Abstract: The present invention relates to an unbleached pulp product comprising of an unbleached pulp, starch and nanocellulose consisting of nanofibrils and the process of producing the same. The unbleached pulp product has a nanocellulose concentration of between 0.1 wt % to 8.0 wt % and a starch concentration of between 0.1 wt % to 8.0 wt % based on the overall weight of the composition. The nanocellulose is derived from various lignocellulosic biomass such as empty fruit bunches of oil palm and any other suitable lignocellulosic biomass. The nanocellulose is added with starch to a corrugating medium pulp at a prescribed concentration and ratio. The composition is then converted into various pulp products such as molded pulp products, paperboard, coreboard, containerboard, corrugating medium, cardboard, linerboard, board liner or any other structural products. In an embodiment, the unbleached pulp may first be converted into various unbleached pulp products.

Abstract: The invention provides a polymer composition comprising from 50 wt % to 99.9 wt % polymer, from 0.1 wt % to 10 wt % nanocellulose as a first nucleating agent, and from 0.01 wt % to 5 wt % of a second nucleating agent. In some embodiments, the polymer is polylactide, the first nucleating agent is lignin-containing nanocellulose, and the second nucleating agent is a sulfur-containing, oxygenated aromatic molecule. The oxygenated aromatic molecule may be an aromatic sulfonic acid or salt, such as dimethyl 5-sulfoisophthalate. In other embodiments, the sulfur-containing, oxygenated aromatic molecule is lignosulfonic acid. Other variations provide a polymer composition comprising polymer, lignin-containing nanocellulose as a dispersing agent, and additives selected from nucleating agents, compatibilizers, plasticizers, fillers, antioxidants, colorants, or flame retardants.

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: 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: 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: The invention provides a polymer composition comprising from 50 wt % to 99.9 wt % polymer, from 0.1 wt % to 10 wt % nanocellulose as a first nucleating agent, and from 0.01 wt % to 5 wt % of a second nucleating agent. In some embodiments, the polymer is polylactide, the first nucleating agent is lignin-containing nanocellulose, and the second nucleating agent is a sulfur-containing, oxygenated aromatic molecule. The oxygenated aromatic molecule may be an aromatic sulfonic acid or salt, such as dimethyl 5-sulfoisophthalate. In other embodiments, the sulfur-containing, oxygenated aromatic molecule is lignosulfonic acid. Other variations provide a polymer composition comprising polymer, lignin-containing nanocellulose as a dispersing agent, and additives selected from nucleating agents, compatibilizers, plasticizers, fillers, antioxidants, colorants, or flame retardants.

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: 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: 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 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 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: 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 new polystyrene-nanocellulose composite material is disclosed. The composite may contain about 0.01 wt % to about 10 wt %, such as about 0.1 wt % to about 2 wt % of nanocellulose. In some embodiments, the nanocellulose is lignin-coated nanocellulose, such as lignin-coated nanocellulose is obtained from an AVAP® biomass-fractionation process. The nanocellulose may include cellulose nanocrystals and/or cellulose nanofibrils. The polymer composite may be in the form of a polymer melt, or a finished polymer material. The composite is characterized by IZOD impact resistance that is at least 50% (such as 75% or more) higher compared to the polystyrene alone.

Abstract: A polymer-nanocellulose-lignin composite as disclosed comprises a polymer, nanocellulose, and lignin, wherein lignin forms a hydrophobic interface between the polymer and the nanocellulose.

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 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: 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: 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: 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.