Abstract:
An electrochemical process for delignification and bleaching of pulp fibers is disclosed. The process involves the use of metallic chlorates and vanadium catalysts in the presence of an electric current to provide a pulp fiber of improved brightness and viscosity.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates to methods for the delignification and bleaching of cellulosic pulp using metallic chlorates in the presence of a vanadium catalyst. 
     BRIEF DESCRIPTION OF THE PRIOR ART 
     The delignification and bleaching of wood pulp employing chlorine dioxide prepared from sodium chlorate is a well-known procedure. The direct use of sodium chlorate for pulp bleaching without first converting it to chlorine dioxide has also been described in the existing art; see for example U.S. Pat. No. 2,938,826 which discloses chlorate bleaching in the presence of a catalyst that comprises vanadium and tin. The use of sodium chlorate in the presence of vanadium pentoxide has been described in Rapson et al., TAPPI, Volume 42, No. 8, August 1959, page 642. 
     U.S. Pat. No. 4,039,374 discloses the bleaching of pulp fibers with chlorine dioxide in the presence of vanadium in the +4 or +5 oxidation state. The vanadium (V 5+ ) oxidizes lignin chromophores and itself reduces to (V 4+ ) which reacts with chlorate to yield chloride ions; see for example U.S. Pat. No. 4,039,374, and TAPPI 62, Volume 62, No. 12, 1979, page 53. (See FIG. 1) 
     The direct use of sodium chlorate for pulp bleaching, without first converting it to chlorine dioxide eliminates the need for a chlorine dioxide generator and allows the chlorate that is found (30% of ClO 2  applied) during chlorine dioxide bleaching to be reused. 
     It is the object of the present invention to provide a bleaching process where chlorates are used directly for pulp bleaching in the presence of a catalyst which is being generated electrochemically. 
     SUMMARY OF THE INVENTION 
     The invention relates to a process for the delignification and bleaching of wood pulp fiber comprising the use of alkali metal chlorates, a redox catalyst (vanadium), and electric current (e-) and vanadium in the V 4+   form being constantly generated electrochemically. 
     Vanadium in the V 4+   form reacts with chlorate to yield chlorine dioxide and other oxidizing species while itself being oxidized to V 5+  ; V 5+   is then electrochemically reduced to V 4+ . The wood pulp is bleached using a metal chlorate directly, and the chlorate formed in the bleaching reaction is fully utilized for bleaching by recycling the filtrate. Because of the efficient pulp washing, the overall requirement for sodium chlorate is reduced as compared to conventional chlorine bleaching. (see FIG. 2) 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic of the process depicting the prior art; 
     FIG. 2 is a schematic diagram of the preferred process of the invention; 
     FIG. 3 is a block diagram of the preferred process of the invention; 
     FIG. 4 is a block diagram of an alternate embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The process of the invention is carried out by adding wood pulp to a solution comprising sodium chlorate and sodium vanadate at an appropriate acid pH (adjusted with mineral acid) and stirring the pulp slurry while electric current is passed through the electrodes immersed in the slurry (FIG. 3). 
     The pH of the solution can range from 1.0 to about 6.0. Such pH is adjusted through the addition of mineral acid. The temperature of the solution is maintained in the range of about 40° C. to about 85° C. Such a process is carried out from 1.0 to about 5.0 hours with a wood pulp consistency of about 0.5%-10%. 
     The concentration of the chlorate ranges from 0.001M to 7M, preferably from 0.1M to about 1.0M. Sodium chloride or sodium sulfate are possible replacements for a portion of the sodium chlorate to serve as an electrolyte. Other vanadium salts may also be applied. 
     Electric current ranging from about 1,350 coulombs/lb pulp to about 13,500 coulombs/lb pulp is passed through the electrodes immersed in the slurry during the entire bleaching period. In addition, electric current may be passed through the solution of sodium chlorate and sodium vanadate for 10 to 60 minutes prior to the addition of pulp to the bleaching solution. 
     In one alternate embodiment, the process of the invention is carried out by passing electric current through a solution containing a metal chlorate and a vanadium compound, to generate V 4+   chlorine dioxide; and other chlorine species; and then using the resulting solution to bleach pulp fibers (FIG. 4). 
     The following examples describe the process of making and using the invention and set forth the best mode contemplated by the inventors of carrying out the invention, but are not to be construed as limiting. 
     Examples 1-6 of the process were all performed in a stainless steel beaker with a Teflon™ cover through which reference electrodes and positive platinum electrodes were passed into the pulp slurry. The stainless steel beaker served as a negative electrode. In Example 7, the bleaching solution containing V 4+   was prepared beforehand, and no electric current was passed through the wood pulp slurry. 
     In general, the pulp slurry, comprising 10 grams of pulp in one liter of a solution containing chlorate and vanadium catalyst, was stirred magnetically during the bleaching period, and then filtered and washed. The bleached pulps were tested for brightness using a GE brightness tester and viscosity: 
     EXAMPLE 1 
     A softwood kraft pulp (Kappa No. 35), after chlorination and alkaline extraction was washed to obtain a C D  E pulp having a permanganate number of 3.0 and a brightness of 43% GE. A slurry of 10 g of the above-identified pulp in one liter of a solution containing 1.0 g of sodium chlorate, 0.58 g of sodium chloride and 0.012 g of sodium vanadate at pH 2.2 was stirred for three hours at 60° C. In four other runs, increasing amounts of electricity were passed through the pulp slurries. The amount of electricity imparted in each run and the resultant brightness of the pulps obtained and their viscosities are shown in Table 1 below. 
     
