Note: Descriptions are shown in the official language in which they were submitted.
CA 02885486 2015-03-17
COMPLEX MICROBIAL FLORA AND APPLICATION THEREOF
BACKGROUND OF THE INVENTION
Field of the Invention
[cam This invention generally relates to synthesis of a single and/or a
complex
microbial flora and application methods thereof in preparing textile fiber,
additive
cellulose, and a biological bacterial solution pulp.
Description of the Related Art
[0002] Recently, with the depletion of fossil fuel resources, the demand for
hemp
fiber synthesized by means with ecological and environmental friendly and many
other fine features have attracted many consumers. Worldwide demand of natural
fibers from natural raw materials has increased at an 8% rate per year. The
most
important features of the raw material of natural hemp fiber include its high
fiber
content, fine and long fibers (which helps the hemp fiber to interlace well),
high
strength; its fiber cell has small lumina!, thick cell wall, and a high ratio
of cell wall to
luminal; it's opaque as hemp fiber has long and fine cell, etc. However, the
drawback is that hemp fiber is not easy to fibrillation, which lowered the air
permeability of fabric made from hemp fiber.
[0003] Prior methods of preparing fiber from hemp are mostly chemical
processes.
Waste and contaminants generated by chemical processes are dumped to the soil,
thereby destroying the land and contaminating the air. In addition, such
processes
require very high power, electricity and water consumption. According to the
current understanding of China's pulping industry, chemical pulp has been
widely
used in leading production plants, which generates contaminated waste
solution,
thereby drastically devastating the land and polluting the air. Chemical
pulping
processes require the use of large amount of sodium hydroxide (strong base) as
additives and the use of harmful chemical elements and waste solutions during
bleaching processes. All of the generated large amounts of waste and chemicals
cannot be fully recycled or reused. Moreover, chemical pulping processes
require
CA 02885486 2015-03-17
very high power, electricity and water consumption. Most chemical pulping
plants
consume large amount of electricity and does not meet national energy
conservation policy. Substances cannot achieve effective recycling. Chemicals
cannot be separated from the waste and can only be dumped into soil to
contaminate the environment. Also,
most organic matters are mixed with
chemicals, such that the organic matters cannot be reused, causing heavy
losses.
Thus, it's necessary to develop a bio-fiber technology system to solve the
fundamental
problems of environmental pollution in order to conserve energy, reduce waste
generation, reduce water consumption, and to reduce production costs and
improve the
percentage of raw material usage.
[0004] Therefore, there is a need to develop and synthesize a novel biological
bacterial
pulping system to process raw materials and generate textile fiber, additive
cellulose.
SUMMARY OF THE INVENTION
[0005] This invention generally relates to biological bacterial species and
systems to
process raw materials and generate textile fiber, additive cellulose, and a
biological
pulping solution for making papers. More specifically, the invention relates
to methods
and biological systems of preparing a biological pulping solution to make
papers. In one
embodiment, provided are a complex microbial flora and an application therefor
in
preparing a textile fabric, a cellulose for use as an additive, and a
biological bacterial
solution pulp. The complex microbial flora comprises Bacillus sp. of deposit
number
CGMCC No. 5971, Rheinheimera tangshanensis of deposit number CGMCC No.
5972, and Wickerhamomyces anomalus of deposit number CGMCC No. 5975. The
method comprises: formulation of a bacterial solution, processing of raw
materials, and
preparation or pulping of the fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] So that the manner in which the above recited features of the present
invention
can be understood in detail, a more particular description of the invention,
briefly
summarized above, may be had by reference to embodiments, some of which are
illustrated in the appended drawings. It is to be noted, however, that the
appended
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drawings illustrate only typical embodiments of this invention and are
therefore not to be
considered limiting of its scope, for the invention may admit to other equally
effective
embodiments.
[0007] Figure 1 illustrates an exemplary flowchart of a method of making
textile fiber
according to one embodiment of the invention.
[00os] Figure 2 illustrates one embodiment of a flow chart of an exemplary
method of
producing additive cellulose.
[0009] Figure 3 illustrates one embodiment of a flow chart of another
exemplary method
of producing additive cellulose.
[0olo] Figure 4 illustrates one embodiment of a flowchart of an exemplary
method of
producing a microbial biological pulping solution system.
[0011] Figure 5 illustrates one embodiment of a flowchart of another exemplary
method
of producing a microbial biological pulping solution system.
DETAILED DESCRIPTION
[00121 The present invention overcomes the drawbacks in the prior chemical
processes
of fiber production and generally includes novel biological pulping systems
and methods
of making fibers, celluloses, and paper-generating biological pulping solution
systems
using one or more microbial/bacterial species. The present invention generally
provides
a bacteria, either alone or as a complex microbial flora in the presence of
other bacteria,
a complex microbial flora, an application thereof in preparing a textile
fabric, a cellulose
for use as an additive, and a biological bacterial solution pulp in the
presence of one or
more bacteria species, and their applications thereof. The complex microbial
flora may
includes one or mroe Bacillus. Sp. under CGMCC Deposit No. 5971 Rheinheimera
tangshanensis under CGMCC Deposit No. 5972, and Wickerhamonyces anomalus
under CGMCC Deposit No. 5975 and their combinations thereof. The method
provided
comprises: formulation of a bacteria solution, processing of raw materials,
and
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preparing a textile fabric, a cellulose for use as an additive, and a
biological bacterial
solution pulp.
