Session: 04-24-05: Materials Processing and Characterization V

Paper Number: 166065

Self-Reinforced All-Cellulose Composites: Processing, Challenges, and Industrial Potential 

Cellulose, the most abundant polymer on Earth, embodies sustainability, circular economy principles, and environmental friendliness. Cellulose is found in plants and also produced by bacteria. It is a valuable resource that can be extracted from agricultural residues, which should be utilized rather than discarded as waste. Its versatile properties make it suitable for applications ranging from packaging to advanced biological systems. One significant application is in the production of all-cellulose composites, which are formed through self-reinforcement without synthetic materials. These composites can be fabricated by either partially dissolving and compressing cellulose fibers or fully dissolving cellulose and reinforcing it with non-dissolved cellulose fibers. For industrial viability, the solvents used in this process must be cost-effective, recyclable, and environmentally friendly. Cold aqueous sodium hydroxide (NaOH)/urea solutions meet these criteria, as NaOH is widely used for both pretreating lignocellulosic materials and dissolving extracted cellulose.

All-cellulose composites can be manufactured using conventional composite processing methods or additive manufacturing. However, existing studies typically report all-cellulose composites with thicknesses below 5 mm due to challenges related to anti-solvent diffusion and differential shrinkage, which limit their broader applications. Overcoming these challenges requires improving anti-solvent diffusion and enhancing regeneration through pressure application. Additionally, all-cellulose composites can be combined with other natural materials, such as lignin, to achieve specific properties, leading to all-lignocellulosic or all-natural composites that maintain recyclability and biodegradability. By integrating these materials, it is possible to develop sustainable alternatives that align with circular economy principles while expanding the functional scope of cellulose-based composites.

This study aims to develop all-cellulose composites with thicknesses exceeding 5 mm using non-woven fibers extracted from date palm frond midribs. The high degree of polymerization of natural lignocellulosic fibers presents challenges for direct dissolution in NaOH/urea. To address this, a portion of the extracted fibers will undergo chemical treatment to produce dissolving pulp for the matrix phase, while the remaining fibers will act as reinforcement. The presence of lignin in the reinforcement phase is expected to enhance the composite’s hydrophobicity, though its potential impact on mechanical properties will be rigorously analyzed. All-cellulose composites have a wide range of applications, and this study specifically explores their potential in construction and packaging. Their lightweight nature, combined with their ability to be processed using sustainable methods, makes them a viable alternative to petroleum-based materials. By advancing the knowledge of cellulose dissolution and composite fabrication, this research contributes to the growing field of bio-based materials that can support a greener and more circular economy.

Presenting Author: Abul-Fazal Arif King Fahd University of Petroleum & Minerals (KFUPM)

Presenting Author Biography: N/A

Authors:

Rakan Alabdali King Fahd University of Petroleum & Minerals (KFUPM)
Abul-Fazal Arif King Fahd University of Petroleum & Minerals (KFUPM)
Bilal Ahmed King Fahd University of Petroleum & Minerals (KFUPM)
Tarique Jamal King Fahd University of Petroleum & Minerals (KFUPM)
Ahmad Sorour King Fahd University of Petroleum & Minerals (KFUPM)