 1994). The chemicals commonly used for
pulp bleaching include oxidants (e.g. chlorine, chlorine dioxide,
oxygen, ozone, and hydrogen peroxide), alkali (e.g. sodium
hydroxide), and, for mechanical pulps, a reducing agent, such as
sodium hydrosulfite. These chemicals, alone, or in simultaneous or
sequential combination, are mixed with pulp suspensions at
prescribed pH, temperature and consistency for a prescribed time,
to achieve improvements in brightness and delignification. The two
major alkaline processes for producing chemical pulps are the
alkaline sulfate or "kraft" process and the soda process. In both
these processes, wood chips are cooked with sodium hydroxide in
order to dissolve the lignin which binds the fibers together.
Sodium sulfide is an additional component of the pulping chemical
mix in the kraft process.
[0007] The bleaching of pulp with hydrogen peroxide is known in the
art. In C. Dence and D. Reeve, "Pulp Bleaching: Principles and
Practice" (Tappi Press 1996), incorporated herein in its entirety,
chapters 1 and 6 discuss the use of hydrogen peroxide in hardwood
(HW) and softwood (SW) kraft and mechanical pulp bleaching
processes. Moreover, U.S. Pat. No. 6,007,678 discloses a process
for the delignification and bleaching of pulp in which the pulp is
delignified with an organic peracid or salts thereof, treated with
a complexing agent, washed, and subsequently bleached with a
chlorine-free peroxide bleaching agent such as hydrogen peroxide or
peracetic acid.
[0008] Due to environmental concerns, the use of totally
chlorine-free and elementally-free chlorine bleaching sequences is
increasing, consequently, the use of hydrogen peroxide in the
bleaching of chemical pulps is also on the rise. This is because
hydrogen peroxide is environmentally benign. After the oxidizing
power of hydrogen peroxide is spent, only water and oxygen remain
as by-products and no chloro-organic compounds are introduced to
waste streams. Conversely, when chlorine based oxidants are used in
pulp bleaching, chlorinated organic compounds remain in the
bleaching effluent.
[0009] Unfortunately, conventional hydrogen peroxide bleaching
processes have several drawbacks as compared to conventional
processes using chlorine-containing bleaching agents. These
drawbacks include providing inferior delignification to
conventional chlorine processes as well as increased cost relative
to conventional processes since larger amounts of expensive
hydrogen peroxide may be required.
[0010] At least three technical approaches to improving the
delignification properties of hydrogen peroxide are known in the
art: 1) removing transition metals from the pulp prior to bleaching
either by chelation or acid washing of the pulp; 2) adding a
peroxide activator to the bleaching stage for kraft pulps; and 3)
using zeolites in the bleaching and/or pre-bleaching of mechanical
pulps.
[0011] Improvement in hydrogen peroxide bleaching through the
removal of transition metals is disclosed, for example, in C. Dence
and D. Reeve, "Pulp Bleaching: Principles and Practice," p. 353
(Tappi Press 1996). A variety of peroxide activators have been
studied for use in chemical pulp bleaching operations. For example,
U.S. Pat. No. 6,048,437 describes a process for bleaching chemical
pulp by simultaneous use of chlorine dioxide, a peroxide, and at
least one reaction catalyst selected from the group consisting of
oxoacids of elements of Groups IV, V, and VI and salts of these
acids. The use of TAED (tetraacetylethylenediamine) as a peroxide
activator is disclosed in N. Turner and A. Mathews, "Enhanced
Delignification and Bleaching Using TAED Activated Peroxide," 1998
TAPPI Pulping Conference, p.1269. The activation of hydrogen
peroxide with nitrilamine is described in W. Sturm and J. Kuchler,
"The Nitrilamine Reinforced Hydrogen Peroxide Bleaching of Kraft
Pulps," 1993 Non-Chlorine Bleaching Conference, Hilton Head, also
disclosed in German Patent No. 41 14 134 A1 discloses the use of
cyanamide or cyanamide salts to activate hydrogen peroxide
bleaching of alkali pulp.