[0013] One embodiment of the invention provides one or more bacteria species
within a
biological pulping solution system, including at least one Bacillus. Sp. under
CGMCC
Deposit No. 5971, either alone or in the presence of one or more Rheinheimera
tangshanensis under CGMCC Deposit No. 5972, and Wickerhamonyces anomalus
under CGMCC Deposit No. 5975 and their combinations thereof. For example, the
biological pulping solution system may include a complex microbial flora of
Bacillus. Sp,
CGMCC Deposit No. 597'1 and Rheinheimera tangshanensis CGMCC Deposit No.
5972; a complex microbial flora of Bacillus. Sp. CGMCC Deposit No. 5971 and
Wickerhamonyces anomalus CGMCC Deposit No. 5975; a complex microbial flora of
Bacillus. Sp. CGMCC Deposit No. 5971, Rheinheimera tangshanensis CGMCC Deposit
No. 5972, and Wickerhamonyces anomalus CGMCC Deposit No. 5975; and any
combinations thereof.
[0014] Another embodiment of the invention provides the preparation of one or
more
bacteria species as a bacterial culture and the use of the bacterial cultures
to prepare
textile fibers, celluloses (to be used as an additive), and/or a biological
pulping solution
system (for making paper). In one aspect, a method of preparing a bacterial
culture
(e.g., a biological bacterial culture solution) to be used to make textile
fibers, cellulose,
and a biological pulping solution system, amongothers, includes growing one or
more
microbial or bacterial species in a malt-agar and culturing for a period of
time (e.g., at
25 C for three days). The resulting bacterial cell colonies may be in a
spherical, oval, or
sausage shape at a size of (4.8-14.4) pm X (3.6-7.2) pm, with possible
formation of
precipitates. When the one or more bacteria species are placed on malt-agar
plate and
cultured at 25 C for one month, the bacterial colonies look cheese-like with
white,
smooth, non-reflective surface and root-like edges. When the one or more
bacteria
species are cultured in Dalmau cornmeal agar plate culture, false hyphae are
grown on
the surface.
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[0015] In another aspect, a method for preparing a textile fiber includes the
following
one or more steps:
[0016] The first step of (1) Bacteria Configurations in a process of making
textile fibers:
preparing one or more bacteria species in a bacterial culture solution.
Bacillus. Sp.
CGMCC Deposit No. 5971 can be present alone or in combination with other
bacteria
as a complex microbial flora of Bacillus. Sp. CGMCC Deposit No. 5971,
Rheinheimera
tangshanensis CGMCC Deposit No. 5972, and Wickerhamonyces anomalus CGMCC
Deposit No. 5975; and any combinations thereof. For example, a bacterial
culture
solution is prepared according to a desired weight ratio. As an example, a
complex
bacterial flora is prepared in a weight ratio of Bacillus: Rheinheimera
tangshanensis :
Wickerhamomyces anomalus at 2-3: 1-2: 2-3.
[0017] The second step of (2) Preparation of raw materials: preparing and
cutting hemp
raw materials into fragments and sections, and soaking the raw materials
inside a
swelling pool to swell the fragments of hemp raw materials. The raw materials
may
include hemp flax, sesame, jute, sisal, combinations thereof, among others.
The
swelled raw materials are then taken out of the swelling pool for further
processing.
[0018] The third step of (3) Fiber Production: Fiber Production may include
the following
step of (a) Biodegradation in a biological system: by removing and draining
the above
biodegraded materials and soaking the prepared raw materials into the prepared
bacterial culture solution, (b) Steam sterilization: by removing and draining
the above
biodegraded materials from the bacteria culture solution, and sterilizing the
biodegraded
materials (e.g., by passing the biodegraded materials through steam
sterilization). (c)
Obtaining Fiber: coarsely grinding the sterilized material for a period of
time to obtain
fiber bundles, then finely grinding the fiber bundles to disperse the fiber
bundles into
individual single fibers. Next, screening and filtering the fiber bundles and
re-grinding
them repeatedly for several times until all of them are grinded into
individual single
fibers. (d) Drying and carding: soaking the above-obtained single fibers in
warm water,
drying and combing the single fibers to use them for making textile fibers.
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[0019] Additional embodiment of the invention provides the preparation of
celluloses to
be used as additives and includes the following steps: (1) Bacteria
Configurations in a
process of making cellulose additives: preparing one or more bacteria species
in a
bacterial culture solution. Bacillus. Sp. CGMCC Deposit No. 5971 can be
present alone
or in combination with other bacteria as a complex microbial flora of
Bacillus. Sp.
CGMCC Deposit No. 5971, Rheinheimera tangshanensis CGMCC Deposit No. 5972,
and Wickerhamonyces anomalus CGMCC Deposit No. 5975; and any combinations
thereof. A bacterial culture solution is prepared according to a desired
weight ratio. As
an example, a complex bacterial flora is prepared in a weight ratio of
Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 2-3: 1-2: 2-3.
[0020] The second step of (2) Preparation of raw materials: debarking woody
raw
material and cutting them into pieces, sections, and fragments; and/or cutting
herbal
raw materials into fragments and sections. Then, ingredients of the chopped
materials
are soaked inside a swelling pool to swell the chopped raw materials. The raw
materials may include any woody plant tissues, chipped wood or tree tissues,
processed wood products, herbal plant tissues, chopped fiber-rich plant
tissues, or any
combinations thereof. The swelled raw materials are then taken out of the
swelling pool
for further processing.
[0021] The third step of (3) Fiber Production: Fiber Production may include
the following
step of (a) Easing the raw material: rolling and/or squeezing the swelled raw
materials.
