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FP6 - 505567
BIOCELSOL - Biotechnological Process for Manufacturing Cellulosic Products with Added Value |
| Contract No: | FP6 - 505567 |
| Source: | Progress Report April 2005 |
Abstract
The Biocelsol project focuses on developing a novel biotechnology-based process for converting cellulose into a variety of shaped items with high value. Realisation of the target is based on the scientific innovation of using safe and biodegradable enzymes instead of toxic and hazardous carbon disulphide (CS2) in order to produce cellulosic regenerated products.
The main goals are divided into scientific and technological objectives. The scientific objective is to understand the enzymatic action on cellulose and its impact on the structure and processability of cellulose. The technological objectives include
The objectives are achieved by studying the changes in properties and super-molecular structure of cellulose due to different treatments, and correlating them to the alkaline solubility and reactivity of treated pulps. Based on the knowledge gathered, the pulp treatments are optimised in order to increase solubility and reactivity as compared to untreated pulp. Dissolving technique and conditions for preparing cellulose solutions from treated pulp are studied and optimised regarding to the solution properties. Coagulation and/or regeneration processes for fibres, films, casings, coatings, sponges, and beads are studied independently and the most potential processes are scaled up to high-lab and pilot scales.
Work performed and results achieved
The Biocelsol project consists of eight workpackages. Research and development work is carried out in WPs 1-5, innovation related issues, knowledge protection, dissemination and exploitation in WP6, demonstrations in WP7 and management in WP8.
The work carried out in WP1 during the reporting period focused on the elucidation of the structure and properties of selected cellulosic pulps and the study of the effects of different pre-treatments and subsequent enzymatic treatments on the structure and properties of the pulps. An additional task was to prepare enzymatically treated pulps for further testing and for the manufacturing of shaped articles and high value products. Different dissolving grade pulps were produced and characterised for the project. Knowledge of the role of mechanical and chemical pre-treatments on the properties of cellulose was generated. The factors affecting the efficiency of various enzymatic treatments in increasing alkali solubility of the native and pretreated pulps were studied. The information and knowledge generated during the reporting period will be exploited in the selection and bio-based modification of a suitable cellulose raw material for further processing in the project. The results obtained will also be exploited in the preparation of scientific papers and presentations.
The work carried out in WP2 during the reporting period focused on the studies and optimisation of dissolution process of Biocelsol pulp, studies on preparation of Biocelsol/viscose solutions, as well as, characterisation of Biocelsol and Biocelsol/viscose solutions. The enzyme-treated pulp was obtained from WP1 and the parameters studied included: temperature of dissolving, solvent concentration, cellulose content, ZnO content, urea content, NaOH content and time of dissolving. Obtained Biocelsol solutions were analysed by viscosity, filterability ( Kw) and insoluble particle content. DPw and DP-distribution of insoluble particles separated from solution was also assessed. On the base of the results obtained the optimal parameters for preparing Biocelsol solutions in laboratory and higher scales were elaborated. The spinning solutions of Biocelsol - viscose blends in composition of 20 - 80 wt% of Biocelsol in viscose were prepared. Spinning solutions were evaluated by rheological measurements using rotation rheoviscosimeter at 0°C and 20°C. Insoluble particles of enzyme-treated cellulose in alkaline spinning solutions were separated and analysed. Viscosity of insoluble particles separated in cuprethylenediamine (CED) were evaluated. Beside, the insoluble part of these particles in CED was investigated. The results obtained will also be exploited in further studies on up-scaling of the solution preparation to be applied in the forming of films, fibres and casings.
WP 3 focuses on developing processes for manufacturing different kind of fibres from enzyme-treated pulp and studying the applicability of the obtained fibres for further processes. Materials and methods for preparing alkaline solutions were delivered by WP1 and WP2. During the reporting period optimisation of wet and electrospinning processes were started. Important parameters, others as known from the viscose fibre spinning, were revealed to affect the fibre properties. The tenacity of the fibres were improved by 42% from the starting point. The work will continue focusing on the fibre tenacity of 2.7 cN/dtex, as well as developing fibres suitable for different end-uses.
The work carried out in WP4 during the reporting period focused on studies on optimisation of film forming in lab scale from selected Biocelsol solutions. The effect of different coagulation bath as well as different finishing agents on properties of films were examined. Mechanical properties of cellulose films obtained were determined according to ISO Standards. Series of Biocelsol-viscose blend films with varying content of Biocelsol in regenerated cellulose were prepared and evaluated by mechanical and physical properties, water swelling properties, as well as by the light transmission. Preliminary trials to make sheets of Biocelsol for the production of casings were made. The results obtained will be exploited in further studies on up-scaling of film and casings forming.
The aim of WP5 is to develop a coagulation technique and apparatus to obtain cellulose sponges and beads from Biocelsol and/or from blends of Biocelsol and viscose solutions. As well as, to produce sponges and beads that are bio-compatible, and thus may be used in various medical and clinical applications. The tasks during the reporting period focused on completing the equipment available for preparing sponges and beads, developing the process for beads production, testing and evaluating the different process parameters, and producing sponges and beads on a laboratory scale under reliable and repeatable conditions. The equipment for beads production was completed and tested with viscose using varying parameters. The tests focused on different atomisers and rotational speeds of atomisers. The resulting beads were analysed for their size, size distribution and form, as well as, for their flow abilities and degree of packing. The results show logical trends and proved that the process is now ready for the production of beads with adjustable features. The results achieved together with a dimensional analysis will be used to provide a simplification of the true running conditions, which may save experimental work.
The sponge production with viscose as such is a known process. During the reporting period the equipment was upgraded and a crystallisation apparatus developed and tested. The sodium sulfate crystals are needed for preparation of the sponges. The equipment is now completed for further tests with Biocelsol solutions.
Expected end results, intentions for use and impacts
It is expected that understanding of the enzymatic action on cellulose and its impact on the structure and processability of cellulose is improved due to Biocelsol project. The knowledge could be used for applying enzymes to various other processes than studied in this project to modify cellulose or cellulose fibres and/or to replace chemicals. Development of new type of enzymes may also take place.
By the end of the Biocelsol project, the research groups are expected to develop novel biotechnology-based laboratory-scale processes for converting cellulose into a variety of shaped items with decreased environmental and health impact as compared to the viscose process. The most successful processes are demonstrated in high-lab, pilot- and/or industrial-scale, and new cellulosic products with built-in functional properties are developed from enzyme-treated cellulose.
It is also expected that the participating companies would
Moreover, it is expected that a strong network between the research institutions and industry has been developed opening new co-operation possibilities in the field of cellulose research for utilising this most common renewable raw material.
Plan for using and disseminating the knowledge
During the first project year, the consortium has disseminated information on the project in various ways through different channels. In the beginning of the project, the partners wrote together a publishable document "Project presentation" (Deliverable 1), which describes the project generally and which has been used in a range of events to disseminate information on the objectives and contents of the project work. After the first project year, the research and innovation work is in progress. The consortium is not yet ready to publicise any exploitable results.
The IPR protection measures and publications are expected to take place mainly in the end of the project.
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