Methods of forming crosslinked cellulose include mixing a crosslinking agent with an aqueous mixture of cellulose fibers containing little to no excess water (e.g., solids content of 25-55%), drying the resulting mixture to 85-100% solids, then curing the dried mixture to crosslink the cellulose fib
Methods of forming crosslinked cellulose include mixing a crosslinking agent with an aqueous mixture of cellulose fibers containing little to no excess water (e.g., solids content of 25-55%), drying the resulting mixture to 85-100% solids, then curing the dried mixture to crosslink the cellulose fibers. Systems include a mixing unit to form, from an aqueous mixture of unbonded cellulose fibers having a solids content of about 25-55% and a crosslinking agent, a substantially homogenous mixture of non-crosslinked, unbonded cellulose fibers and crosslinking agent; a drying unit to dry the substantially homogenous mixture to a consistency of 85-100%; and a curing unit and to cure the crosslinking agent to form dried and cured crosslinked cellulose fibers. Intrafiber crosslinked cellulose pulp fibers produced by such methods and/or systems have a chemical on pulp level of about 2-14% and an AFAQ capacity of at least 12.0 g/g.
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1. A method of forming a crosslinked cellulose product, comprising: mixing a crosslinking agent with an aqueous mixture of unbonded cellulose fibers having a solids content and containing little to no excess water, the crosslinking agent being added at a solids content of 10-50% and in an amount sui
1. A method of forming a crosslinked cellulose product, comprising: mixing a crosslinking agent with an aqueous mixture of unbonded cellulose fibers having a solids content and containing little to no excess water, the crosslinking agent being added at a solids content of 10-50% and in an amount suitable to achieve a desired level of crosslinking of the unbonded cellulose fibers based on the solids content;drying the resulting mixture to 85-100% solids; andcuring the dried mixture under conditions effective to crosslink the unbonded cellulose fibers. 2. The method of claim 1, wherein the aqueous mixture has a solids content of about 25-55%. 3. The method of claim 2, wherein the aqueous mixture has a solids content of about 35-55%. 4. The method of claim 2, wherein the aqueous mixture has a solids content of about 40-50%. 5. The method of claim 1, wherein the crosslinking agent is mixed with the aqueous mixture of unbonded cellulose fibers at ambient conditions. 6. The method of claim 1, wherein the crosslinking agent is added in an amount no more than that required to achieve a desired level of crosslinking of the unbonded cellulose fibers. 7. The method of claim 1, further comprising, prior to mixing, processing the aqueous mixture to reduce fiber clumps. 8. The method of claim 1, wherein mixing is performed in one or more of an extruder, a refiner, and a high-consistency mixer. 9. The method of claim 1, wherein the amount of crosslinking agent added corresponds to a chemical on pulp range of about 2-14%. 10. The method of claim 1, further comprising, prior to mixing, forming the aqueous mixture. 11. The method of claim 10, wherein forming the aqueous mixture includes mixing one or more of wet lap, previously-dried cellulosic fibers, and never-dried cellulosic fibers, with water. 12. The method of claim 11, wherein forming the aqueous mixture is performed in one or more of an extruder, a hydrapulper, and a high-consistency mixer. 13. The method of claim 11, wherein forming the aqueous mixture includes adding the cellulose fibers in bale or roll form to a hydrapulper in the presence of water. 14. The method of claim 10, wherein forming the aqueous mixture includes mixing cellulose fibers with water at a solids content of about 25-55%. 15. The method of claim 10, wherein forming the aqueous mixture includes mixing cellulose fibers with water at a solids content of lower than about 25%, followed by at least partially dewatering the mixture in order to achieve a solids content of about 25-55%. 16. The method of claim 1, wherein the crosslinking agent comprises one or more of a polyacrylic acid and a polycarboxylic acid. 17. A method of forming a crosslinked cellulose product, comprising: forming an aqueous mixture of unbonded cellulose fibers having a solids content of about 40-50%;mixing a polyacrylic acid crosslinking agent with the aqueous mixture in an amount to achieve a chemical on pulp level of about 2-14%, wherein said crosslinking agent is mixed at ambient conditions;drying the resulting mixture to 85-100% solids; andcuring the dried mixture under conditions effective to crosslink the unbonded cellulose fibers. 18. The method of claim 1, performed by a system, the system comprising: a mixing unit being configured to form, from the aqueous mixture of unbonded cellulose fibers having a solids content of about 25-55% and the crosslinking agent, the substantially homogenous mixture of non-crosslinked, unbonded cellulose fibers and crosslinking agent, at ambient conditions;a drying unit downstream of the mixing unit and configured to dry the substantially homogenous mixture to a consistency of 85-100% without curing the crosslinking agent; anda curing unit downstream of the drying unit and configured to cure the crosslinking agent, thereby forming dried and cured crosslinked cellulose fibers. 19. The method of claim 18, wherein the mixing unit includes a first zone configured to form the aqueous mixture of unbonded cellulose fibers, and a second zone configured to receive both the aqueous mixture and the crosslinking agent and form the substantially homogenous mixture. 20. The method of claim 19, wherein the first and second zones are two subsequent regions of an extruder. 21. The method of claim 18, wherein the mixing unit includes a high consistency mixer. 22. Intrafiber crosslinked cellulose pulp fibers produced by the method of claim 1, wherein the fibers have a chemical on pulp level of about 2-14% and an AFAQ capacity of at least 12.0 g/g. 23. The fibers of claim 22, wherein the cellulose pulp fibers include hardwood cellulose pulp fibers. 24. The fibers of claim 23, wherein the cellulose pulp fibers are hardwood cellulose pulp fibers. 25. The fibers of claim 23, wherein the hardwood cellulose pulp fibers are eucalyptus pulp fibers. 26. The fibers of claim 22, wherein the cellulose pulp fibers are intrafiber crosslinked with a polyacrylic add and/or polycarboxylic add crosslinking agent. 27. The fibers of claim 22, having an AFAQ capacity of at least 16.0 g/g. 28. The method of claim 17, wherein mixing includes adding the crosslinking agent at a solids content of 10-50% to the aqueous mixture.
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