U.S. patent application number 14/743779 was filed with the patent office on 2015-12-24 for drilling fluid additives and fracturing fluid additives containing cellulose nanofibers and/or nanocrystals.
The applicant listed for this patent is API Intellectual Property Holdings, LLC. Invention is credited to Jean-Pierre MONCLIN, Kimberly NELSON, Theodora RETSINA.
Application Number | 20150368541 14/743779 |
Document ID | / |
Family ID | 54869070 |
Filed Date | 2015-12-24 |
United States Patent
Application |
20150368541 |
Kind Code |
A1 |
MONCLIN; Jean-Pierre ; et
al. |
December 24, 2015 |
DRILLING FLUID ADDITIVES AND FRACTURING FLUID ADDITIVES CONTAINING
CELLULOSE NANOFIBERS AND/OR NANOCRYSTALS
Abstract
This disclosure provides drilling fluids and additives as well
as fracturing fluids and additives that contain cellulose
nanofibers and/or cellulose nanocrystals. In some embodiments,
hydrophobic nanocellulose is provided which can be incorporated
into oil-based fluids and additives. These water-based or oil-based
fluids and additives may further include lignosulfonates and other
biomass-derived components. Also, these water-based or oil-based
fluids and additives may further include enzymes. The drilling and
fracturing fluids and additives described herein may be produced
using the AVAP.RTM. process technology to produce a nanocellulose
precursor, followed by low-energy refining to produce nanocellulose
for incorporation into a variety of drilling and fracturing fluids
and additives.
Inventors: |
MONCLIN; Jean-Pierre;
(Atlanta, GA) ; NELSON; Kimberly; (Atlanta,
GA) ; RETSINA; Theodora; (Atlanta, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
API Intellectual Property Holdings, LLC |
Atlanta |
GA |
US |
|
|
Family ID: |
54869070 |
Appl. No.: |
14/743779 |
Filed: |
June 18, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62014208 |
Jun 19, 2014 |
|
|
|
Current U.S.
Class: |
507/108 ;
507/207 |
Current CPC
Class: |
C09K 8/64 20130101; C09K
8/88 20130101; C09K 8/685 20130101; C09K 8/887 20130101; C09K 8/10
20130101; C09K 8/90 20130101; C09K 8/68 20130101; C09K 8/82
20130101; C09K 8/32 20130101; C09K 2208/08 20130101; C09K 2208/10
20130101; C09K 8/035 20130101; C09K 8/80 20130101 |
International
Class: |
C09K 8/32 20060101
C09K008/32; C09K 8/68 20060101 C09K008/68; C09K 8/82 20060101
C09K008/82; C09K 8/80 20060101 C09K008/80; C09K 8/10 20060101
C09K008/10 |
Claims
1. A fracturing fluid additive comprising (i) cellulose nanofibers
and/or cellulose nanocrystals and (ii) lignosulfonates.
2. The fracturing fluid additive of claim 1, wherein said cellulose
nanofibers and/or cellulose nanocrystals are hydrophobic.
3. The fracturing fluid additive of claim 2, wherein said cellulose
nanofibers and/or cellulose nanocrystals are lignin-coated.
4. The fracturing fluid additive of claim 1, wherein said cellulose
nanofibers and/or cellulose nanocrystals are hydrophilic.
5. The fracturing fluid additive of claim 1, wherein said cellulose
nanofibers and/or cellulose nanocrystals are crosslinked.
6. A fracturing fluid comprising a drilling fluid additive
containing cellulose nanofibers and/or cellulose nanocrystals.
7. The fracturing fluid of claim 6, wherein said cellulose
nanofibers and/or cellulose nanocrystals are hydrophobic.
8. The fracturing fluid of claim 6, wherein said cellulose
nanofibers and/or cellulose nanocrystals are lignin-coated.
9. The fracturing fluid of claim 6, wherein said cellulose
nanofibers and/or cellulose nanocrystals are hydrophilic.
10. The fracturing fluid of claim 6, wherein said cellulose
nanofibers and/or cellulose nanocrystals are crosslinked.
11. The fracturing fluid of claim 6, wherein said fracturing fluid
is a water-based drilling fluid.
12. The fracturing fluid of claim 6, wherein said fracturing fluid
is an oil-based drilling fluid.
13. The fracturing fluid of claim 6, wherein said fracturing fluid
is a hybrid water-based/oil-based drilling fluid.
14. The fracturing fluid of claim 6, said fracturing fluid further
comprising a material selected from the group consisting of a
biomass-derived acid, a biomass-derived corrosion inhibitor, a
biomass-derived friction reducer, a biomass-derived clay-control
agent, a biomass-derived crosslinking agent, a biomass-derived
scale inhibitor, a biomass-derived breaker, a biomass-derived
iron-control agent, a biomass-derived biocide, a
biorefinery-derived source of recycled or recovered water, and
combinations thereof.
15. The fracturing fluid of claim 14, wherein said acid is selected
from the group consisting of acetic acid, formic acid, levulinic
acid, lignosulfonic acid, and combinations thereof.
16. The fracturing fluid of claim 14, wherein said corrosion
inhibitor comprises lignin or a lignin derivative.
17. The fracturing fluid of claim 14, wherein said friction reducer
comprises lignosulfonate or a lignosulfonate derivative.
18. The fracturing fluid of claim 14, said fracturing fluid further
comprising, or in combination with, a proppant.
19. The fracturing fluid of claim 18, wherein said proppant
includes a biomass-derived proppant.
20. The fracturing fluid of claim 19, wherein said biomass-derived
proppant is ash or sand.
Description
PRIORITY DATA
[0001] This patent application is a non-provisional patent
application claiming priority to U.S. Provisional Patent App. No.
62/014,208, filed on Jun. 19, 2014, which is hereby incorporated by
reference herein.
FIELD
[0002] The present invention generally relates to nanocellulose and
related materials produced by fractionating lignocellulosic biomass
and further processing the cellulose fraction.
BACKGROUND
[0003] Biomass refining (or biorefining) has become more prevalent
in industry. Cellulose fibers and sugars, hemicellulose sugars,
lignin, syngas, and derivatives of these intermediates are being
utilized for chemical and fuel production. Indeed, we now are
observing the commercialization of integrated biorefineries that
are capable of processing incoming biomass much the same as
petroleum refineries now process crude oil. Underutilized
lignocellulosic biomass feedstocks have the potential to be much
cheaper than petroleum, on a carbon basis, as well as much better
from an environmental life-cycle standpoint.
[0004] Lignocellulosic biomass is the most abundant renewable
material on the planet and has long been recognized as a potential
feedstock for producing chemicals, fuels, and materials.
Lignocellulosic biomass normally comprises primarily cellulose,
hemicellulose, and lignin. Cellulose and hemicellulose are natural
polymers of sugars, and lignin is an aromatic/aliphatic hydrocarbon
polymer reinforcing the entire biomass network. Some forms of
biomass (e.g., recycled materials) do not contain
hemicellulose.
[0005] Despite being the most available natural polymer on earth,
it is only recently that cellulose has gained prominence as a
nanostructured material, in the form of nanocrystalline cellulose
(NCC), nanofibrillar cellulose (NFC), and bacterial cellulose (BC).
Nanocellulose is being developed for use in a wide variety of
applications such as polymer reinforcement, anti-microbial films,
biodegradable food packaging, printing papers, pigments and inks,
paper and board packaging, barrier films, adhesives, biocomposites,
wound healing, pharmaceuticals and drug delivery, textiles,
water-soluble polymers, construction materials, recyclable interior
and structural components for the transportation industry, rheology
modifiers, low-calorie food additives, cosmetics thickeners,
pharmaceutical tablet binders, bioactive paper, pickering
stabilizers for emulsion and particle stabilized foams, paint
formulations, films for optical switching, and detergents. Despite
the major advantages of nanocellulose such as its non-toxicity and
great mechanical properties, its use to now has been in niche
applications. Its moisture sensitivity, its incompatibility with
oleophilic polymers, and the high energy consumption needed to
produce, for example, NFC have so far prevented it from competing
with other mass products such as ordinary paper or plastic. See
"THE GLOBAL MARKET FOR NANOCELLULOSE TO 2017," FUTURE MARKETS INC.
TECHNOLOGY REPORT No. 60, SECOND EDITION (October 2012).
[0006] Biomass-derived pulp may be converted to nanocellulose by
mechanical processing. Although the process may be simple,
disadvantages include high energy consumption, damage to fibers and
particles due to intense mechanical treatment, and a broad
distribution in fibril diameter and length.
[0007] Biomass-derived pulp may be converted to nanocellulose by
chemical processing. For example, pulp may be treated with
2,2,6,6-tetramehylpiperidine-1-oxy radical (TEMPO) to produce
nanocellulose. Such a technique reduces energy consumption compared
to mechanical treatment and can produce more uniform particle
sizes, but the process is not regarded as economically viable.
[0008] Improved processes for producing nanocellulose from biomass
at reduced energy costs are needed in the art. Also, improved
starting materials (i.e., biomass-derived pulps) are needed in the
art for producing nanocellulose. It would be particularly desirable
for new processes to possess feedstock flexibility and process
flexibility to produce either or both nanofibrils and nanocrystals,
as well as to co-produce sugars, lignin, and other co-products. For
some applications, it is desirable to produce nanocellulose with
high crystallinity, leading to good mechanical properties of the
nanocellulose or composites containing the nanocellulose. For
certain applications, is would be beneficial to increase the
hydrophobicity of the nanocellulose.
[0009] Oil and natural gas are common fossil-based resources used
for the production of transportation fuels, heat and power,
materials, chemicals, adhesives, pharmaceuticals, polymers, fibers
and other products. Since the first oil well drilled in 1859 and
the introduction of the internal combustion engine, the United
States has been a major producer and consumer of fossil
resources.
[0010] In 2010, the US produced over 2 billion barrels of oil and
26.8 trillion cubic feet of natural gas worth over $180 and $110
billion, respectively. A significant amount of this production can
be attributed to advances in horizontal drilling and hydraulic
fracturing. Previously unrecoverable deposits have been freed up
ensuring access to decades of domestic natural gas and oil.
[0011] Oil and natural gas deposits are located all across the
United States and the World. It is estimated that the total amount
of technically recoverable natural gas resources worldwide is
22,600 trillion cubic feet of which shale gas is 6,622 trillion
cubic feet or nearly 30% (World Shale Gas Resources: An Initial
Assessment of 14 Regions Outside the United States, U.S. Department
of Energy and Energy Information Administration, 2011). Wells are
drilled hundreds of meters deep in order to gain access to the
resources. Once drilled, new wells or old unproductive wells are
hydraulically fractured to stimulate production.
[0012] Drilling fluids or muds are used during the initial well
bore to cool the bit, lubricate the drill string, suspend and
transport cuttings, control hydrostatic pressure and maintain
stability. Drilling fluids are typically water-based or oil-based
but can be pneumatic. Water or oil is the main ingredient in liquid
drilling fluids. Barite, clay, polymers, thinners, surfactants,
inorganic chemicals, bridging materials, lost circulation materials
and specialized chemicals are also added to engineer drilling fluid
properties.
[0013] Hydraulic fracturing was developed in the 1940s to increase
productivity of oil and gas wells. Hydraulic fracturing creates and
maintains cracks within oil and gas formations providing a clear
path for oil and gas to flow. Fracturing can be performed in
vertical and horizontal wells. During a fracturing operation,
perforations are made through cement casing into the oil and gas
formation using explosive charges. Fracturing fluids are injected
into the well at high pressures to create new cracks while further
expanding and elongating the cracks (Hydraulic Fracturing:
Unlocking America's Natural Gas Resources, American Petroleum
Institute, 2010).
[0014] Fracturing fluids are composed primarily of water (87-94%)
and proppant such as sand (4-9%). Sand mixed with the fracturing
fluids is used to prop open formation cracks and maintain a clear
path for oil and natural gas. The remaining fracturing fluid
(0.5-3%) is composed of chemicals that aid the fracturing process.
Chemical additives are mixed into the drilling fluid depending on
the well and formation properties. Chemicals are used to dissolve
minerals, reduce friction, prevent scaling, maintain fluid
properties (viscosity, pH, etc.), eliminate bacteria (biocide),
suspend the sand, prevent precipitation of metal oxides, prevent
corrosion, stabilize fluid, formation and wellbore, thicken fluid
(gelling agent) and break down the gel (breaker).
