Abstract: Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with surprisingly low mechanical energy input. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and mechanically treating the cellulose-rich solids to form nanofibrils and/or nanocrystals. The crystallinity of the nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites. The nanocellulose material may include nanofibrillated cellulose, nanocrystalline cellulose, or both. In some embodiments, the nanocellulose material is hydrophobic via deposition of some lignin onto the cellulose surface. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers.

Abstract: The present invention provides a process for producing a nanocellulose material, comprising: fractionating a lignocellulosic biomass feedstock in the presence of a solvent for lignin and water, but no acid catalyst, to generate cellulose-rich solids; and then mechanically treating the cellulose-rich solids to form a nanocellulose material comprising cellulose nanofibrils and/or cellulose nanocrystals. Many organic or inorganic solvents are possible. In some embodiments, the solvent for lignin is an oxygenated organic compound, such as a C1-C18 alcohol, e.g. ethanol, ethylene glycol, propanol, propanediol, glycerol, butanol, or butanediol. The solvent for lignin may be an aromatic alcohol, such as phenol, cresol, or benzyl alcohol. The solvent for lignin may be a ketone, an aldehyde, or an ether, such as methyl ethyl ketone or diethyl ether. The solvent for lignin may be a non-oxygenated alkane, olefin, or aromatic hydrocarbon. In some embodiments, the solvent for lignin is an ionic liquid.

Abstract: Some variations provide a new nanolignocellulose composition comprising, on a bone-dry, ash-free, and acetyl-free basis, from 35 wt % to 80 wt % cellulose nanofibrils, cellulose microfibrils, or a combination thereof, from 15 wt % to 45 wt % lignin, and from 5 wt % to 20 wt % hemicelluloses. The hemicelluloses may contain xylan or mannan as the major component. Novel properties arise from the hemicellulose content that is intermediate between high hemicellulose content of raw biomass and low hemicellulose content of conventional nanocellulose. The nanolignocellulose composition is hydrophobic due to the presence of lignin. Processes for making and using the nanolignocellulose compositions are also described.

Abstract: An oleophilic and hydrophobic nanocellulose material is disclosed herein, for nanocellulose sponges and other applications. The oleophilic and hydrophobic nanocellulose material comprises lignin-coated cellulose nanofibrils and/or lignin-coated cellulose nanocrystals. In various embodiments, the nanocellulose material is in the form of a 2D coating or layer, or a 3D object (e.g., foam or aerogel). The nanocellulose material may be disposed onto a scaffold.

Abstract: Processes disclosed are capable of converting biomass into high-crystallinity, hydrophobic cellulose. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and depositing lignin onto cellulose fibers to produce lignin-coated cellulose materials (such as dissolving pulp). The crystallinity of the cellulose material may be 80% or higher, translating into good reinforcing properties for composites. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the hydrophobic cellulose to form completely renewable composites.

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® 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.

Abstract: A composition comprising nanocellulose is disclosed, wherein the nanocellulose contains very low or essentially no sulfur content. The nanocellulose may be in the form of cellulose nanocrystals, cellulose nanofibrils, or both. The nanocellulose is characterized by a crystallinity of at least 80%, an onset of thermal decomposition of 300° F. or higher, and a low light transmittance over the range 400-700 nm. Other variations provide a composition comprising lignin-coated hydrophobic nanocellulose, wherein the nanocellulose contains very low or essentially no sulfur content. Some variations provide a composition comprising nanocellulose, wherein the nanocellulose contains about 0.1 wt % equivalent sulfur content, or less, as SO4 groups chemically or physically bound to the nanocellulose. In some embodiments, the nanocellulose contains essentially no hydrogen atoms (apart from hydrogen structurally contained in nanocellulose itself) bound to the nanocellulose.

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® 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.

Abstract: What is disclosed is a biorefining process to co-produce xylitol with ethanol or other products. In some variations, a process for producing ethanol and xylitol from lignocellulosic biomass, comprises: extracting hemicelluloses from lignocellulosic biomass, wherein the hemicelluloses include xylose oligomers and other sugar oligomers; hydrolyzing the xylose oligomers and the other sugar oligomers, using an acid catalyst or enzymes, to generate xylose and other sugar monomers, respectively; fermenting the other sugar monomers to ethanol using a suitable ethanol-producing microorganism; removing at least some of the ethanol (to increase concentration of xylose); fermenting the xylose to xylitol using a suitable xylitol-producing microorganism; and recovering the xylitol at high concentration.