(b) Biodegradation in a biological system: by placing the eased raw materials
to be
soaked in a prepared bacterial culture solution. (c) Steam sterilization: by
removing and
draining the above biodegraded materials from the bacteria culture solution,
and
sterilizing the biodegraded materials (e.g., by passing the biodegraded
materials
through steam sterilization). (d) Obtaining Fiber: coarsely grinding the
sterilized material
for a period of time to obtain fiber bundles, then finely grinding the fiber
bundles to
disperse the fiber bundles into individual single fibers. Next, screening and
filtering the
fiber bundles and re-grinding them repeatedly for several times until all of
them are
grinded into individual single fibers. (e) Sterilization: soaking the above-
obtained single
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fibers in warm water, and then drying and sterilization. (f) Grinding:
grinding the
sterilized fiber into celluloses, which can be used as additives.
[0022] This invention also provides a method for biologically preparing a pulp
solution
system (e.g., a paper-making pupping solution) using one or more bacterial
species.
The method includes the following steps: (1) Bacteria Configurations within
the
biological pulping solution system: preparing the above one or more bacteria
species
into a bacterial culture according to the desired weight ratio and proportion.
Bacillus.
Sp. CGMCC Deposit No. 5971 can be present alone or in combination with other
bacteria as a complex microbial flora of Bacillus. Sp. CGMCC Deposit No. 5971,
Rheinheimera tangshanensis CGMCC Deposit No. 5972, and Wickerhamonyces
anomalus CGMCC Deposit No. 5975; and any combinations thereof. A bacterial
culture
solution is prepared according to a desired weight ratio. As an example, a
complex
bacterial flora is prepared in a weight ratio of Bacillus: Rheinheimera
tangshanensis:
Wickerhamomyces anomalus at 2-3: 1-2: 2-3.
[0023] The second step of (2) Preparation of raw materials: debarking woody
raw
material and cutting them into pieces, sections, and fragments; and/or cutting
herbal
raw materials into fragments and sections. Then, ingredients of the chopped
materials
are soaked inside a swelling pool to swell the chopped raw materials. The raw
materials may include any woody plant tissues, chipped wood or tree tissues,
processed wood products, herbal plant tissues, chopped fiber-rich plant
tissues, or any
combinations thereof. The swelled raw materials are then taken out of the
swelling pool
for further processing.
[0024] The third step of (3) Pulp Production: Pulp Production may include the
following
step of (a) Easing the raw material: rolling and/or squeezing the swelled raw
materials.
(b) Biodegradation in a biological pulping system: by placing the eased raw
materials to
be soaked in a prepared bacterial culture solution. (c) Steam sterilization:
by removing
and draining the above biodegraded materials from the bacteria culture
solution, and
sterilizing the biodegraded materials (e.g., by passing the biodegraded
materials
through steam sterilization). (d) Coarse Pulping: coarsely grinding the
sterilized material
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for a period of time to obtain fiber bundles. (e) Fine Pulping: finely
grinding the fiber
bundles to disperse the fiber bundles into individual single fibers. (f) Pulp
Screening:
screening and filtering the fiber bundles and re-grinding them several times
until all of
them are grinded into individual single fibers. (g) Pulp Washing: Soaking the
obtained
pulp in warm water for a period of time and use the obtained pulp to make
paper (e.g.,
paperboard, etc).
[0025] The method for biologically preparing a paper-making pulp solution
system as
described above may contain, for example, a bacteria culture at a density of
60,000,000/ml at step (1), a raw material swelling time of about 10 to 12
hours at step
(2), and a biodegradation temperature to be maintained at about 35-40 C for 32-
36
hours at step (3). After the Easing step, the mass ratio of raw materials and
the
bacteria solution is 1: 6-9. Steam sterilization is performed at atmospheric
pressure for
10-30 minutes using water vapor sterilization.
[0026] Furthermore, at step (2), after the raw materials are taken out of the
swelling
pool, the solution within the swelling pool can be further processed to be
flocculated and
get rid of sediments to obtain upper layer clear supernatant solution. The
clear solution
can be recycled and used again. The sedimentary materials can be abated into a
biogas pool to generate biogas.
[0027] The invention provides many advantages and characteristics, including:
(1) The
methods described herein do not pollute the environment. The generated waste
can be
directly transformed into organic fertilizers, thereby obtaining zero
emissions, zero
pollution to the environment. (2) The fibers generated by the biological
pulping method
are protected. As compared to the conventional chemical processes, the methods
described herein can obtain almost all cellulose and hemicellulose from the
raw
materials, thereby obtaining high fiber production yield. (3) The biological
degradation
process is conducted under atmospheric pressure to save energy, use a low
carbon
technology, and reduce emission. (4) The costs of a biological process is
lower, thus
high economic effect.
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[0028] The by-products of the processes of the present invention can be
delivered to a
precipitation tank to be flocculated and precipitated. Then, the supernatant
clear
solution is recycled and reused as a pre-soak water solution. The flocculates,
sediments and precipitates are rich in a variety of organic matters and many
other
nitrogen, phosphorus, or potassium-containing phytonutrients. The flocculates,
sediments and precipitates can be mixed with the used, old bacteria culture
solution
(namely the viscous bacteria culture solution that has been repeatedly used to
degrade
raw materials, which also contain nitrogen, phosphorus, potassium, iron and
trace
elements). The mixture, after acidification, can be discharged into a bio-
fermentation
tank to produce biogas. The generated biogas residues, biogas liquids, grinded
ashes,
mixed particles, and other wastes can also be mixed to generate organic
fertilizers or be
abated, resulting in zero pollutant emission to the environment.