[0015] Hydraulic fracturing fluid is made in a step-wise procedure
and carefully engineered to accomplish the fracking process. In its
most basic form, a gelling agent (typically gaur gum) is first
added to water and hydrated. Next a breaker (oxidant or enzyme) is
added which will break the gel bonds after being pumped into the
well. A crosslinking agent such as borate is then added to the
solution which immediately forms a viscous, gelled solution. The
purpose of the gel is to suspend the proppant while being pumped
into the well where it is wedged into formation fractures propping
them apart.
[0016] Eventually the fracturing fluid must be removed from the
well leaving the proppant in the fractures to maintain open
channels for oil or gas to flow through. In order to pump the
fracturing fluid out of the well and leave the proppant behind the
viscous gel must be broken down to a viscosity less than 100 cP.
Since the fracturing fluid is pumped into the well in stages,
precise amounts of breaker are mixed with the fracturing fluid to
break the entire gel solution simultaneously. Once the entire gel
is broken the fracturing fluid is pumped back to the surface where
it is stored in retention ponds or hauled away from the well for
treatment and disposal.
[0017] What are needed in the art are methods and products that
minimize environmental impact and costs of drilling, treating and
hydraulic fracturing for oil and gas. Improved compositions are
desired, including biomass-derived compositions. While
nanocellulose has been generally recognized as a possible component
in drilling and fracturing fluids, heretofore there has not been an
economical process to provide nanocellulose, with adjustable
properties for different types of fluids and additives.
SUMMARY
[0018] In some variations, the invention provides drilling fluid
additives.
[0019] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals.
[0020] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises lignosulfonates.
[0021] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises lignosulfonates.
[0022] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises non-sulfonated lignin.
[0023] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises non-sulfonated lignin.
[0024] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises enzymes.
[0025] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises enzymes.
[0026] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises a crosslinking agent.
[0027] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises a crosslinking agent.
[0028] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose.
[0029] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
lignosulfonates.
[0030] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
non-sulfonated lignin.
[0031] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
enzymes.
[0032] Some embodiments provide a drilling fluid additive
comprising crosslinked hydrophilic nanocellulose and
lignosulfonates.
[0033] Some embodiments provide a drilling fluid additive
comprising crosslinked hydrophobic lignin-coated nanocellulose and
lignosulfonates.
[0034] Some embodiments provide a drilling fluid additive
comprising crosslinked hydrophilic nanocellulose, crosslinked
hydrophobic lignin-coated nanocellulose, and lignosulfonates.
[0035] Some embodiments provide a drilling fluid additive
comprising at least two components selected from the group
consisting of crosslinked cellulose nanofibers, crosslinked
cellulose nanocrystals, lignosulfonates, and enzymes.
[0036] Some embodiments provide a drilling fluid additive
comprising at least two components selected from the group
consisting of cellulose nanofibers, cellulose nanocrystals,
lignin-coated cellulose nanofibers, lignin-coated cellulose
nanocrystals, lignosulfonates, and enzymes.
[0037] Some embodiments provide drilling fluids comprising the
drilling fluid additives as disclosed. The drilling fluid may be a
water-based drilling fluid, an oil-based drilling fluid, or a
hybrid water-based/oil-based drilling fluid.
[0038] In various embodiments, the drilling fluid further comprises
one or more of a biomass-derived weighting material, a
biomass-derived filtration-control agent, a biomass-derived
rheology-control agent, a biomass-derived pH-control agent, a
biomass-derived lost-circulation material, a biomass-derived
surface-activity modifier, a biomass-derived lubricant, and a
biomass-derived flocculant, and/or a biomass-derived
stabilizer.
[0039] In some variations, the invention provides a method of using
a drilling fluid additive, the method comprising combining a
drilling fluid additive as disclosed into a base fluid to generate
a drilling fluid. In some variations, the invention provides a
method comprising introducing a disclosed drilling fluid additive
directly or indirectly into a geological formation.
[0040] In some variations, a method of drilling includes
introducing a drilling fluid additive directly or indirectly into a
geological formation, wherein the drilling fluid additive includes
an enzyme for degelling under effective conditions. In related
variations, a method of drilling includes introducing a drilling
fluid additive directly or indirectly into a geological formation,
and then later introducing an enzyme for degelling under effective
conditions.
[0041] Some variations provide a process for producing a drilling
fluid additive, the process comprising refining biomass under
effective pretreatment conditions and refining conditions to
generate a drilling fluid additive as disclosed. In some
embodiments, the effective pretreatment conditions include the
generation of lignosulfonic acids. Optionally, at least a portion
of the lignosulfonic acids are not removed and remain present in
the drilling fluid additive. In certain embodiments, the drilling
fluid additive comprises a liquid slurry derived from the process.
For example, the slurry may contain nanocellulose derived from the
biomass as well as water and pretreatment chemicals (such as acids,
solvents, etc.).
[0042] The present invention, in other variations, provides
hydraulic fracturing fluid additives. (In this disclosure,
"fracturing" means "hydraulic fracturing.")
[0043] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals.
[0044] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises lignosulfonates.
[0045] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises lignosulfonates.
[0046] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises non-sulfonated lignin.
[0047] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises non-sulfonated lignin.
[0048] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises enzymes.
[0049] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises enzymes.
[0050] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises a crosslinking agent.
[0051] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises a crosslinking agent.
[0052] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose.
[0053] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
lignosulfonates.
[0054] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
non-sulfonated lignin.
[0055] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
enzymes.
[0056] Some embodiments provide a fracturing fluid additive
comprising crosslinked hydrophilic nanocellulose and
lignosulfonates.
[0057] Some embodiments provide a fracturing fluid additive
comprising crosslinked hydrophobic lignin-coated nanocellulose and
lignosulfonates.
[0058] Some embodiments provide a fracturing fluid additive
comprising crosslinked hydrophilic nanocellulose, crosslinked
hydrophobic lignin-coated nanocellulose, and lignosulfonates.
[0059] Some embodiments provide a fracturing fluid additive
comprising at least two components selected from the group
consisting of crosslinked cellulose nanofibers, crosslinked
cellulose nanocrystals, lignosulfonates, and enzymes.
[0060] Some embodiments provide a fracturing fluid additive
comprising at least two components selected from the group
consisting of cellulose nanoflbers, cellulose nanocrystals,
lignin-coated cellulose nanofibers, lignin-coated cellulose
nanocrystals, lignosulfonates, and enzymes.
[0061] Some embodiments provide a fracturing fluid comprising the
fracturing fluid additive as disclosed. The fracturing fluid may be
a water-based fracturing fluid, an oil-based fracturing fluid, or a
hybrid water-based/oil-based fracturing fluid.
[0062] The fracturing fluid may further include, in addition to a
disclosed fracturing fluid additive, one or more of a
biomass-derived acid (such as acetic acid, formic acid, levulinic
acid, and/or lignosulfonic acid), a biomass-derived corrosion
inhibitor (such as lignin or a lignin derivative), a
biomass-derived friction reducer (such as lignosulfonate or a
lignosulfonate derivative), a biomass-derived clay-control agent, a
biomass-derived crosslinking agent, a biomass-derived scale
inhibitor, a biomass-derived breaker, a biomass-derived
iron-control agent, a biomass-derived biocide (e.g., biomass
hydrolysate), and/or a biorefinery-derived source of recycled or
recovered water. Typically, the fracturing fluid carries, includes,
or is intended to be combined with a proppant, which may be a
biomass-derived proppant (such as ash contained in the structure of
biomass and/or sand, ash, or dirt collected with biomass).
[0063] Some variations of the invention provide a method of using a
fracturing fluid additive, the method comprising combining a
disclosed fracturing fluid additive into a base fluid to generate a
fracturing fluid. Some methods include introducing a fracturing
fluid additive directly or indirectly into a geological
formation.
[0064] In some variations, a process for producing a fracturing
fluid additive comprises refining biomass under effective
pretreatment conditions and refining conditions to generate a
fracturing fluid additive as disclosed. In some embodiments, the
pretreatment conditions include the generation of lignosulfonic
acids, which optionally are not entirely removed and are present in
the fracturing fluid additive. In some embodiments, the fracturing
fluid additive comprises a liquid slurry derived from the process.
For example, the slurry may contain nanocellulose derived from the
biomass as well as water and pretreatment chemicals (e.g.,
solvents, acids, bases, and so on).
BRIEF DESCRIPTION OF THE FIGURES
[0065] FIG. 1 demonstrates the performance of an aqueous drilling
fluid containing 1% nanocellulose (CNC) produced by conventional
sulfuric acid treatment, 4% bentonite, with or without 100 ppm
NaCl. A 4% bentonite control is shown for comparison.
[0066] FIG. 2 demonstrates the performance of an aqueous drilling
fluid containing 4% bentonite, 0.5% CNC nanocellulose produced by
the present disclosure, and optionally CMC or XG.
[0067] FIG. 3 demonstrates the performance of an aqueous drilling
fluid containing 4% bentonite, 0.1-0.5% CNF nanocellulose produced
by the present disclosure, and optionally 0.25% CMC.
[0068] FIG. 4 demonstrates the performance of an aqueous drilling
fluid containing 4% bentonite, 0.5% CNC nanocellulose produced by
the present disclosure, and 0.25% CMC, with or without 100 ppm
NaCl.
[0069] FIG. 5 demonstrates the performance of an oil-based drilling
fluid containing 0.5% lignin-coated CNF or lignin-coated CNC, 94.3%
hexane, and 4.7% water.
[0070] FIG. 6 is a plot of viscosity (Pas) versus shear rate (1/s)
for 0.5% cross-linked CNF or CNC, with or without 0.1% guar gum
(GG) or 0.25% borax (AB).
DETAILED DESCRIPTION OF SOME EMBODIMENTS
[0071] This description will enable one skilled in the art to make
and use the invention, and it describes several embodiments,
adaptations, variations, alternatives, and uses of the invention.
These and other embodiments, features, and advantages of the
present invention will become more apparent to those skilled in the
art when taken with reference to the following detailed description
of the invention in conjunction with any accompanying drawings.
[0072] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the context clearly indicates otherwise. Unless defined otherwise,
all technical and scientific terms used herein have the same
meaning as is commonly understood by one of ordinary skill in the
art to which this invention belongs. All composition numbers and
ranges based on percentages are weight percentages, unless
indicated otherwise. All ranges of numbers or conditions are meant
to encompass any specific value contained within the range, rounded
to any suitable decimal point.
[0073] Unless otherwise indicated, all numbers expressing
parameters, reaction conditions, concentrations of components, and
so forth used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless indicated to the contrary, the numerical
parameters set forth in the following specification and attached
claims are approximations that may vary depending at least upon a
specific analytical technique.
[0074] The term "comprising," which is synonymous with "including,"
"containing," or "characterized by" is inclusive or open-ended and
does not exclude additional, unrecited elements or method steps.
"Comprising" is a term of art used in claim language which means
that the named claim elements are essential, but other claim
elements may be added and still form a construct within the scope
of the claim.
[0075] As used herein, the phase "consisting of" excludes any
element, step, or ingredient not specified in the claim. When the
phrase "consists of" (or variations thereof) appears in a clause of
the body of a claim, rather than immediately following the
preamble, it limits only the element set forth in that clause;
other elements are not excluded from the claim as a whole. As used
herein, the phase "consisting essentially of" limits the scope of a
claim to the specified elements or method steps, plus those that do
not materially affect the basis and novel characteristic(s) of the
claimed subject matter.
[0076] With respect to the terms "comprising," "consisting of," and
"consisting essentially of," where one of these three terms is used
herein, the presently disclosed and claimed subject matter may
include the use of either of the other two terms. Thus in some
embodiments not otherwise explicitly recited, any instance of
"comprising" may be replaced by "consisting of" or, alternatively,
by "consisting essentially of."
[0077] Generally it is beneficial to process biomass in a way that
effectively separates the major fractions (cellulose,
hemicellulose, and lignin) from each other. The cellulose can be
subjected to further processing to produce nanocellulose.
Fractionation of lignocellulosics leads to release of cellulosic
fibers and opens the cell wall structure by dissolution of lignin
and hemicellulose between the cellulose microfibrils. The fibers
become more accessible for conversion to nanofibrils or
nanocrystals. Hemicellulose sugars can be fermented to a variety of
products, such as ethanol, or converted to other chemicals. Lignin
from biomass has value as a solid fuel and also as an energy
feedstock to produce liquid fuels, synthesis gas, or hydrogen; and
as an intermediate to make a variety of polymeric compounds.
Additionally, minor components such as proteins or rare sugars can
be extracted and purified for specialty applications.