[0012] Hydrogen peroxide activation using ammonium
triperoxo-phenanthrolin- e vanadate (ATPV) on kraft pulps is
described in M. Suchy and D. Argyropoulos, "Improving Alkaline
Peroxide Delignification Using a Vanadium Activator," 1998 TAPPI
Pulping Conference, p.1277. The use of silicoperoxomolybdate,
sodium molybdate, ammonium molybdate, and molybdosilicate cluster
ions as hydrogen peroxide activators are described, respectively in
J. Jakara and J. Patola, "The Use of Activated Peroxide in ECF and
TCF Bleaching of Kraft Pulp," International Non-Chlorine Bleaching
Conference Proceedings, Amelia Island, (2) p. 38 (1995); V.
Kubelka, R. Francis, and C. Dence, "Delignification with Acidic
Hydrogen Peroxide Activated by Molybdate," J. Pulp & Paper
Sci., 18(3), p. J108 (May 1992); R. Agnemo, "Reinforcement of
Oxygen-Based Bleaching Chemicals with Molybdates," 9th Annual
Symposium on Wood and Pulping Chemistry: 1997, Oral Presentations
International Symposium on Wood and Pulping Chemistry Quebec CA,
Conference Dates: Jun. 9, 1997-Jun. 12, 1997 (CPPA Canadian Society
for Chemistry, China Technical Association of the Paper Industry,
EUCEPA, Japan TAPPI, Paprican, TAPPI, and Technical Association of
the Australian and New Zealand Pulp and Paper Association) pp.
D2-1-D2-3 (Jun. 12, 1997); J. Barna, E. Ratnieks, and F. Souza,
"Use of Activated Hydrogen Peroxide and Peroxyacids in ECF
Bleaching," Trabalho apresentado No. 30, Congresso Anual De
Celulose E Papel Da ABTCP Realizado EM Sao Paulo-SP-Brasil, De 03 A
07 De Novembro De 1997, pp.161-176.
[0013] Moreover, the use of binuclear manganese complexes to
activate hydrogen peroxide bleaching is described in International
Patent Application No. PCT/EP95/033088; in L. Kuhne, J. Odermatt
and T. Wachter, "Application of a Catalyst in Peroxide Bleaching of
Eucalyptus Kraft Pulp," Holzforschung, Vol. 54, No. 4, pp. 407-412
(2000); and in Y. Cui, P. Puthson, C. Chen, J. Gratzl, and A.
Kirkman, "Kinetic Study on Delignification of Draft-AQ Pine Pulp
with Hydrogen Peroxide Catalyzed by Mn(IV)-Me.sub.4DTNE,"
Holzforschung, Vol. 54, No. 4, pp. 407-412 (2000).
[0014] The use of macrocyclic tetramide iron (III) complexes as
hydrogen peroxide activators is disclosed in both U.S. Pat. No.
6,099,586; and J. Hall, L. Vuocolo, I. Suckling, C. Horwitz, R.
Allison, L. Wright, and T. Collins, "Development of the P.sub.Fe
Process: a New Catalysed Hydrogen Peroxide Bleaching Process,"
APPITA, Annula General Conference, 2:455-461 (1999). Also, the use
of polypyridines to activate hydrogen peroxide is described in T.
Jaschinski and R. Patt, "The Effects of Polypyridines as Peroxide
Activators in TCF Bleaching of Kraft Pulps," 1998 International
Pulp Bleaching Conference Proceedings, 2, pp. 417-422, June 1-5,
Helsinki, Finland; and in T. Jaschinski and R. Patt, "Process and
Bleaching Solution for Bleaching Cellulosic Pulps," German Patent
No.19,614,587, Oct. 16, 1997.
[0015] The use of zeolites A and P to improve hydrogen peroxide
bleaching of mechanical pulps by inhibition of transition metal
catalyzed peroxide decomposition, is described in K. Dyhr and J.
Sterte, "Use of Zeolites in Hydrogen Peroxide Bleaching of Pulp,"
Nordic Pulp and Paper Research Journal, Vol. 13, No. 4 (1998).
While improvements in the bleaching of mechanical pulps were
effected by use of zeolites, the researchers observed no effect of
the zeolite additives on the bleaching of chemical pulps.
[0016] Xerogels are zeolite-type structures. Prior to the present
invention, the use of xerogels to enhance chemical bleaching was
not known in the pulp bleaching art. Xerogels have found use in
general oxidative chemistry. For example, In "An Effective
Heterogeneous WO.sub.3/TiO.sub.2--SiO.sub.2 Catalyst for selective
oxidation of cyclopentene to glutaraldehyde by H.sub.2O.sub.2,"
Catalysis Letters, Vol. 62, No. 2-4, pp. 201-207, 1999; R. Jin, X.
