Nanocellulose versatility
It is widely recognised that the demand for sustainable materials has dramatically increased since the turn of the century, with lignocellulosic biomass playing a vital role in the global shift away from the utilisation of petrochemical resources. Lignocellulosic biomass can be transformed into a variety of products ranging from biofuels, biochemicals, cosmetics, paper and packaging materials, biomedical materials, and electronic device components [1]. A key contributor to the advancement of biomass-based products for these applications is the development of nanostructured cellulosic materials from lignocellulosic biomass, either in the form of cellulose nanocrystals (CNCs) or cellulose nanofibres (CNFs) [2]. Nanocellulose is a highly versatile material that is able to be produced from a wide variety of feedstock sources, typically through the deconstruction of terrestrial lignocellulosic biomass, or alternatively through bacterial biosynthesis [3]. In addition, nanocellulose can be generated through a range of different processing routes, involving a combination of enzymatic, thermal, chemical, and mechanical treatments, as have been extensively reviewed in the past [2, 4–6]. Finally, nanocellulose materials can be fabricated into a range of different product formats, including in an aqueous suspension or paste, dried into a networked film, spray dried into solid particles, compounded into a polymer matrix, stabilised into an aqueous hydrogel structure, freeze dried into an aerogel structure, or carbonised at high temperatures to generate biomass carbon [7]. Furthermore, nanocellulose materials can be characterised through an array of different methods, which investigate properties that include the fibre-light interaction, fibre-solvent interaction, fibre-fibre interaction, fibre morphology and specific surface area, or intrinsic physical and chemical properties of fibres [8, 9].
Therefore, the versatility of nanocellulose products arises from the diversity in biomass feedstock, processing methods and product formats, which in turn creates challenges associated with benchmarking the performance and sustainability of samples across different research studies or products available on the market [9, 10]. This benchmarking challenge is expected to be projected forward into the industrial context, in terms of comparative product evaluation and manufacturing quality control to minimise batch-to-batch variation [11]. Like other manufacturing industries, product quality control for nanocellulose production will be crucial for business viability [12]. Biomass-based materials elevate the challenge of quality control through three additional sources of variability: (1) Genetic factors of the biomass, either within-plant variability between the different sections, within-family variability between different sorghum varieties, within-kingdom variability across different plant types including wood, non-wood, and aquatic origin, or across-kingdom variability between plant, animal, or bacterial-derived cellulose; (2) Environmental factors that influence the development of the biomass source in a complex, interactive sense, both from the natural environmental conditions or from human intervention through farm management practices; and (3) Processing factors, which act as a pseudo-environmental condition encompassing all of the biomass handling and material processing factors.
Role of benchmarking
Benchmarking is an emerging priority in the nanocellulose research field, driven by the desire of academics and industrial researchers to access and compare the property profile of industrially produced materials, and to compare factors that influence product performance and sustainability [13]. Delepierre et al. (2021) highlighted that with the emergence of industrially produced nanocellulose materials: “there is a demand to [develop a] benchmarking study so that [nanocellulose] users have access to up-to-date information and can continue to select materials that best fit their research and application needs” [13]. Benchmarking can be applied to all of the sources of variability outlined above, with the following list outlining potential questions that may be addressed through benchmarking-style investigation:
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For biomass benchmarking: What biomass sources generate higher performance and/or more sustainable nanocellulose material?
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For processing benchmarking: What processing methods or conditions generate higher performance and/or more sustainable nanocellulose material?
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For product benchmarking: Given a particular product type, what are the highest performing and/or most sustainable nanocellulose samples?
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For technology benchmarking: How does nanocellulose technology compare to alternative technologies or materials for a given application or to solve a given problem?
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For characterisation benchmarking: How accurately do different characterisation methods predict the ‘true’ property profile of the material? How well does one characterisation metric predict the value of another characterisation metric?
Despite the prominent role of benchmarking in the process of technology commercialisation, few studies in the nanocellulose research field have directly investigated these topics [11, 13–15]. To address this gap in the literature, this study benchmarks the performance of different biomass types (Biomass Benchmarking), the effect of different mechanical processing methods on the resultant CNF-based material (Mechanical Process Benchmarking), and the performance and energy consumption of nanopaper material across different literature studies (Nanopaper Performance Benchmarking), with a focus on highlighting sample properties that contribute to high performance of the material.