[0078] This disclosure describes processes and apparatus to
efficiently fractionate any lignocellulosic-based biomass into its
primary major components (cellulose, lignin, and if present,
hemicellulose) so that each can be used in potentially distinct
processes. An advantage of the process is that it produces
cellulose-rich solids while concurrently producing a liquid phase
containing a high yield of both hemicellulose sugars and lignin,
and low quantities of lignin and hemicellulose degradation
products. The flexible fractionation technique enables multiple
uses for the products. The cellulose is an advantaged precursor for
producing nanocellulose, as will be described herein.
[0079] The present invention, in some variations, utilizes the
discovery that nanocellulose and related materials can be produced
under certain conditions including process conditions and steps
associated with the AVAP.RTM. process. It has been found,
surprisingly, that very high crystallinity can be produced and
maintained during formation of nanofibers or nanocrystals, without
the need for an enzymatic or separate acid treatment step to
hydrolyze amorphous cellulose. High crystallinity can translate to
mechanically strong fibers or good physical reinforcing properties,
which are advantageous for composites, reinforced polymers, and
high-strength spun fibers and textiles, for example.
[0080] A significant techno-economic barrier for production of
cellulose nanofibrils (CNF) is high energy consumption and high
cost. Using sulfur dioxide (SO.sub.2) and ethanol (or other
solvent), the pretreatment disclosed herein effectively removes not
only hemicelluloses and lignin from biomass but also the amorphous
regions of cellulose, giving a unique, highly crystalline cellulose
product that requires minimal mechanical energy for conversion to
CNF. The low mechanical energy requirement results from the
fibrillated cellulose network formed during chemical pretreatment
upon removal of the amorphous regions of cellulose.
[0081] As intended herein, "nanocellulose" is broadly defined to
include a range of cellulosic materials, including but not limited
to microfibrillated cellulose, nanofibrillated cellulose,
microcrystalline cellulose, nanocrystalline cellulose, and
particulated or fibrillated dissolving pulp. Typically,
nanocellulose as provided herein will include particles having at
least one length dimension (e.g., diameter) on the nanometer
scale.
[0082] "Nanofibrillated cellulose" or equivalently "cellulose
nanofibrils" means cellulose fibers or regions that contain
nanometer-sized particles or fibers, or both micron-sized and
nanometer-sized particles or fibers. "Nanocrystalline cellulose" or
equivalently "cellulose nanocrystals" means cellulose particles,
regions, or crystals that contain nanometer-sized domains, or both
micron-sized and nanometer-sized domains. "Micron-sized" includes
from 1 .mu.m to 100 .mu.m and "nanometer-sized" includes from 0.01
nm to 1000 nm (1 .mu.m). Larger domains (including long fibers) may
also be present in these materials.
[0083] Certain exemplary embodiments of the invention will now be
described. These embodiments are not intended to limit the scope of
the invention as claimed. The order of steps may be varied, some
steps may be omitted, and/or other steps may be added. Reference
herein to first step, second step, etc. is for purposes of
illustrating some embodiments only.
[0084] Nanocellulose as provided herein may be incorporated into
drilling fluids, drilling fluid additives, fracturing fluids, and
fracturing fluid additives. The nanocellulose may be present in a
wide variety of concentrations, such as from about 0.001 wt % to
about 10 wt % or higher, e.g. about 0.01 wt %, 0.05 wt %, 0.1 wt %,
0.5 wt %, 1 wt %, or 2 wt %.
[0085] The invention, in some variations, is related to a group of
cellulosic compounds which could be used in different applications.
One of the applications is to use them as product enhancers of
drilling fluids. The nanocellulose may serve one or more functions
in drilling fluids. For example, the nanocellulose may serve as a
gelling agent to increase viscosity, or a viscosifier in general.
The nanocellulose may serve as a friction reducer. Also,
nanocellulose may be a drilling polymer, displacing other polymers
or adding to them.
[0086] Drilling fluids are fluids used in drilling in the natural
gas and oil industries, as well as other industries that use large
drilling equipment. The drilling fluids are used to lubricate,
provide hydrostatic pressure, keep the drill cool, and keep the
hole as clean as possible of drill cuttings. Nanocellulose
materials provided herein are suitable as additives to these
drilling fluids.
[0087] Embodiments of the invention provide hydrophilic
nanocellulose, hydrophobic nanocellulose, and a variety of blends
of the hydrophobic nanocellulose and the hydrophilic nanocellulose.
In some embodiments, the hydrophilic nanocellulose is called "CNF"
(Cellulose NanoFibril) or "CNC" (Cellulose NanoCrystal). Both of
these nanocellulose materials may be made using the AVAP.RTM.
process and/or the methods disclosed herein.
[0088] In some embodiments, the hydrophobic nanocellulose is called
"L-CNF" (Lignin-coated Cellulose NanoFibril) or "L-CNC"
(Lignin-coated Cellulose NanoCrystal). Both of these nanocellulose
materials may be made using the AVAP.RTM. process and/or the
methods disclosed herein.
[0089] Additionally another group of products called "L-Nano
Hydrogel" may be prepared from crosslinked CNF, CNC, L-CNF and/or
L-CNC, optionally with lignosulfonates.
[0090] These compositions exhibit good rheological performance at
high temperature (above 385.degree. F.). Furthermore, a blend of
CNF and CNF allows to reduce friction which as a result should
reduce the injection pressure and increase the rate of
penetration.
[0091] In some embodiments, these compositions provide one or more
of the following functions or advantages: [0092] Polymeric
viscosifiers [0093] Predictable shear thinning through temperature
up approximately 385.degree. F. [0094] Rheology modifiers to
enhance drilling efficiency [0095] Provide increased viscosity of
the fracturing fluid [0096] Provide lower friction loss which will
increase the rate of penetration by reducing the injection pressure
hence enhance reducing fracking time [0097] Shear thinning [0098]
Gelling agents (CNC and CNF being water-soluble) [0099] Linear gels
[0100] Stable crosslinked products [0101] Friction reducers [0102]
Provide improved performance of proppant transport, and for well
cleanup [0103] Biodegradable [0104] Produced from biomass
[0105] Hydrophobic lignin-coated nanocellulose (e.g., L-CNC or
L-CNF) can be useful in oil-based drilling muds, due to the
solubility with an oil phase.
[0106] In some embodiments, enzymes can be used as a "breaker" with
the compositions, to break down nanocellulose after some period of
time or under certain conditions (e.g., temperature or pH).
[0107] In some embodiments, lignosulfonates are incorporated for
enhanced lubricity in drilling applications. Also, the ability of
lignosulfonates to reduce the viscosity of mineral slurries can be
beneficial in oil drilling muds.
[0108] In some embodiments, native lignin or non-sulfonated lignin,
or non-sulfonated lignin derivatives, are incorporated into the
compositions (beyond the lignin coating on the nanocellulose, if
any).
[0109] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals.
[0110] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises lignosulfonates.
[0111] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises lignosulfonates.
[0112] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises non-sulfonated lignin.
[0113] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises non-sulfonated lignin.
[0114] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises enzymes.
[0115] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises enzymes.
[0116] Some embodiments provide a drilling fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises a crosslinking agent.
[0117] Some embodiments provide a drilling fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises a crosslinking agent.
[0118] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose.
[0119] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
lignosulfonates.
[0120] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
non-sulfonated lignin.
[0121] Some embodiments provide a drilling fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
enzymes.
[0122] Some embodiments provide a drilling fluid additive
comprising crosslinked hydrophilic nanocellulose and
lignosulfonates.
[0123] Some embodiments provide a drilling fluid additive
comprising crosslinked hydrophobic lignin-coated nanocellulose and
lignosulfonates.
[0124] Some embodiments provide a drilling fluid additive
comprising crosslinked hydrophilic nanocellulose, crosslinked
hydrophobic lignin-coated nanocellulose, and lignosulfonates.
[0125] Some embodiments provide a drilling fluid additive
comprising at least two components selected from the group
consisting of crosslinked cellulose nanofibers, crosslinked
cellulose nanocrystals, lignosulfonates, and enzymes.
[0126] Some embodiments provide a drilling fluid additive
comprising at least two components selected from the group
consisting of cellulose nanofibers, cellulose nanocrystals,
lignin-coated cellulose nanofibers, lignin-coated cellulose
nanocrystals, lignosulfonates, and enzymes.
[0127] Some embodiments provide drilling fluids comprising the
drilling fluid additives as disclosed. The drilling fluid may be a
water-based drilling fluid, an oil-based drilling fluid, or a
hybrid water-based/oil-based drilling fluid.
[0128] In various embodiments, the drilling fluid further comprises
one or more of a biomass-derived weighting material, a
biomass-derived filtration-control agent, a biomass-derived
rheology-control agent, a biomass-derived pH-control agent, a
biomass-derived lost-circulation material, a biomass-derived
surface-activity modifier, a biomass-derived lubricant, and a
biomass-derived flocculant, and/or a biomass-derived
stabilizer.
[0129] In some variations, the invention provides a method of using
a drilling fluid additive, the method comprising combining a
drilling fluid additive as disclosed into a base fluid to generate
a drilling fluid. In some variations, the invention provides a
method comprising introducing a disclosed drilling fluid additive
directly or indirectly into a geological formation.
[0130] In some variations, a method of drilling includes
introducing a drilling fluid additive directly or indirectly into a
geological formation, wherein the drilling fluid additive includes
an enzyme for degelling under effective conditions. In related
variations, a method of drilling includes introducing a drilling
fluid additive directly or indirectly into a geological formation,
and then later introducing an enzyme for degelling under effective
conditions.
[0131] Some variations provide a process for producing a drilling
fluid additive, the process comprising refining biomass under
effective pretreatment conditions and refining conditions to
generate a drilling fluid additive as disclosed. In some
embodiments, the effective pretreatment conditions include the
generation of lignosulfonic acids. Optionally, at least a portion
of the lignosulfonic acids are not removed and remain present in
the drilling fluid additive. In certain embodiments, the drilling
fluid additive comprises a liquid slurry derived from the process.
For example, the slurry may contain nanocellulose derived from the
biomass as well as water and pretreatment chemicals (such as acids,
solvents, etc.).
[0132] Another application of these compositions is to use them as
product enhancers of hydraulic fracturing fluids. Improvement in
this purpose are particularly due to their impact in friction
reduction, in improved pumping of proppants at a higher rate, at
reduced pressure and predictable viscosity at high temperatures.
Additionally, these products are fully biodegradable; they are
produced from biomass, and are lesser susceptible to biofouling as
could be other products like galactomannan derivatives.
[0133] Nanocellulose may be crosslinked for robust gelling in
fracking fluids. In some embodiments, crosslinking of nanocellulose
to gives a stronger gel with more hydration.
[0134] Biomass-derived ash (from the biomass structure) or sand
(from washing) may be used as a proppant, to displace mined
silica.
[0135] The present invention, in other variations, provides
fracturing fluid additives.
[0136] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals.
[0137] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises lignosulfonates.
[0138] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises lignosulfonates.
[0139] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises non-sulfonated lignin.
[0140] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises non-sulfonated lignin.
[0141] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises enzymes.
[0142] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises enzymes.
[0143] Some embodiments provide a fracturing fluid additive
comprising cellulose nanofibers and/or cellulose nanocrystals,
wherein the additive further comprises a crosslinking agent.
[0144] Some embodiments provide a fracturing fluid additive
comprising hydrophobic lignin-coated cellulose nanofibers and/or
hydrophobic lignin-coated cellulose nanocrystals, wherein the
additive further comprises a crosslinking agent.
[0145] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose.
[0146] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
lignosulfonates.
[0147] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
non-sulfonated lignin.
[0148] Some embodiments provide a fracturing fluid additive
comprising (i) hydrophilic nanocellulose and (ii) hydrophobic
lignin-coated nanocellulose, wherein the additive further comprises
enzymes.
[0149] Some embodiments provide a fracturing fluid additive
comprising crosslinked hydrophilic nanocellulose and
lignosulfonates.
[0150] Some embodiments provide a fracturing fluid additive
comprising crosslinked hydrophobic lignin-coated nanocellulose and
lignosulfonates.
[0151] Some embodiments provide a fracturing fluid additive
comprising crosslinked hydrophilic nanocellulose, crosslinked
hydrophobic lignin-coated nanocellulose, and lignosulfonates.
[0152] Some embodiments provide a fracturing fluid additive
comprising at least two components selected from the group
consisting of crosslinked cellulose nanofibers, crosslinked
cellulose nanocrystals, lignosulfonates, and enzymes.
[0153] Some embodiments provide a fracturing fluid additive
comprising at least two components selected from the group
consisting of cellulose nanofibers, cellulose nanocrystals,
lignin-coated cellulose nanofibers, lignin-coated cellulose
nanocrystals, lignosulfonates, and enzymes.
