High yield and enhanced performance fiber

Abstract

A method of wood pulping having a significantly increased yield is disclosed. Wood chips are chemically pulped to a high kappa number, providing a first accepts component and a first rejects component. The first rejects component is subjected to a high consistency pulping process such as a substantially mechanical pulping process to generate a second accepts component and a second rejects component. The first accepts component may be used in the production of saturating kraft paper with excellent saturability and resin pick up. The second accepts may be used as a second fiber source in the production of multiply linerboard and unbleached paperboard with enhanced stiffness, strength, and smoothness. Alternatively, the first accepts component may be blended with the second accepts component to produce fiber blends, which may be used in a production of paper-based products having enhanced strength and stiffness at low basis weight.

1 . A method of wood pulping, comprising steps of:
 (a) chemically pulping wood chips to generate a first amount of pulp including a first accepts component and a first rejects component;   (b) separating the first accepts component from the first rejects component;   (c) performing a high consistency, substantially mechanical pulping of the first rejects component to generate a second amount of pulp including a second accepts component and a second rejects component; and   (d) separating the second accepts component from the second rejects component.   
   
   
       2 . The method of  claim 1 , wherein the chemically pulping in step (a) comprises a step of chemically pulping the wood chips to a kappa number of at least 30. 
   
   
       3 . The method of  claim 2 , wherein the wood chips comprise softwood. 
   
   
       4 . The method of  claim 1 , wherein the chemically pulping in step (a) comprises a step of chemically pulping the wood chips to a kappa number of at least 20. 
   
   
       5 . The method of  claim 4 , wherein the wood chips comprise a member selected from the group consisting of hardwood, eucalyptus, and combinations thereof. 
   
   
       6 . The method of  claim 1 , wherein the chemical pulping in step (a) comprises a chemical pulping process selected from the group consisting of kraft pulping, soda pulping, and sulfite pulping. 
   
   
       7 . The method of  claim 1 , wherein the first amount of pulp includes a first weight associated therewith, wherein the first rejects component includes a first weight associated therewith, and wherein the ratio of the first weight of the first rejects component to the first weight of the first amount of pulp comprises about 6% to about 50%. 
   
   
       8 . The method of  claim 1 , wherein the first amount of pulp includes a first weight associated therewith, wherein the first rejects component includes a first weight associated therewith, and wherein the ratio of the first weight of the first rejects component to the first weight of the first amount of pulp comprises about 30% to about 35%. 
   
   
       9 . The method of  claim 1 , wherein the separating step in step (b) comprises a step of passing the first amount of pulp through a screen to separate the first accepts component from the first rejects component. 
   
   
       10 . The method of  claim 1 , wherein the high consistency, substantially mechanical pulping comprises a pulping process selected from the group consisting of mechanical pulping, alkaline peroxide mechanical pulping, alkaline thermomechanical pulping, thermomechanical pulping, and chemi-thermomechanical pulping. 
   
   
       11 . The method of  claim 1 , wherein the high consistency, substantially mechanical pulping comprises steps of:
 (11.1) refining the first rejects component; and   (11.2) pre-bleaching the first rejects component.   
   
   
       12 . The method of  claim 1 , wherein the high consistency, substantially mechanical pulping comprises steps of:
 (12.1) refining the first rejects component;   (12.2) pre-bleaching the first rejects component; and   (12.3) retaining the first rejects component treated at the steps (12.1) and (12.2) for a predetermined time period.   
   
   
       13 . The method of  claim 1 , wherein the separating step in step (d) comprises a step of passing the second amount of pulp through a screen to separate the second accepts component from the second rejects component. 
   
   
       14 . The method of  claim 1 , further comprising a step of processing the first accepts component for a production of saturating kraft paper. 
   
   
       15 . The method of  claim 1 , further comprising a step of processing the second accepts component for a production of multiply linerboard. 
   
   
       16 . The method of  claim 1 , further comprising a step of using the second accepts component as a second fiber source for a production of multiply linerboard. 
   
   
       17 . The method of  claim 1 , further comprising a step of processing the second accepts component for a production of paperboard. 
   
   
       18 . The method of  claim 1 , further comprising a step of combining the second rejects component with the first rejects component before further processing. 
   