[0029] The methods described herein further improve cellulose production and
pulping
production, reduces the reaction time, and increases the purity of the
obtained fiber and
their yields, as compared to chemical processes, so that the methods described
herein
can promote large-scale application in the actual production. The methods
described
herein use a bacteria culture solution to degrade plant tissues and obtain
plant fibers in
a short time. The methods described herein can also be used to biologically
degrade
plant lignin within a short time to produce pulp and make paper. The by-
products of the
process can be converted into biogas, which can be used to heat a boiler
(which may
use coal and biogas to heat), thereby saving coal consumption. Lastly, biogas
residues
and wastes can be made into organic fertilizers, thereby forming a new
economic
recycle model for "organic material transformation" (where substances are
transformed
into organic matters) and no discharging of any waste materials. As a result,
the
invention fundamentally solves pollution problems as seen in prior art
chemical fiber
preparation process, conserves energy, reduces emission, saves water, reduces
production costs, and improves material utilization efficiency.
[0030] Examples:
[0031] Example 1: the preparation of a bacteria culture solution
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[0032] 'One or more bacteria species as described herein have been deposited
on April
6, 2012 into the China General Microbiological Culture Collection Center
(CGMCC,
located at No, 3, Division #1, Beichen West Road, Chaoyang District, Beijing,
China).
The deposit numbers are Bacillus sp. Deposit No. 5971, Rheinheimera
tangshanensis
Deposit No. 5972, and Wickerhamomyces anomalus Deposit No. 5975.
[0033] For example, the bacteria Bacillus sp. Deposit No. 5971 can be used
alone or as
a complex microbial flora, including a complex microbial flora of Bacillus.
Sp. CGMCC
Deposit No. 5971 and Rheinheimera tangshanensis CGMCC Deposit No. 5972; a
complex microbial flora of Bacillus. Sp. CGMCC Deposit No. 5971 and
Wickerhamonyces anomalus CGMCC Deposit No. 5975; a complex microbial flora of
Bacillus. Sp. CGMCC Deposit No. 5971, Rheinheimera tangshanensis CGMCC Deposit
No. 5972, and Wickerhamonyces anomalus CGMCC Deposit No. 5975; and any
combinations thereof.
[0034] A bacterial culture solution is prepared according to a desired weight
ratio. As an
example, a complex bacterial flora is prepared in a weight ratio of Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 2-3: 1-2: 2-3. The
bacteria culture solution can be cultured into a density of about
60,000,000/ml or above
and to be used in the methods described herein.
[0035] Example 2: Extraction of fibers from flax.
[0036] A method of making fibers by using flax as an example of raw materials:
a ,
bacterial culture solution is prepared according to a desired weight ratio. As
an
example, a complex bacterial flora is prepared in a weight ratio of Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 3:1:3.
[0037] According to the embodiments of Figure 1, the process of fiber
extraction
generally includes three phases: a preparation phase, a fiber-manufacturing
phase and
a by-product generating phase.
[0038] (A). A preparation phase: from Step 1 (prepare raw material) to Step 4
(soak &
swell.
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[0039] The flax raw material was harvested, prepared, and then soaked & washed
with
cold water in a soaking, wetting, retting pool or tank so as to first wash
away any dirt
and other debris on the surface of the raw materials. The flax raw materials
were
soaked with water at natural temperature until the flax raw materials were
totally retted
and swelled, for example, for about 10-12 hours. After repeat soaking, the
solution
liquid became turbid. Then, after flocculation and sedimentation, the
supernatant clear
solution was recycled for re-use. The precipitates and sediments were
discharged and
abated into a biogas tank for fermentation and producing biogas.
[0040] ÞB) A fiber-manufacturinq phase: from Step 6 (biodegradation) to Step12
(textile
fiber production.
[0041] Step (6) Biodegradation: The treated raw materials were put into a
biodegradation bin or pot to be soaked and mixed inside a bacterial culture
solution (for
example, the bacterial culture solution as prepared in Example 1). The mass
ratio of
the raw materials and the bacterial culture solution is 1 : 8. The temperature
was
maintained at about 35-40 C for a time period of about 32-36 hours. Generally,
the
conditions of biological degradation reaction are adjusted according to the
growth
conditions of the bacterial culture used so as to increase specific bacterial
degradation.
[0042] Step (7) Steam Sterilization: Biodegraded materials were removed from
the
degradation pot, drained, and sterilized to remove bacteria. Then, the
biodegraded
materials were placed inside a steam pot and steam was used to passing through
them
for about 10-30 minutes. The biodegraded materials were then delivered from
the
output of the steam pot into a fiber refiner/grinder.
[0043] Step (8) Fiber Bundle Production: Fiber bundles were obtained by
coarsely
grinding the sterilized materials for a time period. ;
[0044] Step (9) Single Fiber Production: The fiber bundles were finely grinded
and
dispersed into single fibers.
[0045] Step (10) Repeat Screening: The fiber bundles were repeatedly screened,
filtered and re-grinded again to obtain individual single fibers.
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[0046] Step (11) Drying and Combing: The above-obtained fibers were soaked in
warm
water, then gone through drying, combing, drafting to further obtain straight
and
paralleled fibers.
[0047] Step (12) Textile Fiber Extraction & Production: The above-obtained
single fibers
were extracted using further manufacturing techniques to obtain textile
fibers.
[0048] (C) A by-product generating phase: Step A - Step C.