Xia, W. Dai, J. Deng, and H. Li describe the synthesis of
TiO.sub.2--SiO.sub.2 by the xerogel method and its use to prepare a
WO.sub.3/TiO.sub.2--SiO.sub.2 catalyst by an incipient wetness
method. The catalyst was employed as the first heterogenous
catalyst in the liquid phase cyclopentene oxidation by aqueous
H.sub.2O.sub.2 which exhibited higher selectivity (about 75%) to
glutaraldehyde, and, in turn, higher glutaraldehyde yield than a
WO.sub.3/SiO.sub.2 heterogenous catalyst or a tungstic acid
homogeneous catalyst under the same reaction conditions.
[0017] In R. Neumann and M. Levinelad, "Metal-Oxide (TiO.sub.2,
MoO.sub.3, WO.sub.3) Substituted Silicate Xerogels as Catalysts for
the Oxidation of Hydrocarbons with Hydrogen Peroxide," Journal of
Catalysis, Vol. 166, No. 2, pp. 206-217, March 1997, TiO.sub.2,
MoO.sub.3 and W.sub.3 were dispersed in amorphous silica using the
low temperature sol-gel procedure for xerogel preparation. The
resulting metallosilicate compounds are catalytically active in the
30% aqueous H.sub.2O.sub.2 oxidation of alkenes and alcohols
provided the metal oxide precursor in the xerogel synthesis is a
metal-diclorodialkoxy compound yielding
MO(.sub.x)(Cl)--SiO.sub.2.
[0018] In R. Neumann and M. Levinelad, "Vanadium Silicate Xerogels
in Hydrogen Peroxide Catalyzed Oxidations," Applied Catalysis
A-General, Vol. 122, No. 2, pp. 85-97, Feb. 16, 1995, vanadium
silicate xerogels (V.sub.2O.sub.5--SiO.sub.2) were prepared by the
sol-gel method by hydrolysis of vanadium and silicon alkoxides. The
use of these xerogels as catalysts for oxidation of alkenes,
alcohols and phenols was studied using 30% aqueous hydrogen
peroxide as oxidant. This study found that the manner of xerogel
preparation strongly influenced the catalytic activity of the
xerogels.
[0019] Applicants have now surprisingly found that metal
substituted xerogels can be used effectively to improve brightness
and delignification in alkaline hydrogen peroxide bleaching of
kraft pulps.
SUMMARY OF THE INVENTION
[0020] In accordance with the purpose of the invention in one of
its aspects embodied and broadly described herein, there is
disclosed a process for bleaching cellulosic pulp comprising
treating the pulp with at least one oxidizing agent, at least one
alkaline agent and at least one metal substituted xerogel, in
amounts effective to improve brightness and delignification of the
pulp. In another aspect, the present invention includes a process
for bleaching kraft pulp in an alkaline peroxide stage comprising
treating the pulp with hydrogen peroxide, sodium hydroxide, and at
least one metal substituted xerogel in amounts effective to improve
brightness and delignification of the pulp.
[0021] The advantages of the invention may be realized and attained
by means of the instrumentalities and combinations particularly
pointed out in the appended claims.
[0022] Further advantages of the invention will be set forth in
part in the description which follows and in part will be apparent
from the description, or may be learned by practice of the
invention. It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
[0023] The accompanying drawings are included to provide a further
understanding of the invention and are incorporated in and
constitute a part of the specification. The drawings illustrate
embodiments of the invention, and together with the description,
serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a graph of data showing the delignification of SW
kraft pulps using an alkaline hydrogen peroxide stage with a 0.2%
charge of metal (Ti, Mn, V, Mo, W, Li, or Al) substituted
xerogels.
[0025] FIG. 2 is a graph of data showing the delignification of SW
kraft pulps using an alkaline hydrogen peroxide stage with 0.2% and
0.05% metal (Al, Mn, or W) substituted xerogels.