[0154] Some embodiments provide a fracturing fluid comprising the
fracturing fluid additive as disclosed. The fracturing fluid may be
a water-based fracturing fluid, an oil-based fracturing fluid, or a
hybrid water-based/oil-based fracturing fluid.
[0155] The fracturing fluid may further include, in addition to a
disclosed fracturing fluid additive, one or more of a
biomass-derived acid (such as acetic acid, formic acid, levulinic
acid, and/or lignosulfonic acid), a biomass-derived corrosion
inhibitor (such as lignin or a lignin derivative), a
biomass-derived friction reducer (such as lignosulfonate or a
lignosulfonate derivative), a biomass-derived clay-control agent, a
biomass-derived crosslinking agent, a biomass-derived scale
inhibitor, a biomass-derived breaker, a biomass-derived
iron-control agent, a biomass-derived biocide (e.g., biomass
hydrolysate), and/or a biorefinery-derived source of recycled or
recovered water. Typically, the fracturing fluid carries, includes,
or is intended to be combined with a proppant, which may be a
biomass-derived proppant (such as ash contained in the structure of
biomass and/or sand, ash, or dirt collected with biomass).
[0156] Some variations of the invention provide a method of using a
fracturing fluid additive, the method comprising combining a
disclosed fracturing fluid additive into a base fluid to generate a
fracturing fluid. Some methods include introducing a fracturing
fluid additive directly or indirectly into a geological
formation.
[0157] In some variations, a process for producing a fracturing
fluid additive comprises refining biomass under effective
pretreatment conditions and refining conditions to generate a
fracturing fluid additive as disclosed. In some embodiments, the
pretreatment conditions include the generation of lignosulfonic
acids, which optionally are not entirely removed and are present in
the fracturing fluid additive. In some embodiments, the fracturing
fluid additive comprises a liquid slurry derived from the process.
For example, the slurry may contain nanocellulose derived from the
biomass as well as water and pretreatment chemicals (e.g.,
solvents, acids, bases, and so on).
[0158] In some variations, a process for producing a nanocellulose
material comprises: [0159] (a) providing a lignocellulosic biomass
feedstock; [0160] (b) fractionating the feedstock in the presence
of an acid, a solvent for lignin, and water, to generate
cellulose-rich solids and a liquid containing hemicellulose and
lignin; [0161] (c) mechanically treating the cellulose-rich solids
to form cellulose fibrils and/or cellulose crystals, thereby
generating a nanocellulose material having a crystallinity (i.e.,
cellulose crystallinity) of at least 60%; and [0162] (d) recovering
the nanocellulose material for use in a drilling fluid, drilling
fluid additive, fracturing fluid, or fracturing fluid additive.
[0163] In some embodiments, the acid is selected from the group
consisting of sulfur dioxide, sulfurous acid, sulfur trioxide,
sulfuric acid, lignosulfonic acid, and combinations thereof. In
particular embodiments, the acid is sulfur dioxide.
[0164] The biomass feedstock may be selected from hardwoods,
softwoods, forest residues, eucalyptus, industrial wastes, pulp and
paper wastes, consumer wastes, or combinations thereof. Some
embodiments utilize agricultural residues, which include
lignocellulosic biomass associated with food crops, annual grasses,
energy crops, or other annually renewable feedstocks. Exemplary
agricultural residues include, but are not limited to, corn stover,
corn fiber, wheat straw, sugarcane bagasse, sugarcane straw, rice
straw, oat straw, barley straw, miscanthus, energy cane
straw/residue, or combinations thereof. The process disclosed
herein benefits from feedstock flexibility; it is effective for a
wide variety of cellulose-containing feedstocks.
[0165] As used herein, "lignocellulosic biomass" means any material
containing cellulose and lignin. Lignocellulosic biomass may also
contain hemicellulose. Mixtures of one or more types of biomass can
be used. In some embodiments, the biomass feedstock comprises both
a lignocellulosic component (such as one described above) in
addition to a sucrose-containing component (e.g., sugarcane or
energy cane) and/or a starch component (e.g., corn, wheat, rice,
etc.). Various moisture levels may be associated with the starting
biomass. The biomass feedstock need not be, but may be, relatively
dry. In general, the biomass is in the form of a particulate or
chip, but particle size is not critical in this invention.
[0166] In some embodiments, during step (c), the cellulose-rich
solids are treated with a total mechanical energy of less than
about 1000 kilowatt-hours per ton of the cellulose-rich solids,
such as less than about 950, 900, 850, 800, 750, 700, 650, 600,
550, 500, 450, 400, 350, 300, or 250 kilowatt-hours per ton of the
cellulose-rich solids. In certain embodiments, the total mechanical
energy is from about 100 kilowatt-hours to about 400 kilowatt-hours
per ton of the cellulose-rich solids. Energy consumption may be
measured in any other suitable units. An ammeter measuring current
drawn by a motor driving the mechanical treatment device is one way
to obtain an estimate of the total mechanical energy.
[0167] Mechanically treating in step (c) may employ one or more
known techniques such as, but by no means limited to, milling,
grinding, beating, sonicating, or any other means to form or
release nanofibrils and/or nanocrystals in the cellulose.
Essentially, any type of mill or device that physically separates
fibers may be utilized. Such mills are well-known in the industry
and include, without limitation, Valley beaters, single disk
refiners, double disk refiners, conical refiners, including both
wide angle and narrow angle, cylindrical refiners, homogenizers,
microfluidizers, and other similar milling or grinding apparatus.
See, for example, Smook, Handbook for Pulp & Paper
Technologists, Tappi Press, 1992; and Hubbe et al., "Cellulose
Nanocomposites: A Review," BioResources 3(3), 929-980 (2008).
[0168] The extent of mechanical treatment may be monitored during
the process by any of several means. Certain optical instruments
can provide continuous data relating to the fiber length
distributions and % fines, either of which may be used to define
endpoints for the mechanical treatment step. The time, temperature,
and pressure may vary during mechanical treatment. For example, in
some embodiments, sonication for a time from about 5 minutes to 2
hours, at ambient temperature and pressure, may be utilized.
[0169] In some embodiments, a portion of the cellulose-rich solids
is converted to nanofibrils while the remainder of the
cellulose-rich solids is not fibrillated. In various embodiments,
about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 99%, or
substantially all of the cellulose-rich solids are fibrillated into
nanofibrils.
[0170] In some embodiments, a portion of the nanofibrils is
converted to nanocrystals while the remainder of the nanofibrils is
not converted to nanocrystals. In various embodiments, about 10%,
20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 99%, or substantially
all of the nanofibrils are converted to nanocrystals. During
drying, it is possible for a small amount of nanocrystals to come
back together and form nanofibrils.
[0171] Following mechanical treatment, the nanocellulose material
may be classified by particle size. A portion of material may be
subjected to a separate process, such as enzymatic hydrolysis to
produce glucose. Such material may have good crystallinity, for
example, but may not have desirable particle size or degree of
polymerization.
[0172] Step (c) may further comprise treatment of the
cellulose-rich solids with one or more enzymes or with one or more
acids. When acids are employed, they may be selected from the group
consisting of sulfur dioxide, sulfurous acid, lignosulfonic acid,
acetic acid, formic acid, and combinations thereof. Acids
associated with hemicellulose, such as acetic acid or uronic acids,
may be employed, alone or in conjunction with other acids. Also,
step (c) may include treatment of the cellulose-rich solids with
heat. In some embodiments, step (c) does not employ any enzymes or
acids.
[0173] In step (c), when an acid is employed, the acid may be a
strong acid such as sulfuric acid, nitric acid, or phosphoric acid,
for example. Weaker acids may be employed, under more severe
temperature and/or time. Enzymes that hydrolyze cellulose (i.e.,
cellulases) and possibly hemicellulose (i.e., with hemicellulase
activity) may be employed in step (c), either instead of acids, or
potentially in a sequential configuration before or after acidic
hydrolysis.
[0174] In some embodiments, the process comprises enzymatically
treating the cellulose-rich solids to hydrolyze amorphous
cellulose. In other embodiments, or sequentially prior to or after
enzymatic treatment, the process may comprise acid-treating the
cellulose-rich solids to hydrolyze amorphous cellulose.
[0175] In some embodiments, the process further comprises
enzymatically treating the nanocrystalline cellulose. In other
embodiments, or sequentially prior to or after enzymatic treatment,
the process further comprises acid-treating treating the
nanocrystalline cellulose.
[0176] If desired, an enzymatic treatment may be employed prior to,
or possibly simultaneously with, the mechanical treatment. However,
in preferred embodiments, no enzyme treatment is necessary to
hydrolyze amorphous cellulose or weaken the structure of the fiber
walls before isolation of nanofibers.
[0177] Following mechanical treatment, the nanocellulose may be
recovered. Separation of cellulose nanofibrils and/or nanocrystals
may be accomplished using apparatus capable of disintegrating the
ultrastructure of the cell wall while preserving the integrity of
the nanofibrils. For example, a homogenizer may be employed. In
some embodiments, cellulose aggregate fibrils are recovered, having
component fibrils in range of 1-100 nm width, wherein the fibrils
have not been completely separated from each other.
[0178] The process may further comprise bleaching the
cellulose-rich solids prior to step (c) and/or as part of step (c).
Alternatively, or additionally, the process may further comprise
bleaching the nanocellulose material during step (c) and/or
following step (c). Any known bleaching technology or sequence may
be employed, including enzymatic bleaching.
[0179] The nanocellulose material may include, or consist
essentially of, nanofibrillated cellulose. The nanocellulose
material may include, or consist essentially of, nanocrystalline
cellulose. In some embodiments, the nanocellulose material may
include, or consist essentially of, nanofibrillated cellulose and
nanocrystalline cellulose.
[0180] In some embodiments, the crystallinity of the cellulose-rich
solids (i.e., the nanocellulose precursor material) is at least
60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%,
73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%,
86% or higher. In these or other embodiments, the crystallinity of
the nanocellulose material is at least 60%, 61%, 62%, 63%, 64%,
65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%,
78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86% or higher. The
crystallinity may be measured using any known techniques. For
example, X-ray diffraction and solid-state .sup.13C nuclear
magnetic resonance may be utilized.
[0181] It is remarkable that the nanocellulose precursor material
has high crystallinity--which generally contributes to mechanical
strength--yet, very low mechanical energy consumption is necessary
to break apart the nanocellulose precursor material into
nanofibrils and nanocrystals. It is believed that since the
mechanical energy input is low, the high crystallinity is
essentially maintained in the final product.
[0182] In some embodiments, the nanocellulose material is
characterized by an average degree of polymerization from about 100
to about 1500, such as about 125, 150, 175, 200, 225, 250, 300,
400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, or 1400. For
example, the nanocellulose material may be characterized by an
average degree of polymerization from about 300 to about 700, or
from about 150 to about 250. The nanocellulose material, when in
the form of nanocrystals, may have a degree of polymerization less
than 100, such as about 75, 50, 25, or 10. Portions of the material
may have a degree of polymerization that is higher than 1500, such
as about 2000, 3000, 4000, or 5000.
[0183] In some embodiments, the nanocellulose material is
characterized by a degree of polymerization distribution having a
single peak. In other embodiments, the nanocellulose material is
characterized by a degree of polymerization distribution having two
peaks, such as one centered in the range of 150-250 and another
peak centered in the range of 300-700.
[0184] In some embodiments, the nanocellulose material is
characterized by an average length-to-width aspect ratio of
particles from about 10 to about 1000, such as about 15, 20, 25,
35, 50, 75, 100, 150, 200, 250, 300, 400, or 500. Nanofibrils are
generally associated with higher aspect ratios than nanocrystals.
Nanocrystals, for example, may have a length range of about 100 nm
to 500 nm and a diameter of about 4 nm, translating to an aspect
ratio of 25 to 125. Nanofibrils may have a length of about 2000nm
and diameter range of 5 to 50 nm, translating to an aspect ratio of
40 to 400. In some embodiments, the aspect ratio is less than 50,
less than 45, less than 40, less than 35, less than 30, less than
25, less than 20, less than 15, or less than 10.
[0185] Optionally, the process further comprises hydrolyzing
amorphous cellulose into glucose in step (b) and/or step (c),
recovering the glucose, and fermenting the glucose to a
fermentation product. Optionally, the process further comprises
recovering, fermenting, or further treating hemicellulosic sugars
derived from the hemicellulose. Optionally, the process further
comprises recovering, combusting, or further treating the
lignin.