                       TABLE 1______________________________________           PULP PROPERTIES   ELECTRIC      BRIGHT-   VISCOS-   CURRENT       NESS      ITYRUN     (COULOMB&#39;S)   (% GE)    (cP)______________________________________1        0            65.9      23.02       162           73.5      19.03       270           74.3      19.04       540           75.3      16.55       810           74.0      16.6______________________________________ 
    
     The above table illustrates that the brightness level of the pulp improved considerably due to the addition of electric current. Some loss in viscosity takes place as the amount of current is increased. 
     EXAMPLE 2 
     A hardwood kraft pulp (Kappa No. 16), after chlorination and alkaline extraction was washed to obtain a C D  E pulp in one liter solution, at pH 1.7 and a temperature of 60° C., the solution containing 100 g of sodium chlorate and 0.24 g of sodium vanadate. Run 1 was performed with no electric current and a bleaching time of 2 hours; Run 2 was performed with no electric current and a bleaching time of 3 hours; Run 3 was performed with electric current and a bleaching time of 2 hours; Run 4 was performed with electric current and a bleaching time of 2 hours as in Run 3, but in addition current was passed through the solution for about 30 minutes prior to the addition of pulp to the solution. 
     Table 2 illustrates the relation between the electric current and bleaching time impartial to the pulp and the resultant % GE brightness and viscosity. 
     
                       TABLE 2______________________________________              PULP PROPERTIES ELECTRIC    BLEACHING  BRIGHT- VISCOS- CURRENT     TIME       NESS    ITYRUN   (COULOMB&#39;S) (hr)       (% GE)  (cP)______________________________________1      0          2.0        75.3    40.52      0          3.0        78.9    37.33     179         2.0        78.5    42.3 4*   179         2.0        78.2    45.2______________________________________ *An additional electric current (50 coulombs) was passed through the chlorate/vanadium solution prior to addition of the pulp. 
    
     The above table shows that the brightness level is considerably improved when electric current is used. At the same brightness level, the process utilizing the electric current gives higher viscosity than that obtained without current. As can be seen from Run 4, even further improvement occurs in the viscosity of the pulp if electric current is passed through the chlorate/vanadium solution to convert all V 5+   to V 4+   prior to addition of the pulp. This clearly illustrates the superiority of V 4+   catalyst as compared to the V 5+   catalyst. 
     EXAMPLE 3 
     A hardwood kraft pulp after chlorination and alkaline extraction was washed to obtain a C D  E pulp having a permanganate number of 2.5. The pulp was treated with sodium chlorate directly at varying pH in the presence of V 4+   catalyst. The V 4+   form was constantly being produced electrochemically by reducing V 5+   to V 4+ . The results of these runs, as illustrated in Table 3, show that the pulp properties, that is Brightness and Viscosity, approach those of pulp bleached conventionally with chlorine dioxide; pulp viscosity is better at low pH (approximately 2.0); and viscosity loss can be additionally minimized by using a viscosity preserver, such as diethylamine or the like. 
     
                       TABLE 3______________________________________VANADIUM-CATALYZED CHLORATE BLEACHING OFHARDWOOD KRAFT C.sub.D E PULP*                  % GE        VISCOS-RUN                    BRIGHTNESS  ITY (cP)______________________________________1     Standard Dioxide Bleach                  85.1        20.0 (1% ClO.sub.2)2     Electrochemical  82.8         9.5 (pH 4, 60° C.)3     Electrochemical  85.0        11.9 (pH 3, 70° C.)4     Electrochemical  82.5        17.3 (pH 2, 60° C.)5     Electrochemical  83.8        19.7 (pH 2, 60° C.) with viscosity preserver**______________________________________ *Electrochemical bleaching conditions: pulp consistency (1%); sodium chlorate (1 M); vanadium (1 mmo1); T = 3 hr; electric current = 172 coulombs **Selected from the group diethylamine, dimethylamine and sulfamic acid 
    