[0026] FIG. 3 is a graph of data showing the delignification of
EDTA chelated SW kraft pulps using an alkaline hydrogen peroxide
stage with 0.2% and 0.05% metal (Al, Mn, or W) substituted
xerogels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The present invention provides novel processes that use
metal substituted xerogels to improve the delignification and
brightening properties of kraft pulps, preferably in an alkaline
peroxide bleaching stage. The use of metal substituted xerogels for
improving alkaline peroxide delignification of kraft pulps has not
been reported previously. Xerogels are zeolite-type structures,
however, while zeolites have been shown to be ineffective in the
bleaching of kraft pulps. The novel metal xerogel activated
processes of the present invention surprisingly improve hydrogen
peroxide bleaching of a variety of pulps. The term "bleaching"
includes both decolorization and delignification bleaching
processes. The terms "kraft pulps" and "chemical pulps" refer to
pulps containing fibers that have been digested according to one or
more of the sulphate, sulphite, soda, or organosolv processes, or
mixtures thereof, and to recycled pulps, which may be a mixture of
chemical and mechanical pulps. The pulp fibers may be of hardwood
or softwood.
[0028] The inventive process can be effectively employed
immediately after the chemical cooking or later in the pulp
bleaching sequence. In fact, the inventive process can be used with
a myriad of peroxide-based bleaching sequences. Non-limiting
examples of suitable sequences include: the QPQP* and AZQP*
sequences disclosed in C. Gustavsson, K. Sjostrom, W. Wafa
Al-Dajani, "Influence of Cooking Conditions on the Bleachability
and Chemical Structure of Kraft Pulps," Nordic Pulp and Paper
Research Journal, Vol. 14, No. 1, pp. 71-81 (1999), incorporated
herein by reference in its entirety; the (D(EOP)DP, D(EOP)PD and
XD(EOP)DnD sequences disclosed in Y. Sun, "Kraft Bleach Plant ECF
Conversion: Comparison of Sequences involving Enzymes, Chlorine
Dioxide, Oxygen and Hydrogen Peroxide," Appita Journal, Vol. 52,
No. 1, pp. 45-50 (January 1999), incorporated herein by reference
in its entirety; the OD(EPO)DP, O(Z/D)(EPO)DP, (D/C)(EPO)DED,
(D/Z)(EPO)DED, OD(EPO)DD, D(EPO)DED, and OD(EPO)D sequences
disclosed in C. Courchene, B. Khandelwal, V. Magnotta, T.
McDonough, A. Ragauskas and A. Shaket, "Comparative Evaluation of
Low-AOX Hardwood Kraft Pulp Bleaching Sequences," Proceedings of
the 85th Annual Meeting of the Pulp and Paper Technical Association
of Canada, Part B, pp. B307-B314, (Jan. 28-29, 1999), incorporated
herein by reference in its entirety; and the D(EOP)DPP, D(EOP)PDP,
DEDP, and DEPD sequences disclosed in P. Froass, J. Hamilton, A.
Ragauskas, J. Sealey, and D. Senior, "Interaction of Hydrogen
Peroxide and Chlorine Dioxide Stages in ECF Bleaching," TAPPI
Journal, Vol. 81, No. 6, pp. 170-178 (June 1998), incorporated
herein by reference in its entirety. In all of the above-mentioned
exemplary sequences, the inventive process should improve the
performance of the EOP and P-stages (or P*-stage). Performance of
the P-stage should also be improved where elevated temperatures and
pressures are employed, as is disclosed in A. Audet, R. Berry, B.
Roy, B. van Lierop, "High Temperature Alkaline Peroxide Bleaching
of Kraft Pulps," Int'l. Non-Chlorine Bleaching Conference
Proceedings, Orlando Fla., (Pulp & Paper and Emerging
Technology Transfer Inc.) Session Advances in ECF/TCF
Technologies-Part 2, Paper No. 3-3, p. 6 (Mar. 24-28, 1996),
incorporated by reference herein in its entirety.
[0029] Suitable pulps for the inventive process include softwood
pulps with an initial Kappa number between about 5 and about 40,
and hardwood pulps with an initial Kappa number between about 5 and
25. Higher Kappa number pulps could be treated as well but peroxide
costs could be prohibitive. The term "Kappa number" is a well known
term in the art and is calculated to provide a measure of the
lignin content of pulp. Preferably, the initial Kappa number of the
softwood pulp is from about 20 to about 35; more preferably from
about 25 to 30; most preferably from about 28-30. Preferably, the
initial Kappa number of the hardwood pulp is from about 10 to about
25; more preferably from about 15 to about 25 and most preferably
from about 20 to 25.