[0186] Glucose that is generated from hydrolysis of amorphous
cellulose may be integrated into an overall process to produce
ethanol, or another fermentation co-product. Thus in some
embodiments, the process further comprises hydrolyzing amorphous
cellulose into glucose in step (b) and/or step (c), and recovering
the glucose. The glucose may be purified and sold. Or the glucose
may be fermented to a fermentation product, such as but not limited
to ethanol. The glucose or a fermentation product may be recycled
to the front end, such as to hemicellulose sugar processing, if
desired.
[0187] When hemicellulosic sugars are recovered and fermented, they
may be fermented to produce a monomer or precursor thereof. The
monomer may be polymerized to produce a polymer, which may then be
combined with the nanocellulose material to form a
polymer-nanocellulose composite.
[0188] In some embodiments, the nanocellulose material is at least
partially hydrophobic via deposition of at least some of the lignin
onto a surface of the cellulose-rich solids during step (b). In
these or other embodiments, the nanocellulose material is at least
partially hydrophobic via deposition of at least some of the lignin
onto a surface of the nanocellulose material during step (c) or
step (d).
[0189] In some embodiments, the process further comprises
chemically converting the nanocellulose material to one or more
nanocellulose derivatives. For example, nanocellulose derivatives
may be selected from the group consisting of nanocellulose esters,
nanocellulose ethers, nanocellulose ether esters, alkylated
nanocellulose compounds, cross-linked nanocellulose compounds,
acid-functionalized nanocellulose compounds, base-functionalized
nanocellulose compounds, and combinations thereof.
[0190] Various types of nanocellulose functionalization or
derivatization may be employed, such as functionalization using
polymers, chemical surface modification, functionalization using
nanoparticles (i.e. other nanoparticles besides the nanocellulose),
modification with inorganics or surfactants, or biochemical
modification.
[0191] Certain variations provide a process for producing a
nanocellulose material, the process comprising: [0192] (a)
providing a lignocellulosic biomass feedstock; [0193] (b)
fractionating the feedstock in the presence of sulfur dioxide, a
solvent for lignin, and water, to generate cellulose-rich solids
and a liquid containing hemicellulose oligomers and lignin, wherein
the crystallinity of the cellulose-rich solids is at least 70%,
wherein SO2 concentration is from about 10 wt %to about 50 wt %,
fractionation temperature is from about 130.degree. C. to about
200.degree. C., and fractionation time is from about 30 minutes to
about 4 hours; [0194] (c) mechanically treating the cellulose-rich
solids to form cellulose fibrils and/or cellulose crystals, thereby
generating a nanocellulose material having a crystallinity of at
least 70%; and [0195] (d) recovering the nanocellulose
material.
[0196] In some embodiments, the SO.sub.2 concentration is from
about 12 wt %to about 30 wt %. In some embodiments, the
fractionation temperature is from about 140.degree. C. to about
170.degree. C. In some embodiments, the fractionation time is from
about 1 hour to about 2 hours. The process may be controlled such
that during step (b), a portion of the solubilized lignin
intentionally deposits back onto a surface of the cellulose-rich
solids, thereby rendering the cellulose-rich solids at least
partially hydrophobic.
[0197] A significant factor limiting the application of
strength-enhancing, lightweight nanocellulose in composites is
cellulose's inherent hydrophilicity. Surface modification of the
nanocellulose surface to impart hydrophobicity to enable uniform
dispersion in a hydrophobic polymer matrix is an active area of
study. It has been discovered that when preparing nanocellulose
using the processes described herein, lignin may condense on pulp
under certain conditions, giving a rise in Kappa number and
production of a brown or black material. The lignin increases the
hydrophobicity of the nanocellulose precursor material, and that
hydrophobicity is retained during mechanical treatment provided
that there is not removal of the lignin through bleaching or other
steps. (Some bleaching may still be performed, either to adjust
lignin content or to attack a certain type of lignin, for
example.)
[0198] In some embodiments, the present invention provides a
process for producing a hydrophobic nanocellulose material, the
process comprising: [0199] (a) providing a lignocellulosic biomass
feedstock; [0200] (b) fractionating the feedstock in the presence
of an acid, a solvent for lignin, and water, to generate
cellulose-rich solids and a liquid containing hemicellulose and
lignin, wherein a portion of the lignin deposits onto a surface of
the cellulose-rich solids, thereby rendering the cellulose-rich
solids at least partially hydrophobic; [0201] (c) mechanically
treating the cellulose-rich solids to form cellulose fibrils and/or
cellulose crystals, thereby generating a hydrophobic nanocellulose
material having a crystallinity of at least 60%; and [0202] (d)
recovering the hydrophobic nanocellulose material.
[0203] In some embodiments, the acid is selected from the group
consisting of sulfur dioxide, sulfurous acid, sulfur trioxide,
sulfuric acid, lignosulfonic acid, and combinations thereof
[0204] In some embodiments, during step (c), the cellulose-rich
solids are treated with a total mechanical energy of less than
about 1000 kilowatt-hours per ton of the cellulose-rich solids,
such as less than about 500 kilowatt-hours per ton of the
cellulose-rich solids.
[0205] The crystallinity of the nanocellulose material is at least
70% or at least 80%, in various embodiments.
[0206] The nanocellulose material may include nanofibrillated
cellulose, nanocrystalline cellulose, or both nanofibrillated and
nanocrystalline cellulose. The nanocellulose material may be
characterized by an average degree of polymerization from about 100
to about 1500, such as from about 300 to about 700, or from about
150 to about 250, for example (without limitation).
[0207] Step (b) may include process conditions, such as extended
time and/or temperature, or reduced concentration of solvent for
lignin, which tend to promote lignin deposition onto fibers.
Alternatively, or additionally, step (b) may include one or more
washing steps that are adapted to deposit at least some of the
lignin that was solubilized during the initial fractionation. One
approach is to wash with water rather than a solution of water and
solvent. Because lignin is generally not soluble in water, it will
begin to precipitate. Optionally, other conditions may be varied,
such as pH and temperature, during fractionation, washing, or other
steps, to optimize the amount of lignin deposited on surfaces. It
is noted that in order for the lignin surface concentration to be
higher than the bulk concentration, the lignin needs to be first
pulled into solution and then redeposited; internal lignin (within
particles of nanocellulose) does not enhance hydrophobicity in the
same way.
[0208] Optionally, the process for producing a hydrophobic
nanocellulose material may further include chemically modifying the
lignin to increase hydrophobicity of the nanocellulose material.
The chemical modification of lignin may be conducted during step
(b), step (c), step (d), following step (d), or some
combination.
[0209] High loading rates of lignin have been achieved in
thermoplastics. Even higher loading levels are obtained with
well-known modifications of lignin. The preparation of useful
polymeric materials containing a substantial amount of lignin has
been the subject of investigations for more than thirty years.
Typically, lignin may be blended into polyolefins or polyesters by
extrusion up to 25-40 wt % while satisfying mechanical
characteristics. In order to increase the compatibility between
lignin and other hydrophobic polymers, different approaches have
been used. For example, chemical modification of lignin may be
accomplished through esterification with long-chain fatty
acids.
[0210] Any known chemical modifications may be carried out on the
lignin, to further increase the hydrophobic nature of the
lignin-coated nanocellulose material provided by embodiments of
this invention.
[0211] The present invention also provides, in some variations, a
process for producing a nanocellulose-containing product, the
process comprising: [0212] (a) providing a lignocellulosic biomass
feedstock; [0213] (b) fractionating the feedstock in the presence
of an acid, a solvent for lignin, and water, to generate
cellulose-rich solids and a liquid containing hemicellulose and
lignin; [0214] (c) mechanically treating the cellulose-rich solids
to form cellulose fibrils and/or cellulose crystals, thereby
generating a nanocellulose material having a crystallinity of at
least 60%; and [0215] (d) incorporating at least a portion of the
nanocellulose material into a nanocellulose-containing product.
[0216] The nanocellulose-containing product includes the
nanocellulose material, or a treated form thereof. In some
embodiments, the nanocellulose-containing product consists
essentially of the nanocellulose material.
[0217] In some embodiments, step (d) comprises forming a structural
object that includes the nanocellulose material, or a derivative
thereof.
[0218] In some embodiments, step (d) comprises forming a foam or
aerogel that includes the nanocellulose material, or a derivative
thereof.
[0219] In some embodiments, step (d) comprises combining the
nanocellulose material, or a derivative thereof, with one or more
other materials to form a composite. For example, the other
material may include a polymer selected from polyolefins,
polyesters, polyurethanes, polyamides, or combinations thereof.
Alternatively, or additionally, the other material may include
carbon in various forms.
[0220] The nanocellulose material incorporated into a
nanocellulose-containing product may be at least partially
hydrophobic via deposition of at least some of the lignin onto a
surface of the cellulose-rich solids during step (b). Also, the
nanocellulose material may be at least partially hydrophobic via
deposition of at least some of the lignin onto a surface of the
nanocellulose material during step (c) or step (d).
[0221] In some embodiments, step (d) comprises forming a film
comprising the nanocellulose material, or a derivative thereof. The
film is optically transparent and flexible, in certain
embodiments.
[0222] In some embodiments, step (d) comprises forming a coating or
coating precursor comprising the nanocellulose material, or a
derivative thereof. In some embodiments, the
nanocellulose-containing product is a paper coating.
[0223] In some embodiments, the nanocellulose-containing product is
configured as a catalyst, catalyst substrate, or co-catalyst. In
some embodiments, the nanocellulose-containing product is
configured electrochemically for carrying or storing an electrical
current or voltage.
[0224] In some embodiments, the nanocellulose-containing product is
incorporated into a filter, membrane, or other separation
device.
[0225] In some embodiments, the nanocellulose-containing product is
incorporated as an additive into a coating, paint, or adhesive. In
some embodiments, the nanocellulose-containing product is
incorporated as a cement additive.
[0226] In some embodiments, the nanocellulose-containing product is
incorporated as a thickening agent or rheological modifier. For
example, the nanocellulose-containing product may be an additive in
a drilling fluid, such as (but not limited to) an oil recovery
fluid and/or a gas recovery fluid.
[0227] The present invention also provides nanocellulose
compositions. In some variations, a nanocellulose composition
comprises nanofibrillated cellulose with a cellulose crystallinity
of about 70% or greater. The nanocellulose composition may include
lignin and sulfur.
[0228] The nanocellulose material may further contain some
sulfonated lignin that is derived from sulfonation reactions with
SO.sub.2 (when used as the acid in fractionation) during the
biomass digestion. The amount of sulfonated lignin may be about 0.1
wt %(or less), 0.2 wt %, 0.5 wt %, 0.8 wt %, 1 wt %, or more. Also,
without being limited by any theory, it is speculated that a small
amount of sulfur may chemically react with cellulose itself, in
some embodiments.
[0229] In some variations, a nanocellulose composition comprises
nanofibrillated cellulose and nanocrystalline cellulose, wherein
the nanocellulose composition is characterized by an overall
cellulose crystallinity of about 70% or greater. The nanocellulose
composition may include lignin and sulfur.
[0230] In some variations, a nanocellulose composition comprises
nanocrystalline cellulose with a cellulose crystallinity of about
80% or greater, wherein the nanocellulose composition comprises
lignin and sulfur.
[0231] In some embodiments, the cellulose crystallinity is about
75% or greater, such as about 80% or greater, or about 85% or
greater. In various embodiments, the nanocellulose composition is
not derived from tunicates.
[0232] The nanocellulose composition of some embodiments is
characterized by an average cellulose degree of polymerization from
about 100 to about 1000, such as from about 300 to about 700 or
from about 150 to about 250. In certain embodiments, the
nanocellulose composition is characterized by a cellulose degree of
polymerization distribution having a single peak. In certain
embodiments, the nanocellulose composition is free of enzymes.
[0233] Other variations provide a hydrophobic nanocellulose
composition with a cellulose crystallinity of about 70% or greater,
wherein the nanocellulose composition contains nanocellulose
particles having a surface concentration of lignin that is greater
than a bulk (internal particle) concentration of lignin. In some
embodiments, there is a coating or thin film of lignin on
nanocellulose particles, but the coating or film need not be
uniform.
[0234] The hydrophobic nanocellulose composition may have a
cellulose crystallinity is about 75% or greater, about 80% or
greater, or about 85% or greater. The hydrophobic nanocellulose
composition may further include sulfur.
[0235] The hydrophobic nanocellulose composition may or may not be
derived from tunicates. The hydrophobic nanocellulose composition
may be free of enzymes.
[0236] In some embodiments, the hydrophobic nanocellulose
composition is characterized by an average cellulose degree of
polymerization from about 100 to about 1500, such as from about 300
to about 700 or from about 150 to about 250. The nanocellulose
composition may be characterized by a cellulose degree of
polymerization distribution having a single peak.
