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Integrated Forest Products Refinery (IFPR)

2010

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Abstract

Pre-extraction–kraft studies of hardwoods showed that when extracting about 10% of the wood, the final kraft pulp yield and physical properties could only be maintained at a level similar to that of regular kraft pulp when the final extract pH was close to neutral. This so-called “near neutral” pre-extraction condition at a level of 10% wood dissolution was achieved by contacting the wood chips with green liquor (GL) at a charge of about 3% (as Na2O on wood) at 160 °C for almost 2 hours (or an H-factor of about 800 hrs.). During subsequent kraft cooking of the pre-extracted hardwood chips the effective alkali charge could be reduced by about 3% (as Na2O on wood) and the cooking time shortened relative to that during regular kraft cooking, while still producing the same bleachable grade kappa number as the kraft control pulp. For softwood, no extraction conditions were discovered in the present investigation whereby both the final kraft pulp yield and physical properties could be maintained at a level similar to that of regular softwood kraft pulp. Therefore for hardwoods the “near- neutral green liquor pre-extraction conditions do meet the requirements of the IFPR concept, while for softwood, no extraction conditions were discovered which do meet these requirements. Application of simulated industrial GL at an extraction H-factor of about 800 hrs and 3% GL charge in a recirculating digester produced an hardwood extract containing about 4% (on wood) of total anhydro-sugars, 2% of acetic acid, and 1.3% of lignin. Xylan comprised of 80% of the sugars of which about 85% is oligomeric. Since only polymeric hemicelluloses and lignin may be adsorbed on pulp (produced at a yield of about 50% from the original wood), the maximum theoretical yield increase due to adsorption may be estimated as 10% on pulp (or 5% on wood). However, direct application of raw GL hardwood extract for hemicelluloses adsorption onto hardwood kraft pulp led to a yield increase of only about 1% (on pulp). By using the wet-end retention aid guar gum during the adsorption process at a charge of 0.5% on pulp the yield gain may be increased to about 5%. Unfortunately, most of this yield increase is lost during subsequent alkaline treatments in the pulp bleach plant. It was found that by performing the adsorption at alkaline conditions the adsorption loss during alkaline treatment in the bleach plant is mostly avoided. Thus a permanent adsorption yield of about 3 and 1.5% (on pulp) was obtained with addition of guar gum at a charge of 0.5 and 0.1% respectively during adsorption of GL hardwood extract on pre-extracted kraft pulp at optimal conditions of pH 11.5, 90 C for 60 minutes at 5% consistency. The beatability of the adsorbed kraft pulps was improved. Also, significant physical strength improvements were achieved. Further study is needed to determine whether the improvements in pulp yield and paper properties make this an economic IFPR concept. Application of the wood solids of a hot water extract of Acer rubrum wood strands as a substitute for polystyrene used for production of SMC maintained the water adsorption properties of the final product. Further work on the physical properties of the hemicellulose containing SMCs need to be completed to determine the potential of wood extracts for the production of partially renewable SMCs. The discovery of the “near-neutral” green liquor extraction process for hardwood was formed the basis for a commercial Integrated Biorefinery that will extract hemicelluloses from wood chips to make biofuels and other specialty chemicals. The pulp production process will be maintained as is proposed in the present researched IFBR concept. This Integrated Biorefinery will be constructed by Red Shield Acquisition LLC (RSA) at the Old Town kraft pulp mill in Maine. RSA in collaboration with the University of Maine will develop and commercialize the hemicellulose extraction process, the conversion of the hemicellulose sugars into butanol by fermentation, and the separation of specialty chemicals such as acetic acid from the extract. When operating the facility will produce 1.5 million gallons per year of butanol and create 16 new “green collar” jobs. Previously, a spare pulp digester was converted to a new extractor, and in 2009 it was demonstrated that a good hemicellulose extract could be produced, while simultaneously producing market pulp. Since then more than 250 hours of operational experience has been acquired by the mill generating a hemicellulose extract while simultaneously producing market pulp at a scale of 1000 tonnes (OD)/day of mixed northern hardwood chips.

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