   
       19 . The method of  claim 1 , further comprising a step of combining the second accepts component with the first accepts component to generate a fiber blend. 
   
   
       20 . The method of  claim 19 , wherein the fiber blend includes a first weight associated therewith, wherein the first accepts component includes a first weight associated therewith, and wherein the ratio of the first weight of the first accepts component to the first weight of the fiber blend comprises about 50% to about 90%. 
   
   
       21 . The method of  claim 19 , wherein the fiber blend includes a first weight associated therewith, wherein the first accepts component includes a first weight associated therewith, and wherein the ratio of the first weight of the first accepts component to the first weight of the fiber blend comprises about 65% to about 75%. 
   
   
       22 . The method of  claim 19 , wherein the wood chips have a weight associated therewith, wherein the combined the fiber blend has a weight associated therewith, and wherein the weight of the combined the fiber blend is at least 45% of the weight of the wood chips. 
   
   
       23 . The method of  claim 19 , further comprising a step of bleaching the fiber blend. 
   
   
       24 . The method of  claim 19 , further comprising a step of processing the fiber blend for a production of a paper-based product. 
   
   
       25 . A fiber blend produced by the method of  claim 19 . 
   
   
       26 . A saturating kraft paper, comprising the first accepts component produced by the method of  claim 1 . 
   
   
       27 . A multiply linerboard, comprising the second accepts component produced by the method of  claim 1 . 
   
   
       28 . A multiply linerboard, wherein one ply of the linerboard include the second accepts component produced by the method of  claim 1 . 
   
   
       29 . A paperboard, comprising the second accepts component produced by the method of  claim 1 . 
   
   
       30 . A paper-based product, comprising the fiber blend produced by the method of  claim 19 . 
   
   
       31 . A packaging material, including the paper-based product of  claim 30 . 
   
   
       32 . A method of wood pulping, comprising steps of:
 (a) chemically processing wood chips to a predetermined kappa number to produce a first amount of pulp including a first accepts component and a first rejects component, wherein the first rejects component comprises more than 30% of the first amount of pulp;   (b) separating the first accepts component from the first rejects component;   (c) performing a high consistency, substantially mechanical pulping of the first rejects component to generate a second amount of pulp including a second accepts component and a second rejects component; and   (d) separating the second accepts component from the second rejects component.   
   
   
       33 . The method of  claim 32 , wherein the predetermined kappa number for the chemical pulping in step (a) is at least about 30. 
   
   
       34 . The method of  claim 33 , wherein the wood chips comprise softwood. 
   
   
       35 . The method of  claim 32 , wherein the predetermined kappa number for the chemical pulping in step (a) is at least about 20. 
   
   
       36 . The method of  claim 35 , wherein the wood chips comprise a member selected from the group consisting of hardwood, eucalyptus, and combinations thereof. 
   
   
       37 . The method of  claim 32 , wherein the chemical pulping in step (a) comprises a chemical pulping process selected from the group consisting of kraft pulping, soda pulping, and sulfite pulping. 
   
   
       38 . The method of  claim 32 , wherein the separating step in step (b) comprises a step of passing the first amount of pulp through a screen to separate the first accepts component from the first rejects component. 
   
   
       39 . The method of  claim 32 , wherein the high consistency, substantially mechanical pulping comprises a pulping process selected from the group consisting of mechanical pulping, alkaline peroxide mechanical pulping, alkaline thermomechanical pulping, thermomechanical pulping, and chemi-thermomechanical pulping. 
   
   
       40 . The method of  claim 32 , wherein the high consistency, substantially mechanical pulping comprises steps of:
 (40.1) refining the first rejects component; and   (40.2) pre-bleaching the first rejects component.   
   
   
       41 . The method of  claim 32 , wherein the high consistency, substantially mechanical pulping comprises steps of:
 (41.1) refining the first rejects component;   (41.2) pre-bleaching the first rejects component; and   (41.3) retaining the first rejects component treated at the steps (41.1) and (42.2) for a predetermined time period.   
   
   
       42 . The method of  claim 32 , wherein the separating step in step (d) comprises a step of passing the second amount of pulp through a screen to separate the second accepts component from the second rejects component. 
   
   
       43 . The method of  claim 32 , further comprising a step of processing the first accepts component for a production of saturating kraft paper. 
   
