Mid Sweden University

Unlike fossil-based plastics, wood-based packaging materials can be produced in an eco-friendly manner using wood chip residuals from sawmills and pulpwood. To produce high-yield pulp like chemithermomechanical pulps (CTMPs) for paperboard and liquid packaging, it’s crucial to reduce the electric energy consumption during fiber separation. The ultimate objective is to revolutionize paperboard production by achieving a middle-layer CTMP process that consumes less than 200 kWh/t, significantly improving from the current 500-600 kWh/t energy demand.

Optimizing the CTMP impregnation process of sodium sulfite (Na2SO3) in wood chips is crucial for achieving uniform softening, ideally at the fiber level. The properties of the fibers are significantly affected by the content of lignin sulfonates within the walls of the fiber and the middle lamellae. In this study, we employed in-house developed X-ray fluorescence (XRF) techniques, validated by beamline measurements, to map the distribution of sulfonated lignin within fibers. It also seemed possible to enhance the surface area of lignin-rich pulp fibers while losing minimal bulk by refining them with well-optimized low consistency (LC) refining. We aim to achieve a highly efficient separation of coniferous wood fibers by co-optimizing the sulfonation and the temperature in the pre-heater and chip-refiner. Additionally, we explored how lignin's softening behavior and potential crosslinking influence subsequent unit operations, including pressing, peroxide bleaching, and drying, following the defibration process. In defibration during chip refining, the maximum softening of wood fibers is preferred to maximize fiber preservation and minimize energy consumption. However, optimizing the stiffness of finished pulp fibers is preferable to reduce bulk loss during paperboard production. It can strive to optimize processes to develop stronger, lighter, and more sustainable composite packaging materials. Reducing environmental impact and electric energy can help create a more sustainable future.