[0030] In the processing of pulp suspensions, the term
"consistency" refers to the percentage of pulp in the total mass of
suspension. Suitable pulps for the process of the present invention
include pulps having a consistency of from between about 3% and
about 25%; more preferably from about 10% to about 20%; and still
more preferably from about 10% to about 15%. Most preferably, the
pulp has a consistency of about 10%.
[0031] The process of the present invention comprises bleaching
pulp with at least one oxidizing agent to facilitate
delignification of the pulp. Suitable oxidizing agents may include
but are not limited to hydrogen peroxide, and other chlorine-free
oxidizing compounds. Preferably, the oxidizing agent is a
chlorine-free agent selected from oxygen, ozone, hydrogen peroxide,
peracetic acid, peroxo monosulfate (also known as Caro's acid) or
mixtures thereof. Most preferably, the oxidizing agent is hydrogen
peroxide.
[0032] The process of the present invention also comprises use of
at least one alkaline agent during the inventive bleaching stage to
facilitate lignin removal. According to the process of the present
invention, the alkaline agent can be any alkaline agent suitable
for use in pulp bleaching processes. Preferably, the alkaline agent
is selected from NaOH, KOH, Na.sub.2CO.sub.3, Mg(OH).sub.2, and
Ca(OH).sub.2. Most preferably, the alkaline agent is NaOH.
[0033] Bleaching reaction rates can be significantly affected by
pH, consequently, alkali or acid may be required to achieve optimal
pH. Preferably, the pH of the process of the present invention is
from about 9 to about 12.5; more preferably from about 11 to 12.5.
Most preferably, the pH is about 12.2.
[0034] Temperature and pulp residence time are also important
conditions in the inventive bleaching process. Suitably, the
temperature of the present invention can range from about
60.degree. C. to about 90.degree. C. Preferably, the temperature of
the present invention can range from about 70.degree. C. to about
90.degree. C. Most preferably, the temperature of the present
invention is about 70.degree. C. Usually, hydrogen peroxide is
performed at medium consistency (8-15%). The process of the present
invention can be batch or continuous. Residence time for the
inventive bleaching process suitably can range from about 60
minutes to about 180 minutes. Preferably, the residence time ranges
from about 90 minutes to about 180 minutes. Most preferably, the
residence time is about 90 minutes.
[0035] The process of the present invention also comprises a novel
use of at least one metal substituted xerogel to enhance the
bleaching process. Suitable metals for substitution into the
xerogel include, but are not limited to Al, V, W, Mn, Li, and Mo,
and mixtures thereof. Preferably, the metal substituted xerogel
("Xgel") is an alkyl metal substituted xerogel and is selected from
Mn-Xgel, Al-Xgel, and W-Xgel. Most preferably, the alkyl metal
substituted xerogel is Al-Xgel. Optionally, the metal substituted
xerogel used in the process of the present invention may be a
recycled metal-substituted xerogel.
[0036] The manner of xerogel preparation may impact the reactivity
of the xerogel. Different types of metal adapted for xerogel
preparation have a different effects on the reactivity of the
xerogel in peroxide bleaching. Xerogel pore structure can affect
catalytic activity and ion exchange capacity in hydrogen peroxide
bleaching. Appropriate preparation conditions for synthesizing
xerogels would be apparent to the skilled artisan.
[0037] The metal substituted xerogels used in the present invention
can be prepared by processes known to those of skill in the art.
Most preferably, the metal substituted xerogels are prepared
according to the procedure described in R. Neumann, M. Chava, and
M. Levin, "Hydrogen Peroxide Oxidations Catalysed by
Metallosilicate Xerogels," J. Chem. Soc. Che. Commum. pp. 1685-87
(1993), herein incorporated by reference in its entirety, and set
forth in Example 1 of the present disclosure.
[0038] The oxidizing agent, alkaline agent, and metal-substituted
xerogel used in the process of the present invention are provided
in amounts effective to improve brightness and delignification of
the bleached pulp. According to the present invention, improved
brightness and delignification is achieved by increasing brightness
and delignification above that present in the pulp prior to
bleaching in accordance with the present invention. Preferably, the
process of the present invention improves pulp TAPPI brightness
from about 27.8 to about 37.8 and improves pulp delignification by
from about 35% to about 38%. Most preferably, pulp brightness is
improved by at least about 30% and pulp delignification is improved
by at least about 38%.
