Process for making high-strength, high-yield sulfite-modified thermomechanical pulp and a linerboard composition produced therefrom

Claim 2

A linerboard composition having a percent mullen of at least 80%, which includes at least 25% by weight of a sulfite-modified thermomechanical pulp having a yield of at least 85% by weight, a percent bound sulfur level of at least about 0.15% by weight, based on the total weight of lignocellulose employed in producing said sulfite-modified pulp.

Claim 3

The linerboard composition of claim 1, which includes at least 30% by weight of said sulfite-modified thermomechanical pulp.

Claim 4

The linerboard composition of claim 1, wherein said percent bound sulfur level is at least about 0.25% by weight.

Claim 5

The linerboard composition of claim 3, wherein said percent bound sulfur is at least about 0.40% by weight.

Claim 6

The linerboard composition of claim 1, wherein said sulfite-modified thermomechanical pulp has a yield of at least 90% by weight.

Claim 7

The linerboard composition of claim 1, which includes at least 40% by weight of said sulfite-modified thermomechanical pulp.

Claim 8

The linerboard composition of claim 1, wherein the weighted average fiber length of the sulfite-modified thermomechanical pulp is at least 1.4 millimeters.

Claim 9

The linerboard composition of claim 7, wherein the weighted average fiber length is at least 1.6 millimeters.

Claim 10

The linerboard composition of claim 1, wherein dry-strength additives are incorporated in said sulfite-modified pulp to further increase the burst strength of the linerboard sheet.

Claim 11

The linerboard composition of claim 9, wherein at least about 0.05% by weight of dry-strength additive, based on the total weight of pulp in the furnish, is combined with the sulfite-modified thermomechanical pulp.

Claim 12

The linerboard composition of claim 1, wherein said sulfite-modified thermomechanical pulp is combined with up to about 75% by weight chemical pulp.

Claim 13

A process for producing a linerboard composition having a percent mullen of at least 80%, including a replacement quantity of sulfite-modified thermomechanical pulp, which comprises: (a) initially imparting mechanical attritional forces to undefibered lignocellulose which has been subjected to an elevated temperature and corresponding pressure for a residence time period sufficient to soften the lignin portion of the lignocellulose causing substantial fiber separation to occur in the middle lamella layer so that the fibers remain essentially intact with a lignin coating on their outer surfaces, the power imparted to said undefibered lignocellulose by said initial mechanical attritional forces being sufficient to provide said substantial fiber separation without causing significant disassembly of the cellulose layers which form the fibers themselves; (b) adding a sulfite chemical to the lignocellulose prior to, during, or subsequent to said initial mechanical attrition step so that a substantial quantity of carbon-to-sulfur covalent bonds are created when the sulfite interacts with the lignin, the degree of sulfonation being controlled in a manner adequate to produce sulfite-modified thermomechanical pulp having a percent bound sulfur level of at least about 0.15% by weight, based on the total weight of lignocellulose employed in producing said sulfite-modified pulp, while at the same time preventing dissipation of the lignin content of the sulfite-modified thermomechanical pulp to the point where the yield is detrimentally affected; (c) subjecting said sulfite-treated lignocellulose to a second mechanical attrition step, conducted at substantially atmospheric temperature and pressure conditions, to produce a sulfite-modified thermomechanical pulp having a yield of at least about 85% by weight, the average fiber length of the undefiberized lignocellulose being substantially maintained on formation of the sulfite-modified thermomechanical pulp to facilitate the maintenance of a critical bursting strength level; (d) forming an aqueous linerboard furnish, including at least about 25% by weight of said sulfite-modified thermomechanical pulp, capable of being formed into linerboard having a percent mullen of at least about 80%, without altering the ability of the furnish to properly drain; (e) depositing said furnish on a foraminous surface to produce a wet linerboard web; and (f) drying said linerboard web.