Abstract: An oleophilic and hydrophobic nanocellulose material is disclosed herein, for nanocellulose sponges and other applications. The oleophilic and hydrophobic nanocellulose material comprises lignin-coated cellulose nanofibrils and/or lignin-coated cellulose nanocrystals. In various embodiments, the nanocellulose material is in the form of a 2D coating or layer, or a 3D object (e.g., foam or aerogel). The nanocellulose material may be disposed onto a scaffold.

Abstract: A composition comprising nanocellulose is disclosed, wherein the nanocellulose contains very low or essentially no sulfur content. The nanocellulose may be in the form of cellulose nanocrystals, cellulose nanofibrils, or both. The nanocellulose is characterized by a crystallinity of at least 80%, an onset of thermal decomposition of 300° F. or higher, and a low light transmittance over the range 400-700 nm. Other variations provide a composition comprising lignin-coated hydrophobic nanocellulose, wherein the nanocellulose contains very low or essentially no sulfur content. Some variations provide a composition comprising nanocellulose, wherein the nanocellulose contains about 0.1 wt % equivalent sulfur content, or less, as SO4 groups chemically or physically bound to the nanocellulose. In some embodiments, the nanocellulose contains essentially no hydrogen atoms (apart from hydrogen structurally contained in nanocellulose itself) bound to the nanocellulose.

Abstract: The present invention provides a pulp product (e.g., paper) comprising cellulose and nanocellulose, wherein the nanocellulose is derived from the cellulose in a mechanical and/or chemical step that is separate from the main pulping process. The pulping process may be thermomechanical pulping or hydrothermal-mechanical pulping, for example. The pulp product is stronger and smoother with the presence of the nanocellulose. The nanocellulose further can function as a retention aid, for a step of forming the pulp product (e.g., in a paper machine). Other embodiments provide a corrugated medium pulp composition comprising cellulose pulp and nanocellulose, wherein the nanocellulose includes cellulose nanofibrils and/or cellulose nanocrystals and the nanocellulose may be hydrophobic. The nanocellulose improves the strength properties of the corrugated medium. In some embodiments, the cellulose pulp is a GreenBox+® pulp and the nanocellulose is derived from the AVAP® process.

Abstract: In some variations, the invention provides a process for producing a microcrystalline cellulose material, comprising: fractionating lignocellulosic biomass 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; chemically and/or mechanically treating the cellulose-rich solids to form microcrystalline cellulose having an average crystallinity of at least 60%; and recovering the microcrystalline cellulose as a pharmaceutical excipient. The pharmaceutical excipient may function as an antiadherent, a binder, a coating, or a disintegrant. In some embodiments, the pharmaceutical excipient further comprises a lignin-derived lubricant, glidant, sorbent, preservative, or other component. The pharmaceutical excipient may be present in a pill, tablet, capsule, powder, slurry, or other pharmaceutically effective and acceptable form.

Abstract: A low-cost process is provided to render lignocellulosic biomass accessible to cellulase enzymes, to produce fermentable sugars. Some variations provide a process to produce ethanol from lignocellulosic biomass (such as sugarcane bagasse or corn stover), comprising introducing a lignocellulosic biomass feedstock to a single-stage digestor; exposing the feedstock to a reaction solution comprising steam or liquid hot water within the digestor, to solubilize the hemicellulose in a liquid phase and to provide a cellulose-rich solid phase; refining the cellulose-rich solid phase, together with the liquid phase, in a mechanical refiner, thereby providing a mixture of refined cellulose-rich solids and the liquid phase; enzymatically hydrolyzing the mixture in a hydrolysis reactor with cellulase enzymes, to generate fermentable sugars; and fermenting the fermentable sugars to produce ethanol. Many alternative process configurations are described.

