Evaluation of various pretreatment methods to manage fouling in ultrafiltration of wood hydrolysates

Integration of Pre-Treatment with UF/RO Membrane Process for Waste Water Recovery and Reuse in Agro-Based Pulp and Paper Industry

This recent study aims to evaluate the efficacy of membrane filtration on recovery of water resource from agro-waste such as bagasse, crop-based pulp and paper mill waste. A mini pilot scale membrane system having a combination of pre-treatment filter unit (pre-filter, sediment filter and pre-carbon filter), ultra-filtration and reverse osmosis with spiral wound configuration were employed to evaluate the water reuse efficacy of effluent coming from the secondary clarifier of the conventional treatment plant of the mill. The operational conditions were optimized using Taguchi method at pH 8, temperature 32 °C, and pressure 2 bar and a flow rate of 60 l/hr. The qualities of the effluent from the secondary clarifier, and the permeate from both the combination, viz. Combination 1 (pre-treatment + ultra-filtration) and Combination 2 (pre-treatment + ultra-filtration+ reverse osmosis) were analyzed and the percentage reduction in pH, TDS, TSS, BOD, COD, Color, Lignin, Potassium and Sodium were calculated. The elimination of TDS, COD and BOD with Combination 1 was not promising (<22%). However, the installation of a RO membrane greatly reduced (>88%) the contaminants in both paper mill effluents. The obtained qualities of water from all the combinations were compared with the tolerance standard for reuse as process water. The quality of effluent from the secondary clarifier did not agree with any class of water quality. The permeate from the combination of pre-treatment and UF sufficiently reduced the TSS to reach the requirement. However, the combination of (pre-treatment + UF + RO) adequately complied with the quality standard required for reuse in the making of all grades of paper.

Demonstration and Assessment of Purification Cascades for the Separation and Valorization of Hemicellulose from Organosolv Beechwood Hydrolyzates

Hemicellulose and its derivatives have a high potential to replace fossil-based materials in various high-value-added products. Within this study, two purification cascades for the separation and valorization of hemicellulose and its derived monomeric sugars from organosolv beechwood hydrolyzates (BWHs) were experimentally demonstrated and assessed. Purification cascade 1 included hydrothermal treatment for converting remaining hemicellulose oligomers to xylose and the purification of the xylose by nanofiltration. Purification cascade 2 included the removal of lignin by adsorption, followed by ultrafiltration for the separation and concentration of hemicellulose. Based on the findings of the experimental work, both cascades were simulated on an industrial scale using Aspen Plus®. In purification cascade 1, 63% of the oligomeric hemicellulose was hydrothermally converted to xylose and purified by nanofiltration to 7.8 t/h of a xylose solution with a concentration of 200 g/L. In purification cascade 2, 80% of the lignin was removed by adsorption, and 7.6 t/h of a purified hemicellulose solution with a concentration of 200 g/L was obtained using ultrafiltration. The energy efficiency of the cascades was 59% and 26%, respectively. Furthermore, the estimation of specific production costs showed that xylose can be recovered from BWH at the cost of 73.7 EUR/t and hemicellulose at 135.1 EUR/t.

Conversion of Xylose from Birch Hemicellulose Hydrolysate to 2,3-Butanediol with Bacillus vallismortis

Biotechnologically produced 2,3-butanediol (2,3-BDO) is a potential starting material for industrial bulk chemicals, such as butadiene or methyl ethyl ketone, which are currently produced from fossil feedstocks. So far, the highest 2,3-BDO concentrations have been obtained with risk class 2 microorganisms and pure glucose as substrate. However, as glucose stays in competition to food and feed industries, a lot of effort has been done in the last years finding efficient alternative substrates. Thereby xylose from hydrolysed wood hemicelluloses is a promising substrate for the production of 2,3-BDO. The risk class 1 microorganism Bacillus vallismortis strain was identified as a very promising 2,3-BDO producer. The strain is able to utilize xylose almost in the same manner as glucose. B. vallismortis is less prone to common inhibiting compounds in lignocellulosic extracts/hydrolysates. When using a concentrated hemicellulose fraction from birch wood hydrolysate, which was produced with ultrafiltration and after which the acetate concentration was reduced, a yield of 0.43 g g−1 was achieved and the xylose consumption and the 2,3-BDO production is basically the same as using pure xylose.