Biomass Benchmarking
While the production of biomass-derived nanocellulose is a comparatively sustainable technology when compared to the production of petrochemical-derived materials, there remains an opportunity to optimise nanocellulose sustainability in terms of feedstock selection and utilisation [16]. Biomass sources exhibit differences in their biochemical composition, structural morphology, and cell wall architecture, as well as logistical differences such as biomass density, growth rate, seasonal availability, production cost, and transport cost. These parameters lead to differences in the properties and economic viability of nanocellulose products from different biomass sources. There is large diversity in the biomass types used for nanocellulose production with over 100 unique sources identified for nanocellulose production, sourced predominantly from wood, bacterial and agro-industrial byproducts [1]. However, despite this high degree of biomass variability, the majority of commercial nanocellulose production is undertaken using wood-based biomass [17]. In addition, only a limited number of research studies have thoroughly investigated nanocellulose performance across different biomass sources, as outlined in Table 1. System-level investigation across a wide range of biomass sources is required to elucidate biomass-processing-property-quality relationships for nanocellulose materials. The outcomes from this style of investigation would shed light on the best and worst performing biomass sources, the features of the biomass material that are associated with a higher relative performance, the efficiency of biomass deconstruction through chemical and mechanical treatment, and the nanocellulose properties that are generated from the deconstruction process. Table 1 takes a step toward answering these questions through presenting a summary of existing research studies that compare CNF properties across multiple biomass sources, ranking the relative order of characterisation metric values for each biomass source included within the study.
Table 1
Review of studies comparing multiple biomass types for CNF production
Biomass Types | Characterisation Performed | Biomass Properties | CNF Properties | Relationships | Citation |
Coffee residues Sugarcane straw Corn husks Orange bagasse | Biochemical composition Crystallinity NMR TGA | Cellulose = Corn > Sugarcane > Coffee > Orange Lignin = Sugarcane > Coffee > Corn > Orange L:C = Sugarcane > Coffee > Orange ~ Corn H:L = Orange > Corn > Coffee > Sugarcane | Yield = Corn > Coffee > Sugarcane > Orange CrI = Corn > Orange > Sugarcane > Coffee Diameter = Orange > Sugarcane > Corn | A lower L:C ratio was associated with a higher CNF crystallinity | [18] |
Oil palm tree: -Trunk -Mesocarp -Empty fruit bunch (EFB) -Palm kernel shell | Biochemical composition FTIR AFM TGA Crystallinity Tensile properties | Cellulose = Mesocarp > EFB > Trunk > Kernel Lignin = Kernel > Mesocarp > EFB > Trunk L:C = Kernel > Mesocarp > Trunk > EFB H:L = Trunk > EFB > Kernel > Mesocarp | CrI = Trunk > EFB > Kernel > Mesocarp Tensile = Trunk > EFB > Kernel > Mesocarp Strain = Mesocarp > Trunk > EFB > Kernel Modulus = Trunk > Kernel > EFB > Mesocarp | A lower H:L ratio was associated with a CNF sheet with lower tensile strength, Young’s modulus and crystallinity, while lower L:C ratio was associated with a higher tensile strength and crystallinity | [19] |
Coconut coir Softwood Cotton | Biochemical composition Crystallinity SEM, TEM Rheology | Cellulose = Cotton > Wood > Coir Lignin = Coir > > Wood > > Cotton L:C = Coir > Wood > Cotton H:L = Cotton > > Wood > Coir CrI = Cotton > Wood > Coir | Yield = Cotton > Softwood > Coir CrI = Coir > Wood > Cotton Average Diameter = Cotton > Softwood = Coir | The high cellulose content and low hemicellulose and lignin content of cotton yielded a high CrI biomass, but led to the largest diameter and lowest CrI CNFs | [20] |
Wheat straw Soy hulls | Biochemical composition SEM, TEM FTIR XRD TGA | Cellulose = Soy > Wheat L:C = Wheat > Soy H:L = Wheat > > Soy CrI (raw) = Soy > Wheat CrI (treated) = Wheat > Soy | Average Diameter = Soy > Wheat Average Length = Wheat > Soy | The higher H:L ratio and lower raw biomass CrI was associated with higher aspect ratio CNFs | [21] |
