The search for lower-impact pulping technologies is increasingly focused not only on replacing conventional chemicals, but also on whether alternative processes can operate at realistic industrial scales. In a new study in the Journal of Bioresources and Bioproducts , Sunkyu Park assess the feasibility of using a hydrophilic deep eutectic solvent (DES) system to produce high-quality dissolving pulp.
The study combines industrial-scale process simulation with techno-economic analysis and life-cycle assessment. Using a choline chloride-lactic acid DES system, the researchers modeled five process configurations that varied solvent loading, washing strategy, pre-hydrolysis and membrane-based solvent recovery. The simulations assumed processing of 2,250 oven-dry metric tons of hardwood per day.
Across the modeled configurations, dissolving pulp yields remained relatively consistent at about 295-302 kg per metric ton of wood, indicating that the alternative process could achieve production levels comparable to conventional pre-hydrolysis Kraft pulping. The economic analysis, however, highlighted a significant challenge: recovering the DES requires substantial energy, increasing both operating costs and the demand on the powerhouse.
Among the five configurations, introducing pre-hydrolysis before DES cooking and reducing the solvent loading produced the lowest minimum selling price, at 1,330 yuan per air-dry metric ton. Sensitivity analysis further showed that reducing DES consumption and solvent losses could substantially improve the economics, while electricity revenue and natural gas prices also strongly influenced the results.
The environmental assessment provided a more nuanced picture. Replacing the conventional recovery boiler could reduce emissions by up to 60% under the modeled conditions, but the most economically favorable configuration was not the one with the lowest carbon footprint. The findings therefore point to a broader optimization challenge in which solvent recovery, energy integration, economic performance and environmental impact must be considered together.
Rather than presenting DES pulping as an immediate replacement for established Kraft technology, the study identifies the process limitations that need to be addressed before industrial implementation and provides quantitative targets for further process development.
See the article:
DOI
https://doi.org/10.1016/j.jobab.2026.100305
Original Source URL
https://www.sciencedirect.com/science/article/pii/S2369969826000770
Journal
Journal of Bioresources and Bioproducts
Experimental study
Not applicable
Techno-Economic Analysis of Hydrophilic Deep Eutectic Solvents As a Cost-Effective Green Alternative for Dissolving Pulp Production
7-Oct-2026