   
       44 . The method of  claim 32 , further comprising a step of processing the second accepts component for a production of multiply linerboard. 
   
   
       45 . The method of  claim 32 , further comprising a step of using the second accepts component as a second fiber source for a production of multiply linerboard. 
   
   
       46 . The method of  claim 32 , further comprising a step of processing the second accepts component for a production of paperboard. 
   
   
       47 . The method of  claim 32 , further comprising a step of combining the second rejects component with the first rejects component before further processing. 
   
   
       48 . The method of  claim 32 , further comprising a step of combining the second accepts component with the first accepts component to generate a fiber blend. 
   
   
       49 . The method of  claim 48 , wherein the fiber blend includes a first weight associated therewith, wherein the first accepts component includes a first weight associated therewith, and wherein the ratio of the first weight of the first accepts component to the first weight of the fiber blend comprises about 50% to about 90%. 
   
   
       50 . The method of  claim 48 , wherein the fiber blend includes a first weight associated therewith, wherein the first accepts component includes a first weight associated therewith, and wherein the ratio of the first weight of the first accepts component to the first weight of the fiber blend comprises about 65% to about 75%. 
   
   
       51 . The method of  claim 48 , wherein the wood chips have a weight associated therewith, wherein the combined the fiber blend has a weight associated therewith, and wherein the weight of the combined the fiber blend is at least 45% of the weight of the wood chips. 
   
   
       52 . The method of  claim 48 , further comprising a step of bleaching the fiber blend. 
   
   
       53 . The method of  claim 48 , further comprising a step of processing the fiber blend for a production of a paper-based product. 
   
   
       54 . A fiber blend produced by the method of  claim 48 . 
   
   
       55 . A saturating kraft paper, comprising the first accepts component produced by the method of  claim 32 . 
   
   
       56 . A multiply linerboard, comprising the second accepts component produced by the method of  claim 32 . 
   
   
       57 . A multiply linerboard, wherein one ply of the linerboard include the second accepts component produced by the method of  claim 32 . 
   
   
       58 . A paperboard, comprising the second accepts component produced by the method of  claim 32 . 
   
   
       59 . A paper-based product, comprising the fiber blend produced by the method of claim  48 . 
   
   
       60 . A packaging material, including the paper-based product of  claim 59 . 
   
   
       61 . A method of wood pulping comprising steps of:
 (a) chemically pulping wood chips to generate a first amount of pulp including a first accepts component and a first rejects component;   (b) separating the first accepts component from the first rejects component;   (c) pulping the first rejects component at a high consistency to generate a second amount of pulp including a second accepts component and a second rejects component, and   (d) separating the second accepts component from the second rejects component;   characterized by a pulp yield of at least 8% higher than a pulp yield of a chemical pulping using same wood chips.   
   
   
       62 . The method of  claim 61 , wherein the chemical pulping in step (a) comprises a step of chemically pulping the wood chips to a kappa number of at least 30. 
   
   
       63 . The method of  claim 62 , wherein the wood chips comprise softwood. 
   
   
       64 . The method of  claim 61 , wherein the chemical pulping in step (a) comprises a step of chemically pulping the wood chips to a kappa number of at least 20. 
   
   
       65 . The method of  claim 64 , wherein the wood chips comprise a member selected from the group consisting of hardwood, eucalyptus, and combinations thereof. 
   
   
       66 . The method of  claim 61 , wherein the chemical pulping in step (a) comprises a chemical pulping process selected from the group consisting of kraft pulping, soda pulping, and sulfite pulping. 
   
   
       67 . The method of  claim 61 , wherein the first amount of pulp includes a first weight associated therewith, wherein the first rejects component includes a first weight associated therewith, and wherein the ratio of the first weight of the first rejects component to the first weight of the first amount of pulp comprises about 6% to about 50%. 
   
   
       68 . The method of  claim 61 , wherein the first amount of pulp includes a first weight associated therewith, wherein the first rejects component includes a first weight associated therewith, and wherein the ratio of the first weight of the first rejects component to the first weight of the first amount of pulp comprises about 30% to about 35%. 
   
   
       69 . The method of  claim 61 , wherein the separating step in step (b) comprises a step of passing the first amount of pulp through a screen to separate the first accepts component from the first rejects component. 
   
