Patented high concentration alkali extraction for microfibrillated cellulose from sugarbeet pulp and other agro-waste

Overview

KCL has developed a patented process for manufacturing microfibrillated cellulose from sugarbeet pulp, an abundant agro-waste side stream. This high concentration alkali extraction process uses counter-current reactors to produce parenchymal cell cellulose in a water- and energy-efficient manner. The resulting microfibrillated cellulose can be used as a strength additive in papermaking and in surface sizing of paper and paperboard, and as a film-forming additive in barrier coatings for fiber-based packaging. With targeted engineering work and trials, the process can be adapted to other agricultural residues, including apple pomace and citrus peel.

Technical specifications

The process employs high concentration alkali extraction in counter-current reactors, enabling efficient separation of parenchymal cell cellulose from agricultural side streams.

Key features:

• Patented process (US20220162799A1) for microfibrillated cellulose production
• Water- and energy-efficient extraction compared to conventional approaches
• Counter-current reactor design enables continuous, scalable operation
• Demonstrated strength improvement through wet-end addition and surface starch sizing
• Film-forming capability for barrier coating applications
• Adaptable to multiple agro-waste feedstocks, including apple pomace and citrus peel residues

Installed production capacity for sugarbeet pulp processing is 400 dry tons per year. For pilot trials, KCL operates a range of smaller twin-screw counter-current reactors, with scale-up validation planned using a 2,200 L twin-screw reactor.

Technology readiness level

The technology has been demonstrated at TRL 6. Strength improvement properties have been validated through wet-end addition and surface starch sizing using trial paper machines and pilot coaters. The process is proven to be scalable, with 400 dry tons per year of installed production capacity for sugarbeet pulp.

Future validation work includes laboratory trials with customer-provided raw materials to determine adjustments in chemical dosing and processing conditions for new feedstocks, followed by pilot-scale trials using smaller twin-screw counter-current reactors to generate industry-relevant process data and produce material for downstream testing. Final scale-up validation is planned using the 2,200 L twin-screw reactor.