[0049] Step A: Organic Feeds. The remainders of prepared raw materials between
step
(1) and (4) are rich in nutrients and can be fermented into organic feeds for
cattle and
sheep.
pool Step B: Bio-organic fertilizer. After repeated soaking and swelling at
Step 4, the
biodegraded material solution became turbid and was delivered to go through
flocculation and sedimentation. The resulting supernatant solution was
recycled for
future use. Then, the precipitates and sediments were discharged and delivered
into a
biogas pool to be fermented and produce biogas, which can be used to heat a
coal and
biogas compatible boiler and reduce coal consumption.
[00511 Step C: Bio-organic Fertilizer. After fermentation in the biogas pool,
the
generated biogas residues, slurries, biogas liquids are rich bio-organic
fertilizers. So
the liquid residue/slurry solutions can be used as fertilizers for
agricultural crops and
nutrient solutions for flowers. The remaining solid particles and residues can
be used
as base fertilizers. All such fertilizers are green fertilizers. The physical
properties and
measurements of the obtained fibers are shown in Table 1.
[0052] Example 3: Extraction of celluloses from ramie.
[0053] The preparation process is similar to those described in Example 2,
except that
the ratio of a complex microbial flora bacterial culture was configured as
followed. As
an example, a complex bacterial flora is prepared in a weight ratio of
Bacillus:
Rheinheimera tangshanensis Wickerhamomyces anomalus at 3 : 1 : 2. During
biodegradation, the weight ratio of the treated raw materials and the bacteria
culture
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solution is 1: 7. The physical properties and measurements of the obtained
fibers are
shown in Table 1.
[0054] Example 4: Extraction of celluloses from jute and kenaf.
[0055] The preparation process is similar to those described in Example 2,
except that
the ratio of a complex microbial flora bacterial culture was configured as
followed. As
an example, a complex bacterial flora is prepared in a weight ratio of
Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 3: 2: 2. During
biodegradation, the weight ratio of the treated raw materials and the bacteria
culture
solution is 1: 8.5. The physical properties and measurements of the obtained
fibers are
shown in Table 1.
r00561 Example 5: Extraction of celluloses from sisal hemp.
[0057] The preparation process is similar to those described in Example 2,
except that
the ratio of a complex microbial flora bacterial culture was configured as
followed. As
an example, a complex bacterial flora is prepared in a weight ratio of
Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 2: 1: 3. During
biodegradation, the weight ratio of the treated raw materials and the bacteria
culture
solution is 1: 9. The physical properties and measurements of the obtained
fibers are
shown in Table 1.
Table 1
flax ramie jute and kenaf sisal hemp
Thickness (dtex) 5 4.7 4.5 4 .4
Breakage length (km) 6.41 6.13 4.12 3.29
Breakage intensity (cN/dtex) 10.4 9.3 9.3 9
Breakage Extension (%) 5 4.6 3.7 4
[0058] Example 6: Extraction of celluloses from woody materials.
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[0059] Using Caragana as an example of raw materials, a process is described
herein
to specifically illustrate how to extract cellulose from woody materials.
Other woody
materials, such as poplar and willow, can also be used to extract celluloses
accordingly.
[0060] When using caragana as raw materials, the weight ratio of a complex
microbial
flora bacterial culture was configured to be Bacillus: Rheinheimera
tangshanensis :
Wickerhamomyces anomalus at 3: 1: 2. When using poplar as raw materials, the
weight ratio of a complex microbial flora bacterial culture was configured to
be Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 2: 1: 3. When using
willow as raw material, the weight ratio of a complex microbial flora
bacterial culture was
configured to be Bacillus: Rheinheimera tangshanensis : Wickerhamomyces
anomalus
at 3 : 2 : 2.
[0061] According to the embodiments of Figure 2, the process of fiber
extraction
generally includes three phases: a preparation phase, a fiber-manufacturing
phase and
a by-product generating phase.
[0062] (A). A preparation phase: from Step 1 (prepare raw material) to Step 4
(soak &
swell.
[0063] Step (1) to Step (2) Preparing raw materials and Debarking: The stem
and bark
of the harvested caragana raw material's were separated (e.g., using winnowing
machine or other machines). The bark was separated and fed into organic feed
processing plant to be processes into feeds, and the debarked stem was
delivered to a
cutting machine.
[0064] Step (3) Cutting/Slicing: The caragana stem raw materials were cut into
segments, each at a length of about 3-4 cm, preferably in oblique cut, in
order to
increase the area for water penetration.
[0065] Step (4) Soaking & Washing: The harvested caragana stem materials were
soaked with cold water in a retting pool or tank and washed to get rid of dirt
and other
debris on its surface. Then, the caragana stem materials were soaked in water
at
natural temperatures for a time period of about 10-12 hours, or until the stem
are totally
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retted and swelled. After repeat soaking, the solution liquid became turbid.
Then, after
flocculation and sedimentation, the supernatant clear solution was recycled
for re-use.
The precipitates and sediments were discharged and abated into a biogas tank
for
fermentation and producing biogas.
[0066] The above four Steps can be performed in separate batches from time to
time or
step-by-step continuously.
[0067] (B) A fiber-manufacturing phase: from Step 5 (Easing) to Step12
(Additive
cellulose production.
[0068] Step (5) Easing: The soaked and swelled stem raw materials are
delivered into a
threading and rolling machine or a roller to be rolled and squeezed and change
into
woody filament structures so that the bacteria can easily penetrate inside and
degrade
the raw materials.