[0237] A nanocellulose-containing product may include any of the
disclosed nanocellulose compositions. Many nanocellulose-containing
products are possible. For example, a nanocellulose-containing
product may be selected from the group consisting of a structural
object, a foam, an aerogel, a polymer composite, a carbon
composite, a film, a coating, a coating precursor, a current or
voltage carrier, a filter, a membrane, a catalyst, a catalyst
substrate, a coating additive, a paint additive, an adhesive
additive, a cement additive, a paper coating, a thickening agent, a
rheological modifier, an additive for a drilling fluid, and
combinations or derivatives thereof.
[0238] Some variations provide a nanocellulose material produced by
a process comprising: [0239] (a) providing a lignocellulosic
biomass feedstock; [0240] (b) fractionating the feedstock in the
presence of an acid, a solvent for lignin, and water, to generate
cellulose-rich solids and a liquid containing hemicellulose and
lignin; [0241] (c) mechanically treating the cellulose-rich solids
to form cellulose fibrils and/or cellulose crystals, thereby
generating a nanocellulose material having a crystallinity of at
least 60%; and [0242] (d) recovering the nanocellulose
material.
[0243] Some embodiments provide a polymer-nanocellulose composite
material produced by a process comprising: [0244] (a) providing a
lignocellulosic biomass feedstock; [0245] (b) fractionating the
feedstock in the presence of an acid, a solvent for lignin, and
water, to generate cellulose-rich solids and a liquid containing
hemicellulose and lignin; [0246] (c) mechanically treating the
cellulose-rich solids to form cellulose fibrils and/or cellulose
crystals, thereby generating a nanocellulose material having a
crystallinity of at least 60%; [0247] (d) recovering the
nanocellulose material; [0248] (e) fermenting hemicellulosic sugars
derived from the hemicellulose to produce a monomer or precursor
thereof; [0249] (f) polymerizing the monomer to produce a polymer;
and [0250] (g) combining the polymer and the nanocellulose material
to form the polymer-nanocellulose composite.
[0251] Some variations provide a nanocellulose material produced by
a process comprising: [0252] (a) providing a lignocellulosic
biomass feedstock; [0253] (b) fractionating the feedstock in the
presence of sulfur dioxide, a solvent for lignin, and water, to
generate cellulose-rich solids and a liquid containing
hemicellulose oligomers and lignin, wherein the crystallinity of
the cellulose-rich solids is at least 70%, wherein SO2
concentration is from about 10 wt %to about 50 wt %, fractionation
temperature is from about 130.degree. C. to about 200.degree. C.,
and fractionation time is from about 30 minutes to about 4 hours;
[0254] (c) mechanically treating the cellulose-rich solids to form
cellulose fibrils and/or cellulose crystals, thereby generating a
nanocellulose material having a crystallinity of at least 70%; and
[0255] (d) recovering the nanocellulose material.
[0256] Some variations provide a hydrophobic nanocellulose material
produced by a process comprising: [0257] (a) providing a
lignocellulosic biomass feedstock; [0258] (b) fractionating the
feedstock in the presence of an acid, a solvent for lignin, and
water, to generate cellulose-rich solids and a liquid containing
hemicellulose and lignin, wherein a portion of the lignin deposits
onto a surface of the cellulose-rich solids, thereby rendering the
cellulose-rich solids at least partially hydrophobic; [0259] (c)
mechanically treating the cellulose-rich solids to form cellulose
fibrils and/or cellulose crystals, thereby generating a hydrophobic
nanocellulose material having a crystallinity of at least 60%; and
[0260] (d) recovering the hydrophobic nanocellulose material.
[0261] Some variations provide a nanocellulose-containing product
produced by a process comprising: [0262] (a) providing a
lignocellulosic biomass feedstock; [0263] (b) fractionating the
feedstock in the presence of an acid, a solvent for lignin, and
water, to generate cellulose-rich solids and a liquid containing
hemicellulose and lignin; [0264] (c) mechanically treating the
cellulose-rich solids to form cellulose fibrils and/or cellulose
crystals, thereby generating a nanocellulose material having a
crystallinity of at least 60%; and [0265] (d) incorporating at
least a portion of the nanocellulose material into a
nanocellulose-containing product.
[0266] A nanocellulose-containing product that contains the
nanocellulose material may be selected from the group consisting of
a structural object, a foam, an aerogel, a polymer composite, a
carbon composite, a film, a coating, a coating precursor, a current
or voltage carrier, a filter, a membrane, a catalyst, a catalyst
substrate, a coating additive, a paint additive, an adhesive
additive, a cement additive, a paper coating, a thickening agent, a
rheological modifier, an additive for a drilling fluid, and
combinations or derivatives thereof
[0267] It should be noted that the AVAP.RTM. process is not
required in some embodiments of the invention. For example, a
composition comprising nanocellulose and lignosulfonates may be
produced by obtaining nanocellulose and obtaining lignosulfonates,
and combining them into an additive. Or a composition comprising
nanocellulose and lignosulfonates may be produced by obtaining
cellulose, refining the cellulose into nanocellulose, and adding
lignosulfonates (which may be provided by another process or an
AVAP.RTM. process) to make the composition.
[0268] Various embodiments will now be further described, without
limitation as to the scope of the invention. These embodiments are
exemplary in nature.
[0269] In some embodiments, a first process step is "cooking"
(equivalently, "digesting") which fractionates the three
lignocellulosic material components (cellulose, hemicellulose, and
lignin) to allow easy downstream removal. Specifically,
hemicelluloses are dissolved and over 50% are completely
hydrolyzed; cellulose is separated but remains resistant to
hydrolysis; and part of the lignin is sulfonated into water-soluble
lignosulfonates.
[0270] The lignocellulosic material is processed in a solution
(cooking liquor) of aliphatic alcohol, water, and sulfur dioxide.
The cooking liquor preferably contains at least 10 wt %, such as at
least 20 wt %, 30 wt %, 40 wt %, or50 wt % of a solvent for lignin.
For example, the cooking liquor may contain about 30-70 wt %
solvent, such as about 50 wt % solvent. The solvent for lignin may
be an aliphatic alcohol, such as methanol, ethanol, 1-propanol,
2-propanol, 1-butanol, 2-butanol, isobutanol, 1-pentanol,
1-hexanol, or cyclohexanol. The solvent for lignin may be an
aromatic alcohol, such as phenol or cresol. Other lignin solvents
are possible, such as (but not limited to) glycerol, methyl ethyl
ketone, or diethyl ether. Combinations of more than one solvent may
be employed.
[0271] Preferably, enough solvent is included in the extractant
mixture to dissolve the lignin present in the starting material.
The solvent for lignin may be completely miscible, partially
miscible, or immiscible with water, so that there may be more than
one liquid phase. Potential process advantages arise when the
solvent is miscible with water, and also when the solvent is
immiscible with water. When the solvent is water-miscible, a single
liquid phase forms, so mass transfer of lignin and hemicellulose
extraction is enhanced, and the downstream process must only deal
with one liquid stream. When the solvent is immiscible in water,
the extractant mixture readily separates to form liquid phases, so
a distinct separation step can be avoided or simplified. This can
be advantageous if one liquid phase contains most of the lignin and
the other contains most of the hemicellulose sugars, as this
facilitates recovering the lignin from the hemicellulose
sugars.
[0272] The cooking liquor preferably contains sulfur dioxide and/or
sulfurous acid (H.sub.2SO.sub.3). The cooking liquor preferably
contains SO.sub.2, in dissolved or reacted form, in a concentration
of at least 3 wt %, preferably at least 6 wt %, more preferably at
least 8 wt %, such as about 9 wt %, 10 wt %, 11 wt %, 12 wt %, 13
wt %, 14 wt %, 15 wt %, 20 wt %, 25 wt %, 30 wt % or higher. The
cooking liquor may also contain one or more species, separately
from SO.sub.2, to adjust the pH. The pH of the cooking liquor is
typically about 4 or less.
[0273] Sulfur dioxide is a preferred acid catalyst, because it can
be recovered easily from solution after hydrolysis. The majority of
the SO.sub.2 from the hydrolysate may be stripped and recycled back
to the reactor. Recovery and recycling translates to less lime
required compared to neutralization of comparable sulfuric acid,
less solids to dispose of, and less separation equipment. The
increased efficiency owing to the inherent properties of sulfur
dioxide mean that less total acid or other catalysts may be
required. This has cost advantages, since sulfuric acid can be
expensive. Additionally, and quite significantly, less acid usage
also will translate into lower costs for a base (e.g., lime) to
increase the pH following hydrolysis, for downstream operations.
Furthermore, less acid and less base will also mean substantially
less generation of waste salts (e.g., gypsum) that may otherwise
require disposal.
[0274] In some embodiments, an additive may be included in amounts
of about 0.1 wt % to 10 wt % or more to increase cellulose
viscosity. Exemplary additives include ammonia, ammonia hydroxide,
urea, anthraquinone, magnesium oxide, magnesium hydroxide, sodium
hydroxide, and their derivatives.
[0275] The cooking is performed in one or more stages using batch
or continuous digestors. Solid and liquid may flow cocurrently or
countercurrently, or in any other flow pattern that achieves the
desired fractionation. The cooking reactor may be internally
agitated, if desired.
[0276] Depending on the lignocellulosic material to be processed,
the cooking conditions are varied, with temperatures from about
65.degree. C. to 190.degree. C., for example 75.degree. C.,
85.degree. C., 95.degree. C., 105.degree. C., 115.degree. C.,
125.degree. C., 130.degree. C., 135.degree. C., 140.degree. C.,
145.degree. C., 150.degree. C., 155.degree. C., 165.degree. C. or
170.degree. C., and corresponding pressures from about 1 atmosphere
to about 15 atmospheres in the liquid or vapor phase. The cooking
time of one or more stages may be selected from about 15 minutes to
about 720 minutes, such as about 30, 45, 60, 90, 120, 140, 160,
180, 250, 300, 360, 450, 550, 600, or 700 minutes. Generally, there
is an inverse relationship between the temperature used during the
digestion step and the time needed to obtain good fractionation of
the biomass into its constituent parts.
[0277] The cooking liquor to lignocellulosic material ratio may be
selected from about 1 to about 10, such as about 2, 3, 4, 5, or 6.
In some embodiments, biomass is digested in a pressurized vessel
with low liquor volume (low ratio of cooking liquor to
lignocellulosic material), so that the cooking space is filled with
ethanol and sulfur dioxide vapor in equilibrium with moisture. The
cooked biomass is washed in alcohol-rich solution to recover lignin
and dissolved hemicelluloses, while the remaining pulp is further
processed. In some embodiments, the process of fractionating
lignocellulosic material comprises vapor-phase cooking of
lignocellulosic material with aliphatic alcohol (or other solvent
for lignin), water, and sulfur dioxide. See, for example, U.S. Pat.
Nos. 8,038,842 and 8,268,125 which are incorporated by reference
herein.
[0278] A portion or all of the sulfur dioxide may be present as
sulfurous acid in the extract liquor. In certain embodiments,
sulfur dioxide is generated in situ by introducing sulfurous acid,
sulfite ions, bisulfite ions, combinations thereof, or a salt of
any of the foregoing. Excess sulfur dioxide, following hydrolysis,
may be recovered and reused. In some embodiments, sulfur dioxide is
saturated in water (or aqueous solution, optionally with an
alcohol) at a first temperature, and the hydrolysis is then carried
out at a second, generally higher, temperature. In some
embodiments, sulfur dioxide is sub-saturated. In some embodiments,
sulfur dioxide is super-saturated. In some embodiments, sulfur
dioxide concentration is selected to achieve a certain degree of
lignin sulfonation, such as 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or
10% sulfur content. SO.sub.2 reacts chemically with lignin to form
stable lignosulfonic acids which may be present both in the solid
and liquid phases.
[0279] The concentration of sulfur dioxide, additives, and
aliphatic alcohol (or other solvent) in the solution and the time
of cook may be varied to control the yield of cellulose and
hemicellulose in the pulp. The concentration of sulfur dioxide and
the time of cook may be varied to control the yield of lignin
versus lignosulfonates in the hydrolysate. In some embodiments, the
concentration of sulfur dioxide, temperature, and the time of cook
may be varied to control the yield of fermentable sugars.
[0280] Once the desired amount of fractionation of both
hemicellulose and lignin from the solid phase is achieved, the
liquid and solid phases are separated. Conditions for the
separation may be selected to minimize or enhance the
reprecipitation of the extracted lignin on the solid phase.