Analysis of membrane fouling by Brunauer-Emmet-Teller nitrogen adsorption/desorption technique

Membrane fouling is the major factor limiting the wider applicability of the membrane-based technologies in water treatment and in separation and purification processes of biorefineries, pulp and paper industry, food industry and other sectors. Endeavors to prevent and minimize fouling requires a deep understanding on the fouling mechanisms and their relative effects. In this study, Brunauer-Emmett-Teller (BET) nitrogen adsorption/desorption technique was applied to get an insight into pore-level membrane fouling phenomena occurring in ultrafiltration of wood-based streams. The fouling of commercial polysulfone and polyethersulfone membranes by black liquor, thermomechanical pulping process water and pressurized hot-water extract was investigated with BET analysis, infrared spectroscopy, contact angle analysis and pure water permeability measurements. Particular emphasis was paid to the applicability of BET for membrane fouling characterization. The formation of a fouling layer was detected as an increase in cumulative pore volumes and pore areas in the meso-pores region. Pore blocking was seen as disappearance of meso-pores and micro-pores. The results indicate that the presented approach of using BET analysis combined with IR spectroscopy can provide complementary information revealing both the structure of fouling layer and the chemical nature of foulants.

Birch wood pre-hydrolysis vs pulp post-hydrolysis for the production of xylan-based compounds and cellulose for viscose application

Hydrothermal treatments of birch wood and kraft pulp were compared for their ability to extract the xylan and produce viscose-grade pulp. Water post-hydrolysis of kraft pulp produced a high-purity cellulosic pulp with lower viscosity but higher cellulose yield than traditional pre-hydrolysis kraft pulping of wood. Post-hydrolysis of pulp also increased the crystallite dimensions and degree of crystallinity in cellulose, and promoted a higher extent of fibril aggregation. The lower specific surface area in post-hydrolyzed pulps, derived from their larger fibril aggregates, decreased the accessibility of OH groups. However, this lower accessibility did not seem to decrease the pulp reactivity to derivatizing chemicals. In the aqueous side-stream, the xylose yield was similar in both pre- and post-hydrolysates, although conducting post-hydrolysis of pulp in a flow-through system enabled the recovery of high purity and molar mass (∼10 kDa) xylan for high-value applications.

Study of Separation and Fouling of Reverse Osmosis Membranes during Model Hydrolysate Solution Filtration

Prehydrolysate, a dilute solution consisting mainly of pentoses, hexoses, and lesser quantities of organic acids, furfural and phenolics, is generated in the Kraft dissolving pulp process. An obstacle facing the valorization of the solution in hemicellulose biorefineries, by conversion of the sugars into bioproducts such as furfural, is the low sugar concentration. Membrane filtration is typically proposed in several hemicellulose based biorefineries for concentrating the solution, although they are usually generated using different wood species, pretreatment methods, and operating conditions. However, the chemical composition of the solutions is generally not considered. Also, the combined effect of composition and operating conditions is rarely investigated for biorefinery applications. The purpose of this work was to determine the impact of the prehydrolysate composition and operating parameters on the component separation and permeate flux during membrane filtration. Using model prehydrolysate solutions, two commercial reverse osmosis (RO) membranes were screened, and one was selected for use, based on its higher sugar and acetic acid retention. A Taguchi L18 experimental design array was then applied to determine the dominant parameters and limiting factors. Results showed that the feed pressure and temperature have the highest impact on permeate flux, but the least effect on sugar retention. Further experiments to quantify flux decline, due to fouling and osmotic pressure, showed that furfural has the highest membrane fouling tendency, and can limit the lifetime of the membrane. Regeneration of the membrane by cleaning with a sodium hydroxide solution is also effective for reversing fouling. It has been demonstrated that RO can efficiently and sustainably concentrate wood prehydrolysate.

Physico-Chemical Alternatives in Lignocellulosic Materials in Relation to the Kind of Component for Fermenting Purposes

The complete bioconversion of the carbohydrate fraction is of great importance for a lignocellulosic-based biorefinery. However, due to the structure of the lignocellulosic materials, and depending basically on the main parameters within the pretreatment steps, numerous byproducts are generated and they act as inhibitors in the fermentation operations. In this sense, the impact of inhibitory compounds derived from lignocellulosic materials is one of the major challenges for a sustainable biomass-to-biofuel and -bioproduct industry. In order to minimise the negative effects of these compounds, numerous methodologies have been tested including physical, chemical, and biological processes. The main physical and chemical treatments have been studied in this work in relation to the lignocellulosic material and the inhibitor in order to point out the best mechanisms for fermenting purposes. In addition, special attention has been made in the case of lignocellulosic hydrolysates obtained by chemical processes with SO₂, due to the complex matrix of these materials and the increase in these methodologies in future biorefinery markets. Recommendations of different detoxification methods have been given.