[0069] Step (6) Biodegradation: The treated raw materials were put into a
biodegradation bin or pot to be soaked and mixed inside a bacterial culture
solution (for
example, the bacterial culture solution as prepared in Example 1). The mass
ratio of
the eased raw materials and the bacterial culture solution is 1 : 6. The
temperature was
maintained at about 35-40 C for a time period of about 32-36 hours. Generally,
the
conditions of biological degradation reaction are adjusted according to the
growth
conditions of the bacterial culture used so as to increase specific bacterial
degradation.
[0070] Step (7) Steam Sterilization: Biodegraded materials were removed from
the
degradation pot, drained, and sterilized to remove bacteria. Then, the
biodegraded
materials were placed inside a steam pot and steam was used to passing through
them
for about 10-30 minutes. The biodegraded materials were then delivered from
the
output of the steam pot into a fiber refiner/grinder.
[0071] Step (8) Fiber Extraction: Fiber bundles were obtained by coarsely
grinding the
sterilized materials for a time period. The fiber bundles were then finely
grinded and
dispersed into single fibers. The fiber bundles were repeatedly screened,
filtered and
re-grinded again to obtain individual single fibers.
CA 02885486 2015-03-17
[0072] Step (9) Sterilization: The fibers were mechanically grinded after
coarse and fine
grinding. Most of the fibers were curved, twisted, and deformed, and were
extracted by
soaking in warm water to change, draft and extend any curved structures formed
during
mechanical fiber extraction. Then, drying and sterilization of the above-
obtained fibers
were soaked in warm water, then gone through drying, combing, drafting to
further
obtain straight and paralleled fibers.
[0073] Step (10) Textile Fiber Extraction & Production: The above-obtained
single fibers
were extracted using manufacturing techniques known to people skilled in the
art (e.g.,
diluted alkali or low base solution techniques) to remove lignin, sterilize,
grind and
obtain textile fibers at step (11). The resulting single fibers can be used as
additives (12)
in food or medical, or consumer products.
[0074] (C) A by-product generating phase: Step A - Step C.
[0075] Step A: Organic Feeds. The barks of the prepared Caragana raw materials
at
Step (3) are rich in nutrients and can be fermented into feeds for cattle and
sheep.
[0076] Step B: Bio-organic fertilizer. After repeated soaking and swelling at
Step (4), the
biodegraded material solution became turbid and was delivered to go through
flocculation and sedimentation. The resulting supernatant solution was
recycled for
future use. Then, the precipitates and sediments were discharged and delivered
into a
biogas pool to be fermented and produce biogas, which can be used to heat a
coal and
biogas compatible boiler and reduce coal consumption.
[0077] Step C: Bio-organic Fertilizer. After fermentation in the biogas pool,
the
generated biogas residues, slurries, biogas liquids are rich bio-organic
fertilizers. So
the liquid residue/slurry solutions can be used as fertilizers for
agricultural crops and
nutrient solutions for flowers. The remaining solid particles and residues can
be used
as base fertilizers. All such fertilizers are green fertilizers. The physical
properties and
measurements of the obtained celluloses are shown in Table 2.
Table 2
16
CA 02885486 2015-03-17
Caragana poplar willow
Polymer strength 560 520 500
Surface Capacity 7.3 7.2 7.1
(cm3/g)
Average particle 200 180 190
size (pm)
[0078] Example 7: Extraction of celluloses from herbal plant raw materials.
[0079] Using wheat straw as an example of raw materials, a process is
described herein
to specifically illustrate how to extract cellulose from herbal plant
materials. Other
herbal materials, such as rice straw and reeds, can also be used to extract
celluloses
accordingly.
[0080] When using wheat straw as an example of raw materials, the weight ratio
of a
complex microbial flora bacterial culture was configured to be Bacillus:
Rheinheimera
tangshanensis : Wickerhamomyces anomalus at 3: 2 : 2. When using rice straw as
raw
materials, the weight ratio of a complex microbial flora bacterial culture was
configured
to be Bacillus: Rheinheimera tangshanensis : Wickerhamomyces anomalus at 2: 2:
2.
When using reeds as raw material, the weight ratio of a complex microbial
flora bacterial
culture was configured to be Bacillus: Rheinheimera tangshanensis:
Wickerhamomyces
anomalus at 3: 1: 2.
posil According to the embodiments of Figure 3, the process of fiber
extraction
generally includes three phases: a preparation phase, a fiber-manufacturing
phase and
a by-product generating phase.
[0082] (Al. A preparation phase: from Step 1 (prepare raw material) to Step 4
(soak &
swell.
17
CA 02885486 2015-03-17
[0083] Wheat straw raw materials were cut into segments, each at a length of
about 4-5
cm, and then soaked & washed with cold water in a soaking, wetting, retting
pool or
tank so as to first wash away any dirt and other debris on the surface of the
raw
materials. The wheat straw raw materials were soaked with water at natural
temperature until the wheat straw raw materials were totally retted and
swelled, for
example, for about 10-12 hours. After repeat soaking, the solution liquid
became turbid.
Then, after flocculation and sedimentation, the supernatant clear solution was
recycled
for re-use. The precipitates and sediments were discharged and abated into a
biogas
tank for fermentation and producing biogas.
[0084] (B) A fiber-manufacturing _phase: from Step 5 (Easing) to Step12
(Additive
cellulose production; and (C) A by-product generating phase: Step A - Step C
as seen
in Example 2. The bacteria culture solution used are prepared the same as
described
in Example 1. During the biodegradation process, the weight ratio of the
treated raw
materials and the bacteria culture solution is 1: 8. The physical properties
and
measurements of the obtained fibers are shown in Table 3 as below.'