[0039] The amount of oxidizing agent used in the process of the
present invention is preferably from about 2% to about 4% by weight
of oven dry pulp. Most preferably, the amount of oxidizing agent is
about 2% by weight of oven dry pulp. The amount of alkaline agent
is preferably from about 2% to about 4% by weight of oven dry pulp.
Most preferably, the amount of alkaline agent is about 2% by weight
of oven dry pulp. The amount of metal substituted xerogel is
preferably from about 0.05% to about 2% by weight of oven dry pulp;
more preferably from about 0.05% to about 0.2%. Most preferably,
the amount of metal substituted xerogel is about 0.2% by weight of
oven dry pulp. While various combinations of oxidizing agent,
alkaline agent and metal substituted xerogel may be used, the
process of the present invention most preferably includes a
combination of hydrogen peroxide, NaOH, and Mn-Xgel. These
components can be added simultaneously or sequentially, however, if
added sequentially, the oxidizing agent is preferably added
last.
[0040] Manganese and other metallic ions present in kraft pulps can
have a particularly adverse effect on the bleaching efficiency of
chlorine-free bleaching agents such as ozone and alkaline peroxide
compounds. Thus a chelating treatment step, in which a compound is
added to form complexes with metallic ions, may be useful prior to
an alkaline peroxide bleaching step. Suitable chelating agents can
include but are not limited to nitrogenous organic compounds,
polycarboxylic acids, or phosphonic acids. Preferably, the
chelating agent is selected from ethylenediaminetetraacet- ic acid
(EDTA), diethylenetriaminepentaacetic acid (DTPA), nitrilotriacetic
acid (NTA), oxalic acid, citric acid, hydroxyethylene
diaminetetraacetic acid (HEDTA),
diethylenetriaminepentamethylene-phospho- nic acid (DTPMPA), or
tartaric acid. Most preferably, the chelating agent is EDTA.
[0041] The type and added amount of chelating agent depends on the
type and amount of trace metal ions in the incoming pulp, as well
as the conditions in the treatment such as pH, temperature and
residence time. Preferably, the amount of chelating agent added is
in the range of from about 0.3% to about 0.8% by weight of dry
pulp, calculated as 100% chelating agent, and most preferably about
0.6% by weight of oven dry pulp.
[0042] After alkaline peroxide delignification, the pulp can be
used for direct production of paper. Alternatively, the pulp may be
finally bleached to a desired higher brightness in one or more
stages. Final bleaching may be carried out by use of the chlorine
free bleaching agents indicated above, including additional
inventive metal substituted xerogel-catalyzed alkaline peroxide
stages, with optional intermediate washing or extraction stages, or
by use of chlorine containing bleaching agents, such as chlorine
dioxide.
[0043] The invention is further discussed in conjunction with the
following examples, which are merely illustrative of the present
invention.
EXAMPLES
Example 1
[0044] To test the effectiveness of metal substituted xerogels in
catalyzing an alkaline hydrogen peroxide bleaching stage, the
following experiments were performed. SW kraft pulp (Brownstock,
initial Kappa number=28.5) was bleached, with and without a metal
substituted xerogel, using 2.0% hydrogen peroxide and 1.0% NaOH.
The control hydrogen peroxide bleaching experiment employed no
xerogel but included 0.20% MgSO.sub.4. Control hydrogen peroxide
bleaching experiments were also conducted using 0.2% charges of the
alkyl metals Ti(OiPr).sub.4, Mn(OEt).sub.2, V(OiPr).sub.4,
Mo(OEt).sub.4, W(OiPr).sub.4, Li(OEt), and Al(OEt).sub.3, (where
OEt=CH.sub.2CH.sub.3O and OiPr=CH(CH.sub.3).sub.2O) respectively,
and test experiments were conducted with 0.2% charges of the
following alkyl metal substituted xerogels, Ti-Xgel, Mn-Xgel,
V-Xgel, Mo-Xgel, W-Xgel, Li-Xgel, and Al-Xgel, respectively. A
control experiment using only alkyl metal without prepared xerogel
was also performed. All of the experiments were performed at 10.0%
consistency and a temperature of 70.degree. C., for 90 minutes.
