Patent ID: 12195492

DETAILED DESCRIPTION

As briefly discussed above, presented is a method for producing purified alkalilignin salt. The method is a two-stage process as generally described inFIG.1.

In the first stage of the present invention, an alkalilignin precipitate suspension is formed from the alkaline pulping spent liquor, i.e. black liquor (1), (dry solids content typically 25-45 weight-%) by decreasing pH to 9-3110.5 (3), at a temperature between 40-85° C. The formed alkalilignin suspension is filtered (5) making a filter lignin cake (7) and a permeate liquid (6) containing black liquor soluble components which are taken back to the pulp mill chemical cycle process.

In the second stage the above mentioned filter lignin cake (7) is mixed with dilution liquid (8) using certain controlled mixing and temperature (9) and forming an alkalilignin agglomerate colloid (10) at typically 10 weight-% dry solids content. This is the new, unexpected finding, the existence of alkalilignin as large colloidal agglomerate particles in diluted aqueous solution, which particles have an average particle-mass over 50 kilodaltons and which enable the technically and industrially useful production of purified alkalilignin salt.

The alkalilignin agglomerate colloid (10) is fed on a large-pore membrane (11) having cut-off pore size of 50-200 kilodalton typically in the temperature range of 20-85° C. The alkalilignin remains in the concentrate (12), whereas most of the smaller particle and small molecular soluble components transfer through the large-pore membrane into the permeate (13). The difference and the technical advantage are significant compared to conventional ultrafiltration of lignin from black liquor using typically 5 kilodalton pore-size special technology membranes.

A significant advantage of the present invention compared to the prior art lignin membrane separation (ultrafiltration) is that alkalilignin can be enriched as large, colloidal particles, here called alkalilignin agglomerates. This is evident as an enriched concentrate can be made on a large-pore membrane characterized by “molecular mass” cut-off of 50-200 kilodalton. Here this is called large-pore membrane filtration. The “large-pore” in practical terms means typically a membrane pore size ten times the pore size used in conventional ultrafiltration.

Large-pore membrane filtration according to the present invention is distinguished from ultrafiltration by several improvements and advantages. First of all, tight and technically very demanding macromolecule separation membranes, for which the molecular weight cut-off is typically 5 kilodalton, are not needed at all. The 50-200 kilodalton large-pore membranes are much easier to operate and maintain. Secondly, the starting material, alkalilignin filter cake, has already undergone a purification: A lot of the soluble small molecular components, especially inorganic salts, have been removed from the cake as a filtrate. Therefore, the re-diluted membrane filtering process in the second stage is fundamentally in a cleaner environment, and thus, membrane polarization and fouling is considerably less prominent. Thirdly, the product, alkalilignin salt concentrate, is the final product. There is no need for acid wash or other secondary cleaning stages, which require the use of extra chemicals distorting the re-cycle and re-use of the removed components in the permeate.

Commercially available conventional membranes types can be used in the large-pore membrane filtration step. The membranes may be constructed from organic materials such as PP, PE, PTFE, polyacrylic, cellulose acetate, polyacrylonitrile, polysulfone, etc. High durability inorganic membrane materials, such as aluminum oxide or zirconium oxide, can also be used, but such materials are not needed.

Advantageously, the large-pore membrane filtration is carried out at a pH in the range of 7 to 11 and at a temperature in the range 20-85° C.

The concentrate may be used as such, or undergo further treatment such as evaporation, freeze-drying or spray drying. A possible further treatment is to further purify the product by diluting the concentrate and repeating the large-pore-membrane-filtration once or several times.

Various embodiments of the present invention have been described above but a person skilled in the art realizes also further minor alterations, which would fall into the scope of the present invention. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents.

Example 1. Production of a Purified Kraft Lignin Salt by Large-Pore Membrane Filtration

The pH of softwood kraft black liquor was decreased to 10.0 using CO2at 60° C. The lignin precipitate suspension was filtered to obtain a kraft lignin filter cake with 57% dry matter content. The lignin filter cake was mixed with deionized water to form a lignin agglomerate colloid at 10% dry solids content. The lignin agglomerate colloid volume was pre-filtered and subjected to large-pore membrane filtration using Alfa Laval-GR51PP 50 kDa cut-off membrane. The large-pore membrane filtration test was carried out at 50° C. to reach volume reduction Vr=0.7 (Vr=Vpermeate/Vinitial). The resulting oven dry solids concentrations in the concentrate and permeate volumes were 19% and 2.7%, respectively.