Table 3
Wheat straw Rice straw Reeds
Polymer strength 480 450 440
Surface Capacity 7 6.8 6.5
(cm3/g)
Average Particle 180 150 160
Size (pm)
[0085] Example 8: A biological pulping process using a bacterial culture and
woody raw materials.
[0086] Using Caragana as an example of raw materials, a process is described
herein
to specifically illustrate how to prepare a biological pulping solution system
from woody
18
CA 02885486 2015-03-17
materials. Other woody materials, such as poplar and eucalyptus, etc., can
also be
used to in a method of preparing a biological pulping solution system
accordingly.
[0087] When using caragana as raw materials, the weight ratio of a complex
microbial
flora bacterial culture was configured to be Bacillus: Rheinheimera
tangshanensis :
Wickerhamomyces anomalus at 3: 1: 2. When using poplar as raw materials, the
weight ratio of a complex microbial flora bacterial culture was configured to
be Bacillus:
Rheinheimera tangshanensis : Wickerhamomyces anomalus at 3: 2: 2. When using
eucalyptus as raw material, the weight ratio of a complex microbial flora
bacterial culture
was configured to be Bacillus: Rheinheimera tangshanensis : Wickerhamomyces
anomalus at 2: 2 : 3.
[0088] According to the embodiments of Figure 4, the process of making a
biological
pulping solution system generally includes three phases: a preparation phase,
a pulp-
manufacturing phase and a by-product generating phase.
[00891 (A). A preparation phase: from Step 1 (prepare raw material) to Step 4
(soak &
swell.
[0090] Step (1) to Step (2) Preparing raw materials and Debarking: The stem
and
bark/epiderm of the harvested caragana raw materials were separated (e.g.,
using
winnowing machine or other machines). The bark/epiderm was separated and fed
into
organic feed processing plant to be processes into feeds, and the debarked
stem was
delivered to a cutting machine.
[0091] Step (3) Cutting/Slicing: The caragana stem raw materials were cut into
segments, each at a length of about 3-4 cm, preferably in oblique cut, in
order to
increase the area for water penetration.
[0092] Step (4) Soaking & Washing: The harvested caragana stem materials were
soaked with cold water in a retting pool or tank and washed to get rid of dirt
and other
debris on its surface. Then, the caragana stem materials were soaked in water
at
natural temperatures for a time period of about 10-12 hours, or until the stem
are totally
retted and swelled. After repeat soaking, the solution liquid became turbid.
Then, after
19
CA 02885486 2015-03-17
flocculation and sedimentation, the supernatant clear solution was recycled
for re-use.
The precipitates and sediments were discharged and abated into a biogas tank
for
fermentation and producing biogas.
[0093] The above four Steps can be performed in separate batches from time to
time or
step-by-step continuously.
[0094] (B) A fiber-manufacturing phase: from Step 5 (Easing) to Step12
(Biological
pulping solution production).
[0095] Step (5) Easing: The soaked and swelled stem raw materials are
delivered into a
kneading, threading, and/or rolling machine or a roller to be rolled and
squeezed and
changed into woody hairy structures. The kneading machine to destroy the
structure of
woody segment and loosen it into timber filaments so that the bacteria culture
can easily
penetrate inside and degrade the segments.
[0096] Step (6) Biodegradation: The treated raw materials were put into a
biodegradation bin or pot to be soaked and mixed inside a bacterial culture
solution, for
example, inside the bacterial culture solution as prepared from Example 1, The
weight
ratio of the eased raw materials and the bacterial culture solution is 1 : 6.
The
temperature was maintained at about 35-40 C for a time period of about 32-36
hours.
Generally, the conditions of biological degradation reaction are adjusted
according to
the growth conditions of the bacterial culture used so as to increase specific
bacterial
degradation.
[0097] Step (7) Steam Sterilization: Biodegraded materials were removed from
the
degradation pot, drained, and sterilized to remove bacteria. Then, the
biodegraded
materials were placed inside a steam pot and steam was used to passing through
them
for about 10-30 minutes. The biodegraded materials were then delivered from
the
output of the steam pot into a pulping machine.
[0098] Step (8) Coarse Pulping: The sterilized biodegraded materials were
transferred
to a high concentration grinder for a period of coarse pulping and forming
fiber bundles.
CA 02885486 2015-03-17
[0099] Step (9) Fine Pulping: The coarse pulp from the above step were
transferred
into another high concentration grinder for fine grinding and separating the
fiber bundles
into individual single fibers.
[0000] Step (10) Pulp Screening: The pulp solutions after grinding at least
twice may
include small portion of fiber bundles. The fiber bundles were repeatedly
screened,
filtered and re-grinded again to obtain individual single fibers.
[001013Step (11) Pulp Washing: The pulp obtained after coarse pulping and fine
pulping
were further mechanically grinded. Most of the fibers were curved, twisted,
and
deformed, and they need to be extracted by soaking in warm water to change,
draft and
extend any curved fiber structures formed during pulping and grinding, thereby
easing
the pulping fibers.
[00102] Step (12) Paper Board: The above-processed pulping solutions were
transferred
into a papering machine for manufacturing paper boards in a paper-making
process.
[00103] (C) A by-product generating phase: Step A - Step C.
[00104] Step A: Organic Feeds. The barks of the prepared Caragana raw
materials at
Step (3) are rich in nutrients and can be fermented into feeds for cattle and
sheep.
[00105] Step B: Bio-organic fertilizer. After repeated soaking and swelling at
Step (4), the
biodegraded material solution became turbid and was delivered to go through
flocculation and sedimentation. The resulting supernatant solution was
recycled for
future use. Then, the precipitates and sediments were discharged and delivered
into a
biogas pool to be fermented and produce biogas, which can be used to heat a
coal and
biogas compatible boiler and reduce coal consumption.