Minimizing lignin reprecipitation is favored by conducting
separation or washing at a temperature of at least the
glass-transition temperature of lignin (about 120.degree. C.);
conversely, enhancing lignin reprecipitation is favored by
conducting separation or washing at a temperature less than the
glass-transition temperature of lignin.
[0281] The physical separation can be accomplished either by
transferring the entire mixture to a device that can carry out the
separation and washing, or by removing only one of the phases from
the reactor while keeping the other phase in place. The solid phase
can be physically retained by appropriately sized screens through
which liquid can pass. The solid is retained on the screens and can
be kept there for successive solid-wash cycles. Alternately, the
liquid may be retained and solid phase forced out of the reaction
zone, with centrifugal or other forces that can effectively
transfer the solids out of the slurry. In a continuous system,
countercurrent flow of solids and liquid can accomplish the
physical separation.
[0282] The recovered solids normally will contain a quantity of
lignin and sugars, some of which can be removed easily by washing.
The washing-liquid composition can be the same as or different than
the liquor composition used during fractionation. Multiple washes
may be performed to increase effectiveness. Preferably, one or more
washes are performed with a composition including a solvent for
lignin, to remove additional lignin from the solids, followed by
one or more washes with water to displace residual solvent and
sugars from the solids. Recycle streams, such as from
solvent-recovery operations, may be used to wash the solids.
[0283] After separation and washing as described, a solid phase and
at least one liquid phase are obtained. The solid phase contains
substantially undigested cellulose. A single liquid phase is
usually obtained when the solvent and the water are miscible in the
relative proportions that are present. In that case, the liquid
phase contains, in dissolved form, most of the lignin originally in
the starting lignocellulosic material, as well as soluble monomeric
and oligomeric sugars formed in the hydrolysis of any hemicellulose
that may have been present. Multiple liquid phases tend to form
when the solvent and water are wholly or partially immiscible. The
lignin tends to be contained in the liquid phase that contains most
of the solvent. Hemicellulose hydrolysis products tend to be
present in the liquid phase that contains most of the water.
[0284] In some embodiments, hydrolysate from the cooking step is
subjected to pressure reduction. Pressure reduction may be done at
the end of a cook in a batch digestor, or in an external flash tank
after extraction from a continuous digestor, for example. The flash
vapor from the pressure reduction may be collected into a cooking
liquor make-up vessel. The flash vapor contains substantially all
the unreacted sulfur dioxide which may be directly dissolved into
new cooking liquor. The cellulose is then removed to be washed and
further treated as desired.
[0285] A process washing step recovers the hydrolysate from the
cellulose. The washed cellulose is pulp that may be used for
various purposes (e.g., paper or nanocellulose production). The
weak hydrolysate from the washer continues to the final reaction
step; in a continuous digestor this weak hydrolysate may be
combined with the extracted hydrolysate from the external flash
tank. In some embodiments, washing and/or separation of hydrolysate
and cellulose-rich solids is conducted at a temperature of at least
about 100.degree. C., 110.degree. C., or 120.degree. C. The washed
cellulose may also be used for glucose production via cellulose
hydrolysis with enzymes or acids.
[0286] In another reaction step, the hydrolysate may be further
treated in one or multiple steps to hydrolyze the oligomers into
monomers. This step may be conducted before, during, or after the
removal of solvent and sulfur dioxide. The solution may or may not
contain residual solvent (e.g. alcohol). In some embodiments,
sulfur dioxide is added or allowed to pass through to this step, to
assist hydrolysis. In these or other embodiments, an acid such as
sulfurous acid or sulfuric acid is introduced to assist with
hydrolysis. In some embodiments, the hydrolysate is autohydrolyzed
by heating under pressure. In some embodiments, no additional acid
is introduced, but lignosulfonic acids produced during the initial
cooking are effective to catalyze hydrolysis of hemicellulose
oligomers to monomers. In various embodiments, this step utilizes
sulfur dioxide, sulfurous acid, sulfuric acid at a concentration of
about 0.01 wt %to 30 wt %, such as about 0.05 wt %, 0.1 wt %, 0.2
wt %, 0.5 wt %, 1 wt %, 2 wt %, 5 wt %, 10 wt %, or 20 wt %. This
step may be carried out at a temperature from about 100.degree. C.
to 220.degree. C., such as about 110.degree. C., 120.degree. C.,
130.degree. C., 140.degree. C., 150.degree. C., 160.degree. C.,
170.degree. C., 180.degree. C., 190.degree. C., 200.degree. C., or
210.degree. C. Heating may be direct or indirect to reach the
selected temperature.
[0287] The reaction step produces fermentable sugars which can then
be concentrated by evaporation to a fermentation feedstock.
Concentration by evaporation may be accomplished before, during, or
after the treatment to hydrolyze oligomers. The final reaction step
may optionally be followed by steam stripping of the resulting
hydrolysate to remove and recover sulfur dioxide and alcohol, and
for removal of potential fermentation-inhibiting side products. The
evaporation process may be under vacuum or pressure, from about
-0.1 atmospheres to about 10 atmospheres, such as about 0.1 atm,
0.3 atm, 0.5 atm, 1.0 atm, 1.5 atm, 2 atm, 4 atm, 6 atm, or 8
atm.
[0288] Recovering and recycling the sulfur dioxide may utilize
separations such as, but not limited to, vapor-liquid disengagement
(e.g. flashing), steam stripping, extraction, or combinations or
multiple stages thereof. Various recycle ratios may be practiced,
such as about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 0.95, or
more. In some embodiments, about 90-99% of initially charged SO2 is
readily recovered by distillation from the liquid phase, with the
remaining 1-10% (e.g., about 3-5%) of the SO.sub.2 primarily bound
to dissolved lignin in the form of lignosulfonates.
[0289] In a preferred embodiment, the evaporation step utilizes an
integrated alcohol stripper and evaporator. Evaporated vapor
streams may be segregated so as to have different concentrations of
organic compounds in different streams. Evaporator condensate
streams may be segregated so as to have different concentrations of
organic compounds in different streams. Alcohol may be recovered
from the evaporation process by condensing the exhaust vapor and
returning to the cooking liquor make-up vessel in the cooking step.
Clean condensate from the evaporation process may be used in the
washing step.
[0290] In some embodiments, an integrated alcohol stripper and
evaporator system is employed, wherein aliphatic alcohol is removed
by vapor stripping, the resulting stripper product stream is
concentrated by evaporating water from the stream, and evaporated
vapor is compressed using vapor compression and is reused to
provide thermal energy.
[0291] The hydrolysate from the evaporation and final reaction step
contains mainly fermentable sugars but may also contain lignin
depending on the location of lignin separation in the overall
process configuration. The hydrolysate may be concentrated to a
concentration of about 5 wt %to about 60 wt %solids, such as about
10 wt %, 15 wt %, 20 wt %, 25 wt %, 30 wt %, 35 wt %, 40 wt %, 45
wt %, 50 wt %or 55 wt %solids. The hydrolysate contains fermentable
sugars.
[0292] Fermentable sugars are defined as hydrolysis products of
cellulose, galactoglucomannan, glucomannan, arabinoglucuronoxylans,
arabinogalactan, and glucuronoxylans into their respective
short-chained oligomers and monomer products, i.e., glucose,
mannose, galactose, xylose, and arabinose. The fermentable sugars
may be recovered in purified form, as a sugar slurry or dry sugar
solids, for example. Any known technique may be employed to recover
a slurry of sugars or to dry the solution to produce dry sugar
solids.
[0293] In some embodiments, the fermentable sugars are fermented to
produce biochemicals or biofuels such as (but by no means limited
to) ethanol, isopropanol, acetone, 1-butanol, isobutanol, lactic
acid, succinic acid, or any other fermentation products. Some
amount of the fermentation product may be a microorganism or
enzymes, which may be recovered if desired.
[0294] When the fermentation will employ bacteria, such as
Clostridia bacteria, it is preferable to further process and
condition the hydrolysate to raise pH and remove residual SO.sub.2
and other fermentation inhibitors. The residual SO.sub.2 (i.e.,
following removal of most of it by stripping) may be catalytically
oxidized to convert residual sulfite ions to sulfate ions by
oxidation. This oxidation may be accomplished by adding an
oxidation catalyst, such as FeSO.sub.4.7H.sub.2O, that oxidizes
sulfite ions to sulfate ions. Preferably, the residual SO.sub.2 is
reduced to less than about 100 ppm, 50 ppm, 25 ppm, 10 ppm, 5 ppm,
or 1 ppm.
[0295] In some embodiments, the process further comprises
recovering the lignin as a co-product. The sulfonated lignin may
also be recovered as a co-product. In certain embodiments, the
process further comprises combusting or gasifying the sulfonated
lignin, recovering sulfur contained in the sulfonated lignin in a
gas stream comprising reclaimed sulfur dioxide, and then recycling
the reclaimed sulfur dioxide for reuse.
[0296] The process lignin separation step is for the separation of
lignin from the hydrolysate and can be located before or after the
final reaction step and evaporation. If located after, then lignin
will precipitate from the hydrolysate since alcohol has been
removed in the evaporation step. The remaining water-soluble
lignosulfonates may be precipitated by converting the hydrolysate
to an alkaline condition (pH higher than 7) using, for example, an
alkaline earth oxide, preferably calcium oxide (lime). The combined
lignin and lignosulfonate precipitate may be filtered. The lignin
and lignosulfonate filter cake may be dried as a co-product or
burned or gasified for energy production. The hydrolysate from
filtering may be recovered and sold as a concentrated sugar
solution product or further processed in a subsequent fermentation
or other reaction step.
[0297] Native (non-sulfonated) lignin is hydrophobic, while
lignosulfonates are hydrophilic. Hydrophilic lignosulfonates may
have less propensity to clump, agglomerate, and stick to surfaces.
Even lignosulfonates that do undergo some condensation and increase
of molecular weight, will still have an HSO.sub.3 group that will
contribute some solubility (hydrophilic).
[0298] In some embodiments, the soluble lignin precipitates from
the hydrolysate after solvent has been removed in the evaporation
step. In some embodiments, reactive lignosulfonates are selectively
precipitated from hydrolysate using excess lime (or other base,
such as ammonia) in the presence of aliphatic alcohol. In some
embodiments, hydrated lime is used to precipitate lignosulfonates.
In some embodiments, part of the lignin is precipitated in reactive
form and the remaining lignin is sulfonated in water-soluble
form.
[0299] The process fermentation and distillation steps are intended
for the production of fermentation products, such as alcohols or
organic acids. After removal of cooking chemicals and lignin, and
further treatment (oligomer hydrolysis), the hydrolysate contains
mainly fermentable sugars in water solution from which any
fermentation inhibitors have been preferably removed or
neutralized. The hydrolysate is fermented to produce dilute alcohol
or organic acids, from 1 wt % to 20 wt % concentration. The dilute
product is distilled or otherwise purified as is known in the
art.
[0300] When alcohol is produced, such as ethanol, some of it may be
used for cooking liquor makeup in the process cooking step. Also,
in some embodiments, a distillation column stream, such as the
bottoms, with or without evaporator condensate, may be reused to
wash cellulose. In some embodiments, lime may be used to dehydrate
product alcohol. Side products may be removed and recovered from
the hydrolysate. These side products may be isolated by processing
the vent from the final reaction step and/or the condensate from
the evaporation step. Side products include furfural, hydroxymethyl
furfural (HMF), methanol, acetic acid, and lignin-derived
compounds, for example.
[0301] The glucose may be fermented to an alcohol, an organic acid,
or another fermentation product. The glucose may be used as a
sweetener or isomerized to enrich its fructose content. The glucose
may be used to produce baker's yeast. The glucose may be
catalytically or thermally converted to various organic acids and
other materials.
[0302] When hemicellulose is present in the starting biomass, all
or a portion of the liquid phase contains hemicellulose sugars and
soluble oligomers. It is preferred to remove most of the lignin
from the liquid, as described above, to produce a fermentation
broth which will contain water, possibly some of the solvent for
lignin, hemicellulose sugars, and various minor components from the
digestion process. This fermentation broth can be used directly,
combined with one or more other fermentation streams, or further
treated. Further treatment can include sugar concentration by
evaporation; addition of glucose or other sugars (optionally as
obtained from cellulose saccharification); addition of various
nutrients such as salts, vitamins, or trace elements; pH
adjustment; and removal of fermentation inhibitors such as acetic
acid and phenolic compounds. The choice of conditioning steps
should be specific to the target product(s) and microorganism(s)
employed.
[0303] In some embodiments, hemicellulose sugars are not fermented
but rather are recovered and purified, stored, sold, or converted
to a specialty product. Xylose, for example, can be converted into
xylitol.