Sugarcane bagasse Rice straw | Biochemical composition Degree of polymerisation Optical Microscopy SEM, TEM, AFM EDX Tensile properties Opacity | Cellulose = Bagasse > Rice Pentosans = Bagasse > Rice Ash = Rice > > Bagasse Degree of Polymerisation = Bagasse ~ Rice | Tensile strength = Bagasse > Rice Young’s Modulus = Bagasse > Rice Average Diameter (TEM/AFM) = Bagasse ~ Rice Opacity = Rice > > Bagasse | The high ash content in rice straw reduced the tensile strength properties and transparency of nanopaper sheets compared to those of the bagasse pulp." | [22] |
Coconut husk Banana peel Oil palm trunk | Biochemical composition SEM, TEM XRD FTIR TGA | Cellulose = Oil palm > Coconut > > Banana H:L = Banana > > Oil palm > Coconut L:C = Banana > Coconut > Oil Palm CrI = Banana > Oil palm > Coconut Tmax (TGA) = Banana > Coconut > Oil palm | CrI = Oil palm > Coconut > Banana Tmax (TGA) = Coconut > Banana > Oil palm Diameter = Oil palm > Coconut > Banana Length = Coconut > Oil Palm > > Banana | The high H:L ratio in banana peel was associated with smaller diameter fibres | [23] |
Banana rachis Sisal Kapok Pineapple leaf Coconut coir | FTIR SEM, TEM, AFM Birefringence XRD IGC TGA | Tdecomposition (TGA) = Coconut > Kapok > Pineapple > Sisal > Banana Weight loss (TGA) = Kapok > Sisal > Banana > Coconut > Pineapple Residual char (TGA) = Coconut > Banana > Kapok > Sisal > Pineapple | Yield = Pineapple > Sisal > Kapok > Banana > Coconut CrI = Pineapple > Sisal > Kapok > Coconut > Banana Width (TEM) = Pineapple > Banana > Kapok > Coconut > Sisal | Nanofibre crystallinity is associated with treatment yield and the inverse of residual char, which is indicative of a higher cellulose content. | [24] |
Abaca Sisal Hemp Jute Flax | Biochemical composition Degree of polymerisation AFM DMTA XRD Tensile properties Transparency | Hemicellulose = Sisal > Abaca > Jute > Hemp > Flax | Yield = Sisal > Abaca > Jute > Hemp > Flax CrI = Hemp = Flax > > Jute > Abaca = Sisal µ = Abaca > > Hemp > Jute > Sisal > Flax DP = Abaca > > Hemp > Jute > Sisal > Flax Width (AFM) = Flax > Jute ~ Hemp > Abaca > Sisal Nanocomposite tensile strength (10%) = Flax > Abaca ~ Jute > Sisal | A higher hemicellulose content was associated with a smaller width nanofibres, while flax with the lowest hemicellulose content had the lowest intrinsic viscosity and degree of polymerisation. However, the high nanocomposite reinforcement efficiency of flax was unexpected. | [25] |
Wheat straw Barley straw Corn straw Oat straw | Biochemical composition FTIR XRD TGA DLS ZP | Cellulose (raw) = Corn > Wheat > Oat > Barley Hemicellulose (raw) = Corn ~ Wheat > Oat ~ Barley Ash (raw) = Barley > Wheat > Oat > Corn L:C (raw) = Barley ~ Wheat ~ Oat ~ Corn H:L (raw) = Oat > Wheat ~ Barley ~ Corn Hemicellulose (treated) = Wheat > Corn > Barley > Oat L:C (treated) = Oat > Barley > Wheat > Corn H:L (treated) = Wheat > Corn > Barley > Oat SR (treated) = Wheat > Oat > Corn > Barley Yield (treated) = Barley = Oat > Wheat > Corn DP (treated) = Corn > Wheat > Oat > Barley Length (treated) = Barley > Oat > Wheat > Corn Diameter (treated) = Oat > Corn ~ Barley ~ Wheat | SSA = Wheat > > Oat > Barley > Corn Diameter = Barley > Corn > Oat > Wheat DP = Corn ~ Wheat > Oat > Barley Yield = Wheat > > Oat > Corn > Barley | Wheat biomass generated CNFs that were significantly better than all other biomass in terms of SSA, fibre diameter, DP, and nanofibrillation yield. This was associated with the highest Hemicellulose content in the biomass and pulp stages, 2nd and 1st highest H:L ratio in the biomass and pulp stages respectively, and the highest Schopper-Riegler degree in the pulp stage. | [26] |
While this qualitative style of information does not allow statistical modelling of the data, it does provide an overview of the literature that allows the reader to investigate relationships without getting lost in the quantitative data. However, this summary table does not provide information around the relative processing sustainability between the different biomass sources investigated, which is an increasingly important facet of the nanocellulose research field. It also does not inform upon the relative magnitude of values between different biomass sources for each characterisation metric.