[0045] The improvements in delignification are summarized in Table
I and FIG. 1. A comparison of the delignification data indicates
that the usage of 0.2% tungsten, lithium, or aluminum ethoxide
substituted xerogels in an alkaline peroxide stage improves
delignification by 44, 37, and 38% respectively. This extent of
delignification is greater than what can be achieved with 4%
hydrogen peroxide under comparable bleaching conditions as
summarized in Table 2. Also, the additional control studies, with
alkyl metals (no xerogel) and xerogel only, failed to yield
improved peroxide delignification of SW kraft pulps, as shown in
Table 1. These latter experiments demonstrate that the improved
peroxide bleaching properties observed with metal substituted
xerogels is due to the chemical composition of the catalyst and not
to the individual components.
1TABLE 1 Delignification of SW kraft pulp using an alkaline
hydrogen peroxide stage with and without alkyl metal modified
xerogels or alkyl metals Kappa # after alkaline peroxide stage:
Initial Kappa # was 28.5 Catalyst Ti Mn V Mo W Li Al Alkyl metal
22.2 22.1 20.1 20.6 20.4 20.2 20.1 Alkyl metal 19.1 19.1 19.5 19.0
18.3 18.8 18.7 xerogel No catalyst: 21.4 Xerogel: 21.0
[0046]
2TABLE 2 Alkaline hydrogen peroxide delignification of SW kraft
pulp with a starting kappa number of 28.5 and TAPPI brightness
value of 25.2. Peroxide Bleaching Kappa Number after TAPPI
Brightness after Conditions.sup.1 Peroxide Stage Peroxide Stage 2%
charge of H.sub.2O.sub.2 21.4 30.8 1% charge of NaOH 3% charge of
H.sub.2O.sub.2 20.3 31.3 1% charge of NaOH 4% charge of
H.sub.2O.sub.2 19.6 32.5 1% charge of NaOH .sup.10.5% charge Of
MgSO.sub.4, experiments performed at 10% consistency, 70.degree.C.
for 90 min.
[0047] The metal xerogels used in the above and below-mentioned
experiments were prepared in the following manner: silicone
tetraethoxide (57 mmol) was dissolved in absolute ethanol (17 ml)
and 0.15 N HCl aqueous solution (0.11 ml). The mixture was heated
to 60.degree. C. for 90 minutes and then cooled to room temperature
followed by addition with stirring of 3.00 mmol of the appropriate
metal alkoxide (i.e., metal=Ti, Mn, V, Mo, W, Li, and Al,
respectively). The mixture formed a gel immediately and was left in
an open-beaker allowing slow evaporation of solvent. A solid was
formed within 12 -24 hours. The solidified xerogel was ground and
dried at 100.degree. C. for 12 hours. The improved delignification
accomplished with the metal substituted xerogels also yields
improved pulp brightness values as summarized in Table 3. All metal
substituted xerogels (i.e., metal=Ti, Mn, V, Mo, W, Li, and Al,
respectively) improved pulp brightness properties with the
tungsten, lithium, and aluminum substituted xerogels being the most
effective, providing brightness gains of +30%. Control studies
using 2% hydrogen peroxide indicated that the brightness gains
achieved with 0.2% W, Li, or Al substituted xerogels was comparable
to what could be achieved with 4% hydrogen peroxide. In the
presence of hydrogen peroxide, the metal substituted xerogels may
act as catalysts leading to the formation of inorganic peroxides
and/or chelate unwanted metals present in the pulp.
3TABLE 3 TAPPI brightness of SW kraft pulp bleached with an
alkaline hydrogen peroxide stage, with and without alkyl metal
modified xerogels or alkyl metals. Tappi Brightness Catalyst Ti Mn
V Mo W Li Al Alkyl metal 30.1 29.7 30.9 31.7 31.4 31.7 31.8 Alkyl
metal 32.4 31.7 31.9 31.8 32.5 32.2 32.4 xerogel No catalyst: 30.8
Xerogel: 25.2
[0048] These experiments clearly show that the use of alkyl metal
xerogels with an alkaline peroxide stage improves the
delignification and brightening properties of a peroxide bleaching
stage for kraft pulps.
Example 2
[0049] Experiments were also conducted to determine if a metal
xerogel-catalyzed peroxide bleaching treatment had an detrimental
effects on pulp strength properties. SW kraft pulp (Brownstock,
initial Kappa number=21.2) was bleached, with and without a metal
substituted xerogel, using 2.0% hydrogen peroxide and 2.0% NaOH.