Limited adsorption selectivity of active carbon toward non-saccharide compounds in lignocellulose hydrolysate

Prehydrolysis of lignocellulose produces abundant hemicellulose-derived saccharides (HDS). To obtain pure HDS for application in food or pharmaceutical industries, the prehydrolysis liquor (PHL) must be refined to remove non-saccharide compounds (NSC) derived from lignin depolymerization and carbohydrate degradation. In this work, activated carbon (AC) adsorption was employed to purify HDS from NSC with emphasis on adsorption selectivity. The adsorption isotherms showed the priority of NSC to be absorbed over HDS at low AC level. However, increase of AC over 90% of NSC removal made adsorption non-selective due to competitive adsorption between NSC and HDS. Size exclusion chromatography showed that the adsorption of oligomeric HDS was dominant while monomeric HDS was inappreciable. The limited selectivity suggested that AC adsorption is infeasibility for HDS purification, but applicable as a pretreatment method.

Improvement membrane filterability in nanofiltration of prehydrolysis liquor of kraft dissolving pulp by laccase treatment

In this work, laccase treatment was employed to enhance nanofiltration process by lignin removal. Results showed that the membrane filterability was increased in terms of deionized water flux and PHL filtration process. On the other hand, the hemicellulosic sugars were negligible affected and can be concentrated to 172 g/L, which was increased about 300% from the original one. The combined laccase-nanofiltration process provides an alternative approach to utilize hemicellulosic sugars of PHL in an environmentally friendly way.

Specific lignin precipitation for oligosaccharides recovery from hot water wood extract

Hot water extraction is an important strategy of wood fractionation, by which the hemicelluloses can be separated for value-added products, while the residual solid can still be processed into traditional wood products. In this study, a combined process consisting of specific lignin precipitation and dialysis was proposed to recover hemicellulosic oligosaccharides (OS) from hot water extract (HWE). The results showed that polyaluminium chloride (PAC) precipitation was highly specific to large molecular lignin, leading to 25.1% lignin removal with negligible OS loss through charge neutralization mechanism. The separation was further enhanced by dialysis, reaching 37.6% OS recovery from HWE with remarkable purity of 94.1%. By the proposed process, 56.36 g OS, mainly xylooligosaccharides with two fractions of 5.2 and 0.51 kDa was recovered from one kg dried wood. This process can be envisaged as a great contribution to wood biorefinery.

Enhanced membrane filtration of wood hydrolysates for hemicelluloses recovery by pretreatment with polymeric adsorbents

In this study adsorption of foulants from birch and pine/eucalyptus wood hydrolysates on two polymeric adsorbents was studied aiming to reduce the membrane fouling. The effect of the pretreatment of hydrolysate on polyethersulphone membrane performance was studied in dead-end filtration experiments. Adsorption pretreatment improved significantly filtration capacity and decreased membrane fouling. Especially high-molecular weight lignin was efficiently removed. A multistep adsorption pretreatment was found to reduce the amount of adsorbent required. While large adsorbent amount was shown to increase flux in filtration, it was found also to cause significant hemicellulose losses.

Production and recovery of monosaccharides from lignocellulose hot water extracts in a pulp mill biorefinery

Processing of hemicelluloses obtained with pressurized hot water extraction (PHWE) from Scots pine to monosaccharides and other chemicals was investigated experimentally. A process scheme consisting of ultrafiltration, acid hydrolysis, and chromatographic separation was proposed and evaluated. A two-stage ultrafiltration was found necessary for efficient fractionation of the wood extract. It was shown that the monosaccharides can be released from a concentrated hemicellulose fraction with sulfuric acid hydrolysis without a significant loss of yield due to decomposition of monosaccharides. Acid hydrolysate was successfully fractionated with ion exchange chromatography and the hydrolysis acid was recovered for reuse. The product fractions obtained include polyphenols and high molar mass hemicelluloses (from UF stage 1), arabinose (from UF stage 2), as well as acetic acid and a mixture of monosaccharides (xylose, galactose, mannose, glucose) from chromatography.

A combined process of activated carbon adsorption, ion exchange resin treatment and membrane concentration for recovery of dissolved organics in pre-hydrolysis liquor of the kraft-based dissolving pulp production process

To recover dissolved organics in pre-hydrolysis liquor (PHL) of the kraft-based dissolving pulp production process, a new combined process concept of sequential steps of activated carbon adsorption, ion exchange resin treatment, and membrane concentration, was proposed. The removal of lignin in the PHL was achieved in the activated carbon adsorption step, which also facilitates the subsequent operations, such as the membrane filtration and ion exchange resin treatment. The ion exchange resin treatment resulted in the removal/concentration of acetic acid, which opens the door for acetic acid recovery. The membrane filtration is to recover/concentrate the dissolved sugars. The combined process resulted in the production of PHL-based concentrate with relatively high concentration of hemicellulosic sugars, i.e., 22.13%.