   
       70 . The method of  claim 61 , wherein the high consistency pulping in step (c) comprises a pulping process selected from the group consisting of mechanical pulping, alkaline peroxide mechanical pulping, alkaline thermomechanical pulping, thermomechanical pulping, and chemi-thermomechanical pulping. 
   
   
       71 . The method of  claim 61 , wherein the high consistency pulping in step (c) comprises steps of:
 (71.1) refining the first rejects component; and   (71.2) pre-bleaching the first rejects component.   
   
   
       72 . The method of  claim 61 , wherein the high consistency pulping in step (c) comprises steps of:
 (72.1) refining the first rejects component;   (72.2) pre-bleaching the first rejects component; and   (72.3) retaining the first rejects component treated at the steps (72.1) and (72.2) for a predetermined time period.   
   
   
       73 . The method of  claim 61 , wherein the separating step in step (d) comprises a step of passing the second amount of pulp through a screen to separate the second accepts component from the second rejects component. 
   
   
       74 . The method of  claim 61 , further comprising a step of processing the first accepts component for a production of saturating kraft paper. 
   
   
       75 . The method of  claim 61 , further comprising a step of processing the second accepts component for a production of multiply linerboard. 
   
   
       76 . The method of  claim 61 , further comprising a step of using the second accepts component as a second fiber source for a production of multiply linerboard. 
   
   
       77 . The method of  claim 61 , further comprising a step of processing the second accepts component for a production of paperboard. 
   
   
       78 . The method of  claim 61 , further comprising a step of combining the second rejects component with the first rejects component before further processing. 
   
   
       79 . The method of  claim 61 , further comprising a step of combining the second accepts component with the first accepts component to generate a fiber blend. 
   
   
       80 . The method of  claim 79 , wherein the fiber blend includes a first weight associated therewith, wherein the first accepts component includes a first weight associated therewith, and wherein the ratio of the first weight of the first accepts component to the first weight of the fiber blend comprises about 50% to about 90%. 
   
   
       81 . The method of  claim 79 , wherein the fiber blend includes a first weight associated therewith, wherein the first accepts component includes a first weight associated therewith, and wherein the ratio of the first weight of the first accepts component to the first weight of the fiber blend comprises about 65% to about 75%. 
   
   
       82 . The method of  claim 79 , wherein the wood chips have a weight associated therewith, wherein the combined the fiber blend has a weight associated therewith, and wherein the weight of the combined the fiber blend is at least 45% of the weight of the wood chips. 
   
   
       83 . The method of  claim 79 , further comprising a step of bleaching the fiber blend. 
   
   
       84 . The method of  claim 79 , further comprising a step of processing the fiber blend for a production of a paper-based product. 
   
   
       85 . A fiber blend produced by the method of  claim 79 . 
   
   
       86 . A saturating kraft paper, comprising the first accepts component produced by the method of  claim 61 . 
   
   
       87 . A multiply linerboard, comprising the second accepts component produced by the method of  claim 61 . 
   
   
       88 . A multiply linerboard, wherein one ply of the linerboard include the second accepts component produced by the method of  claim 61 . 
   
   
       89 . A paperboard, comprising the second accepts component produced by the method of  claim 61 . 
   
   
       90 . A paper-based product, comprising the fiber blend produced by the method of  claim 79 . 
   
   
       91 . A packaging material, including the paper-based product of  claim 90 . 
   
   
       92 . A fiber blend, characterized by a fiber length distribution containing at least 2 weight percent of long fibers as defined by a 14 mesh-size screen of a Bauer-McNett classifier and at least 15 weight percent of short fibers as defined by a 200 mesh-size screen of a Bauer-McNett classifier. 
   
   
       93 . A paper-based product including a fiber blend, wherein a fiber length distribution of the fiber blend contains at least 2 weight percent of long fibers as defined by a 14 mesh-size screen of a Bauer-McNett classifier and at least 15 weight percent of short fibers as defined by a 200 mesh-size screen of a Bauer-McNett classifier. 
   
   
       94 . A paper-based product, characterized by a stiffness of at least 8% higher than a stiffness of a single ply paper-based product made of kraft pulp at the same basis weight, and wherein the stiffness is determined according to a TAPPI standard procedure Lorentzen & Wettre No. T-556.