(00106] Step C: Bio-organic Fertilizer. After
fermentation in the biogas pool, the
generated biogas residues, slurries, biogas liquids are rich bio-organic
fertilizers. So
the liquid residue/slurry solutions can be used as fertilizers for
agricultural crops and
nutrient solutions for flowers. The remaining solid particles and residues can
be used
as base fertilizers. All such fertilizers are green fertilizers.
21
CA 02885486 2015-03-17
[oolonThe physical properties and index measurements of the paper after the
pulping
process are shown in Table 4 as below. The data results have shown the reach
of
Class AA level of excellence for corrugated paper (as seen in Table 6):
Table 4
Caragana Eucalyptus Poplar
Free flowing per ml 125 215 290
115 118.5 112.9
Weight g/cm2
Whitening %ISO 40.6 37.96 48.28
Bulk level cm3/g 1.83 1.87 2.31
Tear Index mN m2/g 7.13 3.96 3.72
Tensile Index N m/g 39.11 51.3 35.8
Burst Index kpa m2/g 1.62 2.5 1.5
Ring crush strength index N m/g 9.6 10.2 9.7
[oolosjExample 9: A biological pulping process using a bacterial culture and
herbal raw materials.
[00109] Using wheat straw as an example of raw materials to specifically
illustrate a
method of making a biological pulping solution from herbal raw material. As to
other
herbal raw materials, such as straw, rice straw and cornstalk, a biological
pulping
process can be carried out according to the process described herein.
romoiWhen using wheat straw as an example of raw materials, the weight ratio
of a
complex microbial flora bacterial culture was configured to be Bacillus:
Rheinheimera
tangshanensis : Wickerhamomyces anomalus at 2 : 2: 3. When using rice straw as
raw
materials, the weight ratio of a complex microbial flora bacterial culture was
configured
to be Bacillus: Rheinheimera tangshanensis : Wickerhamomyces anomalus at 1 : 3
: 3.
When using cornstalk as raw materials, the weight ratio of a complex microbial
flora
22
CA 02885486 2015-03-17
bacterial culture was configured to be Bacillus: Rheinheimera tangshanensis :
Wickerhamomyces anomalus at 2 : 2: 3.
[001 According to the embodiments of Figure 5, the process of a biological
pulping
solution system generally includes three phases: a preparation phase, a fiber-
manufacturing phase and a by-product generating phase.
Table 5
Wheat Straw Rice Straw Cornstalk
Pulp level SR 48 46 45
60.5 62.5 57.1
Weight g/cm2
Whitening %ISO 19.9 23.8 20.8
Bulk level cm3/g 2.08 2.46 2.80
Tear Index mN m2/g 3.39 4.77 2.94
Tensile Index N m/g 70.6 47.8 43.7
Burst Index kpa m2/g 3.09 1.95 1.82
poi 12)(A). A preparation phase: from Step 1 (prepare raw material) to Step 4
(soak &
swell.
(00113]Wheat straw raw materials were cut into segments, each at a length of
about 4-5
cm, and then soaked & washed with cold water in a soaking, wetting, retting
pool or
tank so as to first wash away any dirt and other debris on the surface of the
raw
materials. The wheat straw raw materials were soaked with water at natural
temperature until the wheat straw raw materials were totally relied and
swelled, for
example, for about 10-12 hours. After repeat soaking, the solution liquid
became turbid.
Then, after flocculation and sedimentation, the supernatant clear solution was
recycled
for re-use. The precipitates and sediments were discharged and abated into a
biogas
tank for fermentation and producing biogas.
Table 6 Quality Index of Crude Corrugated Paper
23
CA 02885486 2015-03-17
Unit Rule
Name of the Index Level of Best Product Top
Qualified
Excellence Product
Product
Weight Quantified g/cm2 AAA (80, 90, 100, (80, 90,
100, 110,
(80, 90, 100, 110, AA 110, 120,
140, 120, 140, 160, 180,
120, 140, 160, 180, A 160, 180, 200) 200) +5%
200) +4%
Tightness (no less giem3 AAA 0.55
than) AA 0.53 0.5 0.45
A 0.50
Vertical km AAA 5.0
Torn Length (no less AA 4.5 3.75 2.5
than) A 4.3
Cross-Sectional N nn/g' AAA 7.5
Pressure Index (no 8.5
less than) 10.0
s90 g/cm2 11.5
AA 7.5 5.0 3.0
>90-140 g/cm2
7.5 5.3 3.5
?..140-180 g/cm2 9.0 6.3 4.4
:180 g/cm2 10.5 7.7 5.5
A 6.5
6.8
7.7
9.2
[001141(B) A fiber-manufacturing phase: from Step 5 (Easing) to Step12
(Additive
cellulose production; and (C) A by-product generating phase: Step A - Step C
as seen
in Example 8. The bacteria culture solution used are prepared the same as
described
24
CA 02885486 2015-03-17
in Example 1. During the biodegradation process, the weight ratio of the
treated raw
materials and the bacteria culture solution is 1: 8. The physical properties
and
measurements of the obtained fibers are shown in Table 5.
[oolis]Although the present invention has been disclosed in the preferred
embodiment
described above, however it is not intended to limit the present invention,
any ordinary
skill in the art, without departing from the spirit and scope of the present
invention, the
inner and it is intended that modifications and improvements, Therefore, the
scope of
the invention as defined in claim depending on whichever.