Abstract: A method of enzymatically hydrolyzing pretreated lignocellulosic biomass at high solids concentration includes introducing pretreated biomass to a hydrolysis reactor, to hydrolyze the cellulose to glucose monomer and glucose oligomers, and circulating a liquid stream, from which glucose is removed to reduce glucose inhibition of cellulose hydrolysis. A surfactant may be added to the hydrolysis reactor. Heat and/or acid treatment of the glucose oligomers may be used to generate additional glucose monomer. Some variations introduce pretreated biomass to a hydrolysis reactor to hydrolyze cellulose to glucose monomer and glucose oligomers, followed by conveying a portion of the solid phase to a mechanical refiner and/or a unit under reduced pressure, to generate a refined and/or exploded solid phase; and recycling the refined and/or exploded solid phase, optionally reheated, back to an input of the hydrolysis reactor.

Abstract: The present invention provides a pulp product (e.g., paper) comprising cellulose and nanocellulose, wherein the nanocellulose is derived from the cellulose in a mechanical and/or chemical step that is separate from the main pulping process. The pulping process may be thermomechanical pulping or hydrothermal-mechanical pulping, for example. The pulp product is stronger and smoother with the presence of the nanocellulose. The nanocellulose further can function as a retention aid, for a step of forming the pulp product (e.g., in a paper machine). Other embodiments provide a corrugated medium pulp composition comprising cellulose pulp and nanocellulose, wherein the nanocellulose includes cellulose nanofibrils and/or cellulose nanocrystals and the nanocellulose may be hydrophobic. The nanocellulose improves the strength properties of the corrugated medium. In some embodiments, the cellulose pulp is a GreenBox+® pulp and the nanocellulose is derived from the AVAP® process.

Abstract: In some variations, the invention provides a process for producing a microcrystalline cellulose material, comprising: fractionating lignocellulosic biomass 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; chemically and/or mechanically treating the cellulose-rich solids to form microcrystalline cellulose having an average crystallinity of at least 60%; and recovering the microcrystalline cellulose as a pharmaceutical excipient. The pharmaceutical excipient may function as an antiadherent, a binder, a coating, or a disintegrant. In some embodiments, the pharmaceutical excipient further comprises a lignin-derived lubricant, glidant, sorbent, preservative, or other component. The pharmaceutical excipient may be present in a pill, tablet, capsule, powder, slurry, or other pharmaceutically effective and acceptable form.

Abstract: The present invention provides a process for producing a nanocellulose material, comprising: fractionating a lignocellulosic biomass feedstock in the presence of a solvent for lignin and water, but no acid catalyst, to generate cellulose-rich solids; and then mechanically treating the cellulose-rich solids to form a nanocellulose material comprising cellulose nanofibrils and/or cellulose nanocrystals. Many organic or inorganic solvents are possible. In some embodiments, the solvent for lignin is an oxygenated organic compound, such as a C1-C18 alcohol, e.g. ethanol, ethylene glycol, propanol, propanediol, glycerol, butanol, or butanediol. The solvent for lignin may be an aromatic alcohol, such as phenol, cresol, or benzyl alcohol. The solvent for lignin may be a ketone, an aldehyde, or an ether, such as methyl ethyl ketone or diethyl ether. The solvent for lignin may be a non-oxygenated alkane, olefin, or aromatic hydrocarbon. In some embodiments, the solvent for lignin is an ionic liquid.

Abstract: A process for the production of cellulose, lignocellulosic sugars, lignosulfonate, and ethanol from lignocellulosic biomass. The process comprises steaming, pretreatment, chemical recovery, saccharification, and optionally fermentation. The pretreatment conditions use only sulfur dioxide and water, simultaneously resulting in high glucan conversion to glucose at low enzyme charges, high recovery of hemicellulose-derived monomeric sugars, high lignosulfonate yield, and the absence of lignin precipitates. High-yield production of ethanol through fermentation can be obtained using this process.

Abstract: Processes disclosed are capable of converting biomass into high-crystallinity, hydrophobic cellulose. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and depositing lignin onto cellulose fibers to produce lignin-coated cellulose materials (such as dissolving pulp). The crystallinity of the cellulose material may be 80% or higher, translating into good reinforcing properties for composites. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the hydrophobic cellulose to form completely renewable composites.