Process for making a composition for conversion to lyocell fiber from an alkaline pulp having low average degree of polymerization values

• US 7,083,704 B2
• Filed: 10/10/2001
• Issued: 08/01/2006
• Est. Priority Date: 08/23/1996
• Status: Expired due to Fees

• Current Assignee: International Paper Company
• Original Assignee: Weyerhaeuser Company (Weyerhauser)
• Inventors: Persinger, W. Harvey Jr., Sealey, James E. II, Neogi, Amar N., Luo, Mengkui, Roscelli, Vincent A.
• Primary Examiner(s): HUG, ERIC J
• Application Number:
  US09/975,670
• Publication Number:
  US 20020041961A1
• Time in Patent Office: 1,756 Days
• Field of Search: 162/78, 162/76, 162/79, 162/90, 162 65- 67, 162/63, 162/9, 162/71, 162 87- 91, 162/142, 162/146, 162/150, 162/157.1, 162/157.6, 162/157.7, 428/393, 428/357, 428/364, 428/395, 428/375, 264/203, 264/211.14, 264/211.15, 264/5, 264/187, 811/61, 812/5
• US Class Current: 162/90
• CPC Class Codes: D01D 5/098 with simultaneous stretching
• CPC Class Codes: D01D 5/18 by means of rotating spinnerets
• CPC Class Codes: D01F 2/00 Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
• CPC Class Codes: D21C 3/02 with inorganic bases or alkaline reacting compounds, e.g. sulfate processes
• CPC Class Codes: D21C 9/004 inorganic compounds
• CPC Class Codes: D21C 9/10 Bleaching ; Apparatus therefor
• CPC Class Codes: Y10T 428/23964 U-, V-, or W-shaped or continuous strand, filamentary material
• CPC Class Codes: Y10T 428/29 Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/2965 Cellulosic

Abstract

The present invention provides compositions, useful for making lyocell fibers, having a high hemicellulose content, a low copper number and including cellulose that has a low average degree of polymerization (D.P.) and a narrow molecular weight distribution. Further, the present invention provides processes for making compositions, useful for making lyocell fibers, by contacting an alkaline pulp having a high hemicellulose content of at least about 7% with an oxidant sufficient to reduce the average degree of polymerization to about 200 to 1100 without substantially reducing the hemicellulose content or increasing the copper number of the pulp.

Claims

1. A process for making a composition for conversion to lyocell fiber, said process comprising:

contacting an alkaline pulp comprising cellulose and at least about 7% hemicellulose under alkaline conditions with an amount of an oxidant sufficient to reduce the average degree of polymerization of the cellulose to within the range of from about 200 to about 1100, without substantially reducing the hemicellulose content of the pulp or substantially increasing the copper number.

2. The process of claim 1 wherein said oxidant comprises at least one member of the group consisting of a chemical with a peroxide group, oxygen, chlorine dioxide, ozone and combinations thereof.

3. The process of claim 2 wherein the reduction in the average degree of polymerization of the cellulose occurs in the presence of a ratio of magnesium to transition metals of less than about 50%.

4. The process of claim 1 wherein the hemicellulose content of the pulp is reduced less than about 50%.

5. The process of claim 4 wherein the hemicellulose content of the pulp is reduced less than about 15%.

6. The process of claim 4 wherein the hemicellulose content of the pulp is reduced less than about 5%.

7. The process of claim 1 wherein the copper number increases less than 50%.

8. The process of claim 1 wherein the copper number increases less than about 25%.

9. The process of claim 2 wherein the contacting step further comprises contacting the pulp with an alkali source selected from the group consisting of sodium hydroxide, oxidized white liquor, and unoxidized white liquor.

10. The process of claim 1, wherein the alkaline pulp and oxidant are contacted at a pH greater than about 8.0.

11. The process of claim 1, wherein the contacting step occurs in the substantial absence of an inhibitor to the degradation of the cellulose by the oxidant.