Conventional microcrystalline cellulose (MCC) production via aqueous mineral acid hydrolysis is energy- and water-intensive, generating high wastewater volumes. An alternative green chemistry approach employs concentrated gaseous acids to enhance yield and conserve resources. This work aimed to develop an efficient, sustainable gas-phase hydrochloric acid (HCl)-air hydrolysis process for MCC production from cotton linters. MCC yield, structure, powder properties, tablet performance, and environmental impacts were characterized. The gas phase method successfully produced 96% MCC yield and 87% crystallinity, higher than commercial MCC (93% yield, 39% crystallinity). MCC powder exhibited 141 μm mean diameter, 0.91 m²/g surface area, and 245 °C onset decomposition. Tablet testing revealed balanced ductility and toughness. Reduced water (40 kg/kg cellulose), energy (188 MJ/kg MCC), and wastewater generation (39 kg/kg cellulose) were achieved versus conventional production. Tablet testing of MCC compacts revealed balanced ductility and toughness during compression. The HCl-air approach enabled high-yield, high-purity MCC synthesis under mild conditions while enhancing powder attributes, tablet performance, and sustainability compared to commercial manufacturing.

通过水性无机酸水解进行的传统微晶纤维素 (MCC) 生产是能源和水密集型的，会产生大量废水。另一种绿色化学方法采用浓缩气态酸来提高产量并节约资源。这项工作旨在开发一种高效、可持续的气相盐酸 (HCl)-空气水解工艺，用于从棉短绒生产 MCC。对 MCC 产量、结构、粉末特性、片剂性能和环境影响进行了表征。气相法成功生产了96%的MCC收率和87%的结晶度，高于商业MCC（93%的收率，39%的结晶度）。 MCC 粉末的平均直径为 141 μm，表面积为0.91 m ² /g，245 °C 开始分解。片剂测试显示延展性和韧性达到平衡。与传统生产相比，减少了水（40 kg/kg 纤维素）、能源（188 MJ/kg MCC）和废水产生（39 kg/kg 纤维素）。 MCC 压片的片剂测试显示了压缩过程中延展性和韧性的平衡。与商业制造相比，HCl-空气方法能够在温和条件下实现高产率、高纯度的 MCC 合成，同时增强粉末属性、片剂性能和可持续性。