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: Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with low mechanical energy input. In some variations, the process includes fractionating biomass with sulfur dioxide or a sulfite compound 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 total mechanical energy may be less than 500 kilowatt-hours per ton. 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: Nanocellulose dispersion compositions containing a partitioning agent and a nanocellulose, and methods of making the nanocellulose dispersion compositions, are disclosed. These compositions can promote improved dispersibility of the nanocellulose fibrils and nanocellulose crystals in polymer matrices, such as in elastomer formulations for use in tire production.

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: Various processes are disclosed for producing nanocellulose materials following steam extraction or hot-water digestion of biomass. Processes are also disclosed for producing nanocellulose materials from a wide variety of starting pulps or pretreated biomass feedstocks. The nanocellulose materials may be used as rheology modifiers in many applications. Water-based and oil-based drilling fluid formulations and additives are provided. Also, water-based and oil-based hydraulic fracturing fluid formulations and additives are provided. In other embodiments, polymer-nanocellulose composites are provided.

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 present invention provides an oil-resistant paperboard material coated with hydrophobic nanocellulose. The paperboard material is free of a fluorocarbon coating. In other variations, an oil-resistant paper is coated with hydrophobic nanocellulose and is free of a fluorocarbon coating. The hydrophobic nanocellulose may include lignin-coated cellulose nanofibrils, lignin-coated cellulose nanocrystals, or a combination thereof.

Abstract: Some variations provide a process for producing a nanocellulose material, comprising: providing a biomass feedstock comprising a bleached or unbleached pulp material; 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; and mechanically treating the cellulose-rich solids to form cellulose fibrils and/or cellulose crystals, thereby generating a nanocellulose material. The process is preferably co-located with, or adjacent to, a mill that generates the pulp material. There are several advantages of a bolt-on AVAP® nanocellulose plant to an existing pulp mill, as disclosed herein.

Abstract: The present invention allows the production of nanocellulose in dry form, enabling incorporation into a wide variety of end-use applications. Some variations provide a nanocellulose-slurry dewatering system comprising: a nanocellulose slurry feed sub-system; a pre-concentration unit (e.g., a centrifuge) to remove at least a portion of the water from the nanocellulose slurry; an inlet for a dispersion/drying agent; a twin-screw extruder in flow communication with the nanocellulose slurry feed sub-system, wherein the twin-screw extruder intimately mixes the nanocellulose slurry and the dispersion/drying agent, wherein the twin-screw extruder shears the nanocellulose slurry, and wherein the twin-screw extruder is configured with one or more extruder vents to remove water from the nanocellulose slurry; and an extruder outlet for recovering a nanocellulose-dispersion concentrate. A milling device may be employed to generate a fine powder of the nanocellulose-dispersion concentrate.

Abstract: In some variations, a process for converting a biomass feedstock into a pretreated biomass material comprises: providing a biomass feedstock containing cellulose, hemicellulose, and lignin; introducing the biomass feedstock and a recycled vapor stream to a biomass-heating unit, thereby generating a heated biomass stream at a first temperature, wherein the recycled vapor stream is at a first pressure of at least atmospheric pressure; feeding the heated biomass stream to a biomass digestor operated at a second temperature and a second pressure to pretreat the biomass feedstock, thereby generating a digested stream comprising a solid-liquid mixture and a digestor vapor, wherein the second temperature is higher than the first temperature, and wherein the second pressure is higher than the first pressure; recycling at least a portion of the digestor vapor to the biomass-heating unit; and recovering or further processing the solid-liquid mixture as a pretreated biomass material. Many variations are disclosed.

Abstract: In some variations, OCC is screened, cleaned, deinked, and mechanically refined to generate cellulose nanofibrils. The OCC may be subjected to further chemical, physical, or thermal processing, prior to mechanical refining. For example, the OCC may be subjected to hot-water extraction, or fractionation with an acid catalyst, a solvent for lignin, and water. In certain embodiments to produce cellulose nanocrystals, OCC is exposed to AVAP® digestor conditions. The resulting pulp is optionally bleached and is mechanically refined to generate cellulose nanocrystals. In certain embodiments to produce cellulose nanofibrils, OCC is exposed to GreenBox+® digestor conditions. The resulting pulp is mechanically refined to generate cellulose nanofibrils. The site of a system to convert OCC to nanocellulose may be co-located with an existing OCC processing site. The nanocellulose line may be a bolt-on retrofit system to existing infrastructure.

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: 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: This disclosure provides a polymer composite including a polymer, nanocellulose, and a compatibilizer, wherein the nanocellulose comprises cellulose nanocrystals and/or cellulose nanofibrils, and wherein the compatibilizer comprises a maleated polymer. In some embodiments, the nanocellulose includes lignin-coated nanocellulose. The polymer may be selected from polyethylene, polypropylene, polystyrene, polylactide, or poly(ethylene terephthalate). The maleated polymer may be selected from maleated polyethylene, maleated polypropylene, maleated polystyrene, maleated polylactide, or maleated poly(ethylene terephthalate.

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: Nanocellulose dispersion compositions containing a partitioning agent and a nanocellulose, and methods of making the nanocellulose dispersion compositions, are disclosed. These nanocellulose dispersion compositions can be used in tire formulations with carbon black and a suitable elastomer to produce articles of manufacture for use in tire and tread applications.