The control hydrogen peroxide bleaching experiment employed no
xerogel but included 0.30% MgSO.sub.4 (This salt was not added to
the xerogel experiments). Test experiments were conducted with
0.05%, 0.2%, and 0.3%, respectively, charges of the following alkyl
metal substituted xerogels, Mn-Xgel, W-Xgel,and Al-Xgel,
respectively. All of the experiments were performed at 10.0%
consistency and a temperature of 70.0.degree. C., for 90 minutes.
After bleaching, the pulps were washed with deionized water (it is
not necessary that deionized water be used) and physical properties
were determined using standard TAPPI T220 om-88 "Physical Testing
of Pulp Handsheets" testing procedures.
[0050] FIG. 2 summarizes the observed changes in delignification
for the pulp bleached with Al, W, and Mn xerogels (xerogels
prepared as discussed above example 1). Table 4 summarizes the
physical properties of the bleached pulps.
4TABLE 4 Physical Properties of SW Kraft Pulp Bleached with an
Alkaline Hydroxide Stage with and without Selected Metal
Substituted Xerogels (X-Gel). Tensile Tear Burst Freeness Density
Index Index Index Pulp (CSF, ml) (kg/m.sup.2) (Nm/g) (m Nm.sup.2/g)
(KPa m.sup.2/g) Brownstock 315 560 87.4 13.0 7.1 P-Bleached(No 320
541 86.5 13.0 6.7 X-gel) 0.05% W 321 536 90.9 12.9 6.7 X-gel 0.05%
Al 300 537 91.3 12.5 7.0 X-gel 0.05% Mn 308 549 87.7 12.6 6.9 X-gel
0.2% W X-gel 324 488 87.9 12.7 7.1
[0051] All pulps are refined by PFI (revs. 4000). Pulp refining is
a mechanical treatment of pulp fibers. This process increases the
strength by increasing the surface area and improves the capacity
of the pulp to absorb water. The treatment is described in C. J.
Biermann, Essentials of Pulping and Paper-making, Academic Press,
p. 137, (1993), incorporated herein by reference in its
entirety.
[0052] The bleaching and physical property results summarized in
FIG. 2 and Table 4 indicate that the metal xerogels improve
delignification of a peroxide stage while yielding peroxide
bleached pulps that exhibit equal or better physical properties to
the control pulp bleached only with hydrogen peroxide.
Example 3
[0053] Experiments were also conducted to determine the effect of a
Q (chelating) stage on a metal substituted xerogel peroxide stage.
SW kraft pulp was chelated with EDTA at a pH of 5, for 30 minutes,
at a pulp consistency of 2%. The consistency on pulp bleaching is
usually calculated as the weight percent of pulp in given pulp
suspension (CSC %=od pulp wt/wet pulp wt* 100) The required
consistency is easily obtained by adjusting the amount of water in
the pulp suspension. Sulfuric acid was used to adjust pH. The
peroxide bleaching experiments of Example 2 were then repeated
using a 2.0% charge of hydrogen peroxide at 10.0% consistency and a
temperature of 70.degree. C., for 90 minutes.
5TABLE 5 Effect of Xerogel on Peroxide Bleaching of EDTA Pretreated
Pulp H.sub.2O.sub.2 NaOH Xerogel Amt. Kappa Tappi Xerogel Type (%)
(%) (%) No. Brightness Original 21.2 27.8 Control 2 2 0 14.7 46.3 4
4 0 12.4 50.0 W 2 2 0.05 13.4 47.1 0.2 14.0 43.7 4 4 0.05 11.1 53.8
0.2 12.3 51.3 Al 2 2 0.05 13.1 50.0 0.2 12.5 50.0 4 4 0.05 11.3
56.0 0.2 10.6 56.1 Mn 2 2 0.05 14.3 40.2 0.2 15.2 36.0 4 4 0.05
13.0 43.6 0.2 13.0 40.5 *At control bleaching, 0.3% MgSO.sub.4 is
added. *Addition of xerogel is based on metal contents. *Bleaching
conditions: 70.degree. C., 90 min.
[0054] The results of the peroxide delignification using a chelated
pulp with and without metal substituted xerogels are summarized in
FIG. 3 and Table 5. These results indicate that the tungsten,
aluminum and manganese xerogels still enhance delignification,
although the former two operate significantly better.
[0055] Other embodiments of the invention will be apparent to those
skilled in the art from consideration of the specification and
practice of the invention disclosed herein. It is intended that the
specification and examples be considered as exemplary only, with
the true scope of the invention being indicated by the following
claims.
* * * * *