Processes for producing lignin-coated hydrophobic cellulose, and compositions and products produced therefrom

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.

What is claimed is: 
     
         1 . A process for producing a lignin-coated cellulose material, said process comprising:
 (a) providing a lignocellulosic biomass feedstock;   (b) fractionating said 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;   (c) depositing at least some of said lignin, from said liquid, onto a surface of said cellulose-rich solids to generate a lignin-coated cellulose material;   (d) optionally mechanically treating said lignin-coated cellulose material; and   (e) recovering said lignin-coated cellulose material,   wherein cellulose crystallinity of said lignin-coated cellulose material is at least 60%, and wherein said lignin-coated cellulose material is at least partially hydrophobic.   
     
     
         2 . The process of  claim 1 , wherein said acid is selected from the group consisting of sulfur dioxide, sulfurous acid, sulfur trioxide, sulfuric acid, lignosulfonic acid, and combinations thereof. 
     
     
         3 . The process of  claim 2 , wherein said acid is sulfur dioxide. 
     
     
         4 . The process of  claim 3 , wherein sulfur dioxide concentration in step (b) is from about 12 wt % to about 30 wt %. 
     
     
         5 . The process of  claim 1 , wherein fractionation temperature in step (b) is from about 140° C. to about 170° C. 
     
     
         6 . The process of  claim 1 , wherein fractionation time in step (b) is from about 1 hour to about 2 hours. 
     
     
         7 . The process of  claim 1 , wherein step (d) is performed and wherein steps (c) and (d) are integrated. 
     
     
         8 . The process of  claim 1 , wherein step (d) is performed and wherein said lignin-coated cellulose material is treated with a total mechanical energy of less than about 500 kilowatt-hours per ton of said lignin-coated cellulose material. 
     
     
         9 . The process of  claim 1 , wherein said process further comprises treatment of said lignin-coated cellulose material with one or more enzymes. 
     
     
         10 . The process of  claim 1 , wherein said process further comprises treatment of said lignin-coated cellulose material with one or more acids. 
     
     
         11 . The process of  claim 10 , wherein said one or more acids are selected from the group consisting of sulfur dioxide, sulfurous acid, lignosulfonic acid, acetic acid, formic acid, and combinations thereof. 
     
     
         12 . The process of  claim 1 , wherein said process further comprises treatment of said lignin-coated cellulose material with heat. 
     
     
         13 . The process of  claim 1 , wherein said cellulose crystallinity of said lignin-coated cellulose material is at least 70%. 
     
     
         14 . The process of  claim 13 , wherein said cellulose crystallinity of said lignin-coated cellulose material is at least 80%. 
     
     
         15 . The process of  claim 1 , wherein said lignin-coated cellulose material includes, or is characterized as, lignin-coated dissolving pulp. 
     
     
         16 . The process of  claim 1 , wherein said lignin-coated cellulose material includes, or is characterized as, lignin-coated fibrillated cellulose. 
     
     
         17 . The process of  claim 1 , wherein said lignin-coated cellulose material includes, or is characterized as, lignin-coated microcrystalline cellulose. 
     
     
         18 . The process of  claim 1 , wherein said lignin-coated cellulose material includes, or is characterized as, lignin-coated nanocellulose. 
     
     
         19 . The process of  claim 1 , said process further comprising chemically converting said lignin-coated cellulose material to one or more lignin-coated cellulose derivatives. 
     
     
         20 . The process of  claim 19 , wherein said lignin-coated cellulose derivatives are selected from the group consisting of cellulose esters, cellulose ethers, cellulose ether esters, alkylated cellulose compounds, cross-linked cellulose compounds, acid-functionalized cellulose compounds, base-functionalized cellulose compounds, and combinations thereof.