Process and device for the formation of directly-formed cellulosic webs

A device for manufacturing cellulose-based webs which are directly formed from lyocell spinning solution comprising:

• a. an extrusion device comprising a meltblown air supply and being capable of extruding and extending a plurality of lyocell solution threads, arranged in one or more rows to form a curtain,
• b. a first washing zone comprising a delivery device comprising at least one nozzle, slit, rotating nip roller, or rotating disc and being capable of delivering a first wash liquor to the lyocell solution threads directly after extension and prior to web formation, whereby partially coagulated cellulose filaments may be formed,
• c. a web forming zone comprising a web forming device onto which the partially coagulated filaments may be laid to form a web, wherein the web forming device comprises a sieve belt or a perforated drum and has porosity sufficient to allow a gas stream and the first wash liquor to be extracted, and
• d. a second washing zone with a washing device comprising one or more belts or drums separate from the web forming zone, the washing device including multiple washing modules, each washing module comprising a wash liquor supply box comprising two chambers and an outlet slot and being capable of applying a second wash liquor to the web as a uniform, closed liquor curtain over the full width of the web at a controlled rate and temperature and of sufficiently low force in such a way as not to damage the web and the coagulated filaments and wherein each washing module further comprises a dewatering device comprising a vacuum suction and being capable of at least partially dewatering the web, and wherein the device can operate at line production speeds from 5 m/min to 1000 m/min.