81% of the lignin in the feed was recovered in the concentrate volume, while 63% of the main inorganic anions (carbonate, sulphate) and 41% of the sodium were transferred into the permeate. Lignin concentration in the concentrate was 82% of total dry matter content, compared to 67% in the feed. The concentration of the main inorganic anions (carbonate and sulphate) in the permeate was more or less half of that in the feed. The results indicate considerable enrichment of lignin in the concentrate and inorganics in the permeate. More detailed results are shown in Table 1 below.

TABLE 1The concentration and yield of selected componentsin the feed, concentrate, and permeate volumes oflarge-pore membrane filtration test in Example 1.FEED #1CONCENTRATE #1PERMEATE #1Concen-Concen-Concen-tration, %tration, %Yield,tration, %Yield,of dryof dry%of dry%mattermatterof feedmatterof feedLignin678281113Sodium (Na+)7.65.4471741Carbonate4.52.0301563Sulfate1.20.6374.063

Example 2. Further Purification of the Lignin Salt Via Repeated Large-Pore Membrane Filtration

The concentrate volume from Example 1 was mixed with deionized water to achieve 10% dry solids content and subjected to another large-pore membrane filtration test using Alfa Laval-GR51PP 50 kDa cut-off membrane. The test was carried out at 50° C. and continued until volume reduction Vr=0.7 was reached (Vr=Vpermeate/Vinitial). The resulting oven dry solids concentrations in the concentrate and permeate volumes were 21% and 1.3%, respectively.

95% of the lignin in feed #2 was recovered in the concentrate, while more than half of the carbonate was transferred thru the membrane into the permeate. Lignin concentration in the concentrate was 90% of total dry matter content, compared to 82% in the feed. The results of example 2 indicate that considerable further purification of lignin was achieved by re-diluting the concentrate and repeating the large-pore membrane filtration. More detailed results are shown in Table 2 below.

TABLE 2The concentration and yield of selected components inthe feed, concentrate, and permeate volumes of the secondlarge-pore membrane filtration test in Example 2.FEED #2(CONCEN-CONCEN-TRATE #1)TRATE #2PERMEATE #2Concen-Concen-Yield,Concen-Yield,tration, %tration, %% oftration, %% ofof dryof dryfeedof dryfeedmattermatter#2matter#2Lignin829095152Sodium (Na+)5.44.9781729Carbonate2.00.8331353

EXAMPLE 1 and EXAMPLE 2 demonstrate that large-pore membrane filtration efficiently enriches and purifies the lignin agglomerates in the concentrate. High retention of lignin is achieved using 50 kDa membrane. This aspect is exceptional compared to for instance separation and purification of lignin macromolecules by ultrafiltration of black liquor, which, while using a smaller pore 15 kDa membrane, only results in small lignin enrichment in the concentrate (20-30% of the lignin in feed, Vr=0.9). [Wallberg et al (2003), Holmqvist et al. (2005)]

It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention may be referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention.

Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

While the foregoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below.

The verbs “to comprise” and “to include” are used in this document as open limitations that neither exclude nor require the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of “a” or “an”, i.e. a singular form, throughout this document does not exclude a plurality.

CITATION LIST

Patent Literature

WO 2006/038863WO 2013/002687

Non-Patent Literature

1. Luque, Rodriquez, Alvarez, Cova, TAPPI Pulping Conference 1994, p. 5073. Orlando J. Rojas, John Song, Dimitris S. Argyropoulos Forest Biomaterials Laboratory, College of Natural Resources, North Carolina State University, Raleigh, NC 27695-8005, USA, Juan Bullón Department of Chemical Engineering, Universidad de Los Andes, Merida (Venezuela), “LIGNIN SEPARATION FROM KRAFT BLACK LIQUORS BY TANGENTIAL ULTRAFILTRATION”, Science and Technology, La Chimica e l'Industria-Gennaio-Febbraio '06 n. 1-ANNO 88. (Year 2006)4. Selda Aminzadeh,MarisLauberts, Galina Dobelev, Jevgenija Ponomarenkov, Tuve Mattsson, Mikael E. Lindström, Olena Sevastyanova, MEMBRANE FILTRATION OF KRAFT LIGNIN: STRUCTURAL CHARACTERISTICS AND ANTIOXIDANT ACTIVITY OF THE LOW-MOLECULAR-WEIGHT FRACTION, Industrial Crops & Products 112 (2018) 200-209.5. Wallberg, O.; Jönsson, A.-S.; Wimmerstedt, R., Ultrafiltration of kraft black liquor with a ceramic membrane., Desalination 2003, 156, 145-153.6. Holmqvist, A; Wallberg, O.; Jönsson, A.-S., Ultrafiltration of Kraft Black Liquor from Two Swedish Pulp Mills., Chem. Eng. Res. Des. 2005, 83, 994-999.