One of the most commonly investigated characterisation methods is the biochemical composition of the biomass feedstock, which has been associated with the amenability and recalcitrance of the nanocellulose production process. A higher hemicellulose content has been linked with nanocellulose processing amenability, as hemicellulose is a relatively amorphous, hydrophilic component that promotes fibre swelling and chemical pretreatment efficiency. On the other hand, lignin is a relatively rigid, hydrophobic component that has been linked with nanocellulose processing recalcitrance [27–29]. Previous studies have proposed that the ratio between hemicellulose to lignin (H:L) has a positive impact on nanofibrillation efficiency, while the lignin to cellulose (L:C) has a negative impact on nanofibrillation efficiency [30]. In addition, biomass crystallinity index (CrI) has been proposed to have an inverse relationship with nanofibrillation efficiency, such that biomass with a lower CrI will enhance penetration of chemical pretreatment agents into the fibre structure and promote fibrillation during mechanical processing [31]. However, despite a drive to enhance processing sustainability and the widespread understanding that different biomass feedstocks generate differential outcomes in nanofibre properties, there is a paucity of systematic investigation into the biomass properties that encourage sustainable nanocellulose production, and which biomass types exhibit these properties.
Mechanical Process Benchmarking
Similar to different biomass feedstock, it is well established that different processing routes for nanocellulose production can lead to different nanocellulose properties, industrial scalability, and sustainability outcomes in terms of energy and water consumption. Alternative mechanical treatments have been extensively outlined in the literature, including milling, microfluidisation, disk refining, ultrafine grinding, high-intensity ultra-sonication, extrusion, cryocrushing, blending, and steam explosion [5, 6, 32, 33]. Different mechanical treatments exert a unique mechanism of action and force profile on the lignocellulosic material, which impacts the subsequent CNF morphology. Consequently, different mechanical treatments operate with different energy demand, commonly defined as the unit of energy consumed per dry weight of material processed (kWh/t or kWh/kg). The selection of a mechanical fibrillation method that demonstrates energy efficient processing is a key component of sustainability for the production of fibrillated cellulose materials. While the concept of sustainability encompasses a broader scope than merely processing sustainability, this is the central aspect of this benchmarking study. Li et al. (2021) highlighted this concept when stating that: “The sustainability and energy requirements for the production of fibrillated cellulose are tied not only to the biomass source but also to the processing methods employed. A resource such as fibrillated cellulose is only truly sustainable when its processing is also sustainable” [16]. A comparison between the alternative mechanical treatment processes used for the production of CNF suspensions is outlined in Table 2.