Claim 14

A process for producing a linerboard composition having a percent mullen of at least 80%, including a replacement quantity of sulfite-modified thermomechanical pulp, which comprises: (a) initially imparting mechanical attritional forces to undefibered lignocellulose which has been subjected to an elevated temperature and corresponding pressure for a residence time period sufficient to soften the lignin portion of the lignocellulose causing substantial fiber separation to occur in the middle lamella layer so that the fibers remain essentially intact with a lignin coating on their outer surfaces, the power imparted to said undefibered lignocellulose by said initial mechanical attritional forces being sufficient to provide said substantial fiber separation without causing significant disassembly of the cellulose layers which form the fibers themselves; (b) adding a sulfite chemical to the lignocellulose prior to, during, or subsequent to said initial mechanical attrition step so that a substantial quantity of carbon-to-sulfur covalent bonds are created when the sulfite interacts with the lignin, the degree of sulfonation being controlled in a manner adequate to produce sulfite-modified thermomechanical pulp having a percent bound sulfur level of at least about 0.15% by weight, based on the total weight of lignocellulose employed in producing said sulfite-modified pulp, while at the same time preventing dissipation of the lignin content of the sulfite-modified thermomechanical pulp to the point where the yield is detrimentally affected; (c) subjecting said sulfite-treated lignocellulose to a second mechanical attrition step, conducted at substantially atmospheric temperature and pressure conditions, to produce a sulfite-modified thermomechanical pulp having a yield of at least about 85% by weight, the average fiber length of the undefiberized lignocellulose being substantially maintained on formation of the sulfite-modified thermomechanical pulp to facilitate the maintenance of a critical bursting strength level; (d) forming an aqueous linerboard furnish, including at least about 25% by weight of said sulfite-modified thermomechanical pulp, capable of being formed into linerboard having a percent mullen of at least about 80%, without altering the ability of the furnish to properly drain; (e) depositing said furnish on a foraminous surface to produce a wet linerboard web; and (f) drying said linerboard web.

Claim 15

The process of claim 12, wherein the Canadian Standard Freeness of the furnish is from about 150 CSF to about 650 CSF.

Claim 16

The process of claim 12, wherein said linerboard composition includes at least about 30% by weight of said sulfite-modified thermomechanical pulp.

Claim 17

The process of claim 12, wherein said sulfite-modified thermomechanical pulp has a percent bound sulfur of at least about 0.25% by weight.

Claim 18

The process of claim 15, wherein said percent bound sulfur is at least about 0.40% by weight.

Claim 19

The process of claim 12, wherein said sulfite-modified thermomechanical pulp has a yield of at least about 90% by weight.

Claim 20

The process of claim 17, wherein said linerboard composition includes at least about 40% by weight of said sulfite-modified thermomechanical pulp.

Claim 21

The process of claim 12, wherein the weighted average fiber length of the sulfite-modified thermomechanical pulp is at least about 1.4 millimeters.

Claim 22

The process of claim 12, wherein sulfite-modified thermomechanical pulp is combined with up to about 75% by weight chemical pulp.

Claim 23

The process of claim 12, wherein sulfur dioxide, in gaseous or liquid form, is added to said lignocellulose subsequent to said initial mechanical attrition step, but prior to further mechanical attrition.

Claim 24

The process of claim 12, wherein alkaline pH conditions are maintained during said initial mechanical attrition step.

Claim 25

The process of claim 22, wherein said pH is maintained at a pH of at least about 8 up to a pH of about 11.

Claim 26

The process of claim 12, wherein the undefibered lignocellulose is subjected to a pressure of at least about 30 psia for a residence time period of at least about 1.5 minutes.

Claim 27

The process of claim 24, wherein the residence time period is limited to about 5 minutes.

Claim 28

The process of claim 24, wherein the pressure is at least about 50 psia and the residence time is at least about 2.0 minutes.

Claim 29

The process of claim 26, wherein the residence time is limited to about 4 minutes.

Claim 30

The process of claim 12, wherein the power imparted to the undefibered lignocellulose during the initial mechanical treatment is less than about 50 HPD/T.

Claim 31

The process of claim 12, wherein the second mechanical attrition step is conducted at a lignocellulose consistency level of from about 20% by weight up to about 35% by weight.