     EXAMPLE 4 
     A softwood kraft pulp after being semi-bleached through C D  EDE was washed to obtain a pulp having 64% GE brightness and a viscosity of 24 cP. The C D  EDE pulp (10 g) and sulfamic acid (2 g) were added to a solution (1 liter) comprising sodium chlorate (100 g) and sodium vanadate (0.6 g) at pH 1.8 and T=60° C., and stirred for 2 hours while current (50 mAmp) was passed. In addition, current (25 mAmp) was passed through the solution containing chlorate and vanadium for 30 minutes prior to the addition of the pulp. Table 4 shows the pulp properties of the run as compared with the pulp properties obtained by standard chlorine dioxide bleaching. 
     
                       TABLE 4______________________________________          PULP PROPERTIES            % GE        VISCOS-PROCESS          BRIGHTNESS  ITY (cP)______________________________________1.    Chlorate/vanadium/                85          23 electric current bleaching2.    Standard ClO.sub.2                85          24 Bleaching______________________________________ 
    
     As can be seen from the results in Table 4, the pulp properties are comparable. 
     EXAMPLE 5 
     A softwood kraft pulp (Kappa No. 35) after chlorination and extraction was washed to obtain a pulp having permanganate number of 3.5. Three equal portions of this pulp were treated with chlorine dioxide (1.2% on pulp) using vanadyl sulfate (V 4+ ) and sodium vanadate (V 5+ ) respectively as additives. No current was passed through the pulp slurry during these runs. 
     The results in Table 5 show that both the V 4+   and V 5+   forms increase pulp brightness with a slight reduction of viscosity, when they are added in the dioxide bleaching stage. However, it was observed that the chlorate concentration in the effluent is reduced only in the case of the V 4+   addition. This supports the conclusion that V 4+ , rather than V 5+ , is the active species in generating the oxidizing species in situ (ClO 2  and possibly others) from chlorate, and this mechanism clearly differs from the mechanism suggested by the Deutsch et al article, &#34;Vanadium Pentoxide Catalysis of Chlorine Dioxide Bleaching&#34;, TAPPI 62 (12):53, 1979. 
     
                       TABLE 5______________________________________EFFECT OF VANADIUM ADDITIONS IN D.sub.1 STAGE OFSOFTWOOD KRAFT PULP BLEACHING               BRIGHT-   CHLORATE INFIL-       END     NESS      TRATE, % MOLEADDITIVE    pH      % GE      OF ADDED ClO.sub.2______________________________________1.  Control ClO.sub.2           4.1     78.1    33    bleaching    (w/o additive)2.  V.sup.4+, 0.5%           3.9     80.4    193.  V.sup.5+, 0.5%           3.0     80.4    27______________________________________ 
    
     EXAMPLE 6 
     A softwood kraft pulp (Kappa No. 35) was treated with sodium chlorate, sodium vanadate at varying pH while electric current was passed through the slurry. The results in Table 6 show that delignification of kraft pulp is effective under these conditions. 
     
                       TABLE 6______________________________________CHLORATE/VANADIUM (V.sup.4+) DELIGNIFICATION OF35 KAPPA SOFTWOOD KRAFT PULP      PULP PROPERTIES*pH           KAPPA NO.  VISCOSITY, cP______________________________________1.    4          16.0       20.92.    3          9.6        20.93.    2          6.3        22.2______________________________________ *Kappa No. and viscosity determinations were made after an alkaline extraction following the chlorate/vanadium treatment. 
    
     EXAMPLE 7 
     A semibleached (C D  EDE) softwood kraft pulp (10 g) having 64% GE brightness and 0.5 CED viscosity of 25 cP&#39;s was stirred in a solution containing sodium chlorate (60 mg) and vanadyl sulfate (60 mg) for 3 hours at 60° C. In a similar run, the vanadyl sulfate was replaced by 12 mg of sodium vanadate and electrical current. The results as displayed in Table 7 show that properties of pulps obtained from both experiments are comparable. 
     The bleaching process can be operated in either of the methods as illustrated in FIGS. 3 and 4. 
     
                       TABLE 7______________________________________               SODIUM CHLORATESODIUM CHLORATE     AND SODIUMAND VANADYL         VANADATE ANDSULFATE (V.sup.4+)  ELECTRIC CURRENTWITHOUT ELEC-       TO GENERATE V.sup.4+TRIC CURRENT        CONTINUOUSLY______________________________________Brightness,   80.1            80.0% GeViscosity,   20.8            21.4 -cP______________________________________ 
    
     Inasmuch as the invention is subject to various change and variations, the foregoing should be regarded as merely illustrative of the invention defined by the following claims.