Table 2
Comparison of mechanical processing methods for CNF production
Mechanical Processing Method | Mechanism of Action | Solids Content | Citations |
High Pressure Homogenisation | A dilute pulp slurry is pumped through a spring loaded valve assembly under high pressure (50–2000 bar), such that the fibre-water suspension undergoes intense micronisation caused by a rapid drop in pressure, generation of cavitation and shockwaves forces, turbulent flow, and high mechanical shearing as the material passed through a small gap between the homogenising valve and the impact ring. The generated fibres typically have a high specific surface area and a high aspect ratio. | 0.5–1 wt. % | [33, 34] |
Ball Milling | A dilute pulp slurry is pumped into a hollow cylindrical container, partially filled with ceramic, zirconia or metal balls of 0.4–1 mm diameter. When the container rotates, the heavy, millimetric-sized balls impart a high degree of impaction force through collisions between the balls, fibres, and container wall. Ball milled nanofibres are typically more branched with a lower aspect ratio. | 0.5–2 wt. % | [4] |
Microfluidization | A dilute pulp slurry is pumped through a N-shaped, Y-shaped, or Z-shaped channel at a speed of several Mach and a high pressure of 200–300 MPa, such that the material is subjected to large shear forces when passed through the tortuous flow channel. Unlike homogenisation, which operates at a constant processing volume, microfluidization operates at constant shear rate, which reduces the likelihood of clogs. | 0.5–2 wt. % | [34, 35] |
Disk Refining | A dilute pulp slurry is passed between two disks fitted with grooved surfaces, one that is stationary while the other rotates. Fibres are sheared to smaller dimensions through repeated cyclic stress as the disk rotates, with the gap between the grinding disks continuing to shrink during processing to promote delamination and fibrillation. | 0.5–10 wt. % | [35] |
Ultrafine Grinding / Microgrinding | A dilute pulp slurry is passed between a static and rotating grinding disk, generating shearing force that delaminates and fibrillates fibres. The grinding process is very similar to disk refining, whereas the main difference is the possibility of a lower gap between the discs for these grinders. | 0.5–10 wt. % | [4] |
Twin Screw Extrusion | A pulp paste is fibrillated by two intermeshing, co-rotating screws mounted in a closed barrel. The material is subjected to a thermo-physico-chemical method involving heat, compression, and shear force that promote the physical disruption of fibres as they pass through the extruder. | 15–40 wt. % | [4] |
Blending / High Shear Mixing | A dilute pulp slurry undergoes high speed rotor-stator mixing to impact a high degree of shear force on the material. High shear mixed fibres typically have a lower aspect ratio than homogenised fibres due to the cutting of fibres, and lower degree of fibrillation. | 0.2–3 wt. % | [36] |
Ultrasonication | High-energy acoustic waves sent through the cellulose fibre suspension promote growth and rupture of flow field bubbles (i.e. cavitation) that generate strong hydrodynamic shear forces during bubble implosion, leading to further fibrillation and dispersion of fibres. | 0.5–4 wt. % | [35] |
Steam Explosion | A dilute pulp slurry is exposed to pressurized steam, followed by a rapid release of pressure as the material is vented into the collection vessel, which promotes hydrolytic rupturing of the fibre structure and partial hydrolysis of non-cellulosic components. | 10–30 wt. % | [4] |
Cryocrushing | A pulp slurry is frozen with liquid nitrogen and crushed through the application of shear force, such that the mechanical force causes ice crystals to exert pressure on the fibre structure, leading to partial fibrillation. | ~ 2 wt. % | [4] |
Aqueous counter collision | Two streams of pulp slurry collide against each other under high pressure, resulting in pulverization and fibrillation of fibres. | < 0.4 wt. % | [4] |
Nanopaper Performance Benchmarking
Cellulose nanopaper is a strong and tough fibre network material composed primarily of cellulose nanofibres, exhibiting a dual elastic and inelastic stress-strain curve when subjected to tensile testing [37]. Although pure nanopaper consists of 100% CNFs, there is still diversity in their mechanical properties due to the variability in biomass source and processing conditions, as outlined above. Benítez & Walther (2017) highlight this challenge in their unifying review of nanopaper mechanical performance, stating that: “The material space in the CNF world is unfortunately very wide, which makes it profoundly difficult to understand property space and derive general conclusions […] Important points to consider are first the origin and the processing of CNFs, which leads to variation in the degree of polymerization (DP), crystallinity (Xc), diameter, aspect ratio and hemicellulose/ lignin content” [38]. Moreover, the nanopaper fabrication route can impact the resulting mechanical properties, which is typically achieved through film casting or vacuum filtration, and an optional hot-pressing step [38]. To establish a comparative evaluation of CNF material generated within the academic literature, this study benchmarks the performance of CNFs in the simple product format of a vacuum filtered nanopaper handsheet. Nanopaper performance is assessed through mechanical tensile testing, while standardising the performance by the energy consumption required to process the CNF sample.