[0304] A lignin product can be readily obtained from a liquid phase
using one or more of several methods. One simple technique is to
evaporate off all liquid, resulting in a solid lignin-rich residue.
This technique would be especially advantageous if the solvent for
lignin is water-immiscible. Another method is to cause the lignin
to precipitate out of solution. Some of the ways to precipitate the
lignin include (1) removing the solvent for lignin from the liquid
phase, but not the water, such as by selectively evaporating the
solvent from the liquid phase until the lignin is no longer
soluble; (2) diluting the liquid phase with water until the lignin
is no longer soluble; and (3) adjusting the temperature and/or pH
of the liquid phase. Methods such as centrifugation can then be
utilized to capture the lignin. Yet another technique for removing
the lignin is continuous liquid-liquid extraction to selectively
remove the lignin from the liquid phase, followed by removal of the
extraction solvent to recover relatively pure lignin.
[0305] Lignin produced in accordance with the invention can be used
as a fuel. As a solid fuel, lignin is similar in energy content to
coal. Lignin can act as an oxygenated component in liquid fuels, to
enhance octane while meeting standards as a renewable fuel. The
lignin produced herein can also be used as polymeric material, and
as a chemical precursor for producing lignin derivatives. The
sulfonated lignin may be sold as a lignosulfonate product, or
burned for fuel value.
[0306] The present invention also provides systems configured for
carrying out the disclosed processes, and compositions produced
therefrom. Any stream generated by the disclosed processes may be
partially or completed recovered, purified or further treated,
and/or marketed or sold.
[0307] Certain nanocellulose-containing products provide high
transparency, good mechanical strength, and/or enhanced gas (e.g.,
O.sub.2 or CO.sub.2) barrier properties, for example. Certain
nanocellulose-containing products containing hydrophobic
nanocellulose materials provided herein may be useful as
anti-wetting and anti-icing coatings, for example.
[0308] Due to the low mechanical energy input,
nanocellulose-containing products provided herein may be
characterized by fewer defects that normally result from intense
mechanical treatment.
[0309] Some embodiments provide nanocellulose-containing products
with applications for sensors, catalysts, antimicrobial materials,
current carrying and energy storage capabilities. Cellulose
nanocrystals have the capacity to assist in the synthesis of
metallic and semiconducting nanoparticle chains.
[0310] Some embodiments provide composites containing nanocellulose
and a carbon- containing material, such as (but not limited to)
lignin, graphite, graphene, or carbon aerogels.
[0311] Cellulose nanocrystals may be coupled with the stabilizing
properties of surfactants and exploited for the fabrication of
nanoarchitectures of various semiconducting materials.
[0312] The reactive surface of --OH side groups in nanocellulose
facilitates grafting chemical species to achieve different surface
properties. Surface functionalization allows the tailoring of
particle surface chemistry to facilitate self-assembly, controlled
dispersion within a wide range of matrix polymers, and control of
both the particle-particle and particle-matrix bond strength.
Composites may be transparent, have tensile strengths greater than
cast iron, and have very low coefficient of thermal expansion.
Potential applications include, but are not limited to, barrier
films, antimicrobial films, transparent films, flexible displays,
reinforcing fillers for polymers, biomedical implants,
pharmaceuticals, drug delivery, fibers and textiles, templates for
electronic components, separation membranes, batteries,
supercapacitors, electroactive polymers, and many others.
[0313] Other nanocellulose applications suitable to the present
invention include reinforced polymers, high-strength spun fibers
and textiles, advanced composite materials, films for barrier and
other properties, additives for coatings, paints, lacquers and
adhesives, switchable optical devices, pharmaceuticals and drug
delivery systems, bone replacement and tooth repair, improved
paper, packaging and building products, additives for foods and
cosmetics, catalysts, and hydrogels.
[0314] Aerospace and transportation composites may benefit from
high crystallinity. Automotive applications include nanocellulose
composites with polypropylene, polyamide (e.g. Nylons), or
polyesters (e.g. PBT).
[0315] Nanocellulose materials provided herein are suitable as
strength-enhancing additives for renewable and biodegradable
composites. The cellulosic nanofibrillar structures may function as
a binder between two organic phases for improved fracture toughness
and prevention of crack formation for application in packaging,
construction materials, appliances, and renewable fibers.
[0316] Nanocellulose materials provided herein are suitable as
transparent and dimensional stable strength-enhancing additives and
substrates for application in flexible displays, flexible circuits,
printable electronics, and flexible solar panels. Nanocellulose is
incorporated into the substrate-sheets are formed by vacuum
filtration, dried under pressure and calandered, for example. In a
sheet structure, nanocellulose acts as a glue between the filler
aggregates. The formed calandered sheets are smooth and
flexible.
[0317] Nanocellulose materials provided herein are suitable for
composite and cement additives allowing for crack reduction and
increased toughness and strength. Foamed, cellular
nanocellulose-concrete hybrid materials allow for lightweight
structures with increased crack reduction and strength.
[0318] Strength enhancement with nanocellulose increases both the
binding area and binding strength for application in high strength,
high bulk, high filler content paper and board with enhanced
moisture and oxygen barrier properties. The pulp and paper industry
in particular may benefit from nanocellulose materials provided
herein.
[0319] Nanofibrillated cellulose nanopaper has a higher density and
higher tensile mechanical properties than conventional paper. It
can also be optically transparent and flexible, with low thermal
expansion and excellent oxygen barrier characteristics. The
functionality of the nanopaper can be further broadened by
incorporating other entities such as carbon nanotubes, nanoclay or
a conductive polymer coating.
[0320] Porous nanocellulose may be used for cellular bioplastics,
insulation and plastics and bioactive membranes and filters. Highly
porous nanocellulose materials are generally of high interest in
the manufacturing of filtration media as well as for biomedical
applications, e.g., in dialysis membranes.
[0321] Nanocellulose materials provided herein are suitable as
coating materials as they are expected to have a high oxygen
barrier and affinity to wood fibers for application in food
packaging and printing papers.
[0322] Nanocellulose materials provided herein are suitable as
additives to improve the durability of paint, protecting paints and
varnishes from attrition caused by UV radiation.
[0323] Nanocellulose materials provided herein are suitable as
thickening agents in food and cosmetics products. Nanocellulose can
be used as thixotropic, biodegradable, dimensionally stable
thickener (stable against temperature and salt addition).
Nanocellulose materials provided herein are suitable as a Pickering
stabilizer for emulsions and particle stabilized foam.
[0324] The large surface area of these nanocellulose materials in
combination with their biodegradability makes them attractive
materials for highly porous, mechanically stable aerogels.
Nanocellulose aerogels display a porosity of 95% or higher, and
they are ductile and flexible.
EXAMPLES
[0325] Colloidal suspensions are used in wide range of applications
such as paints, coatings, cosmetics, ceramics, pharmaceutical
formulations, food and household products. Addition of polymers to
colloidal suspensions is a common practice to obtain the desired
flow properties of such materials. Physical adsorption of polymers
at the particle interface stabilizes or destabilizes colloidal
suspensions. In addition, non-adsorbing polymers can also cause
flocculation and/or phase separation. For the micron-size
particles, polymer interactions have been studied extensively both
experimentally and theoretically during the last three decades.
While the nanoparticle-polymer mixtures are believed to start to
play major roles in different fields, including drilling fluids and
other oil field formulations, polymer-CNC and polymer-CNF
interactions in aqueous solutions and their potential applications
have not been exploited.
[0326] Drilling fluids have to meet multi-functional performance
requirements. First of all, additives in the formulations have to
be easily metered and mixed in the mud formulation. It has to have
low viscosity at the pumping and transfer stage (medium to high
shear rate) and keep cuttings suspended and transferable from the
drilled point to the surface (yield strength and high viscosity at
low shear rate). Besides it has to allow easy to separate the
cuttings from the drilling mud at the screening stage. Drilling mud
has to easily flow after the stop and start of drilling
operation.
[0327] Hence, investigating rheological properties such as shear,
salt and temperature dependencies of viscosity are crucial during
the drilling fluids and other oil field formulations.
[0328] Rheological properties of aqueous CNF and CNC suspensions in
the presence of colloidal bentonite, and optionally xanthan gum or
carboxymethyl cellulose are investigated.
[0329] CNF, CNC, lignin-coated CNF and lignin-coated CNC samples
are provided according to processes described herein, derived from
eucalyptus. Sodium carboxy methyl cellulose (CMC) and xanthan Gum
(XG) are purchased from Sigma Aldrich. Wyoming bentonite is
purchased from a commercial supplier. All concentrations are wt
%.
[0330] Rheological measurements are performed with TA Instruments
AR-G2 with Cone and Plate Geometry. Steady-state shear viscosity
vs. shear sweep is analyzed, and yield point at two temperatures,
25.degree. C. and 60.degree. C., is determined. All figures (FIGS.
1-6) plot viscosity (Pas) on the y-axis versus shear rate
(sec.sup.-1) on the x-axis.
[0331] FIG. 1 demonstrates the performance of an aqueous drilling
fluid containing 1% nanocellulose (CNC) produced by conventional
sulfuric acid treatment, 4% bentonite, with or without 100 ppm
NaCl. A 4% bentonite control is shown for comparison.
[0332] FIG. 2 demonstrates the performance of an aqueous drilling
fluid containing 4% bentonite, 0.5% CNC nanocellulose produced by
the present disclosure, and optionally CMC or XG.
[0333] FIG. 3 demonstrates the performance of an aqueous drilling
fluid containing 4% bentonite, 0.1-0.5% CNF nanocellulose produced
by the present disclosure, and optionally 0.25% CMC.
[0334] FIG. 4 demonstrates the performance of an aqueous drilling
fluid containing 4% bentonite, 0.5% CNC nanocellulose produced by
the present disclosure, and 0.25% CMC, with or without 100 ppm
NaCl.
[0335] According to FIGS. 1-4, CNC and CNF provided herein are
superior thickeners over sulfuric acid CNCs or bentonite alone. CNF
provides the greatest thickening. In addition, CNC and CNF
formulations provided herein are salt-stable. This property is due
to the reduced amount, or absence, of no charged functional groups
on surfaces.
[0336] The CNC according to the invention is an excellent thickener
together with bentonite (Wyoming) gel. Its thickening character at
0.5% concentration is comparable to 0.25% XG. The thickening effect
is enhanced further with CMC. Unexpectedly, compared with XG, it is
easy to disperse, shear-stable and thermally stable. Typically,
hydrophilic powder is difficult to dissolve. Finally, the CNC is
salt-stable.
[0337] CNF provided herein is a good thickener as-is, without CMC,
but is enhanced with CMC. CNF thickening is not salt sensitive.
This is in contrast to CNF provided in the prior art methods.
[0338] Nanocellulose is also evaluated in oil-based drilling
fluids. FIG. 5 demonstrates the performance of an oil-based
drilling fluid containing 0.5% lignin-coated CNF or lignin- coated
CNC, 94.3% hexane, and 4.7% water. Especially at low shear rate,
the behavior of lignin-coated CNF and lignin-coated CNC is similar.
Lignin-coated fibrils and crystals powder (0.5 wt %) dispersed in
hexane and water with 0.1% surfactant to form a gel. It is
surprising that these powders were able to be dispersed in the
solvent phase.
[0339] FIG. 6 is a plot of viscosity versus shear rate for 0.5%
cross-linked CNF or CNC, with or without 0.1% guar gum (GG) or
0.25% borax (AB). The viscosity of cross-linked CNF with 0.1% guar
gum and 0.25% borax is orders of magnitude higher than guar gum and
borax alone.
[0340] In this detailed description, reference has been made to
multiple embodiments of the invention and non-limiting examples
relating to how the invention can be understood and practiced.
Other embodiments that do not provide all of the features and
advantages set forth herein may be utilized, without departing from
the spirit and scope of the present invention. This invention
incorporates routine experimentation and optimization of the
methods and systems described herein. Such modifications and
variations are considered to be within the scope of the invention
defined by the claims.
[0341] All publications, patents, and patent applications cited in
this specification are herein incorporated by reference in their
entirety as if each publication, patent, or patent application were
specifically and individually put forth herein.
[0342] Where methods and steps described above indicate certain
events occurring in certain order, those of ordinary skill in the
art will recognize that the ordering of certain steps may be
modified and that such modifications are in accordance with the
variations of the invention. Additionally, certain of the steps may
be performed concurrently in a parallel process when possible, as
well as performed sequentially.
[0343] Therefore, to the extent there are variations of the
invention, which are within the spirit of the disclosure or
equivalent to the inventions found in the appended claims, it is
the intent that this patent will cover those variations as well.
The present invention shall only be limited by what is claimed.
* * * * *