Resource efficient fibre web technologies, Erkki Hellen

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FIBIC Seminar 20.11.2013

FIBIC Seminar 20.11.2013

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  • 1. Resource efficient fibre web technologies Erkki Hellén, VTT Scientific coordinator 21.11.2013 FIBIC
  • 2. Efficient Networking towards Novel Products and Processes (EffNet) • The EffNet program focuses on – a completely new type of energy- and resource-efficient production technology for web products and – designing nanocellulose-based production concepts and new products. • The target is to develop and demonstrate new types of fibre-based products to expand the range of products offered by the existing forest cluster companies. Special efforts will be made to minimise the energy consumption of new products and processes and develop resource-efficient processes. EffNet 21.11.201 3 Erkki Hellén
  • 3. EffNet - Partners and international networking EffTech (2a) + EffNet (3a): ~4+15M€ • Partners: 8 Research Institutes and universities, 8 companies • International Networking • • • • • EffNet 21.11.201 3 Erkki Hellén Co-operation with 10 countries (Canada, Denmark, France, Germany, Ireland, Israel, Sweden, U.K, Uruguay, U.S.A ) The collaboration with research groups (FPInnovations, KHT, Sweden). Long term research visits (Imperial College, UK, Trinity College Dublin, Ireland and the University of Texas at Austin, USA) Co-operation with Yttkemiska Institutet (YKI), Sweden, on foam chemistry Joint M. Sc. Theses (University of Uruguay)
  • 4. Concept level approach • Efficiency through area-based measurement criteria • Energy MWh/(km)² • Water m³/(km)² • Total costs (fixed+variable) €/(km)² • • • • New production technologies: foam and ultra high consistency forming Raw material efficiency through biominerals and binding fillers Reduction of total cost of ownership over the entire value chain Scientific excellence of nanocelluloses: characterization -> rheology -> dewatering -> safety -> environmental sustainability • Lean concepts by optimized design of production line wide performance • Multi-objective design methodology for production systems EffNet 21.11.201 3 Erkki Hellén
  • 5. FOAM FORMING – LEAP IN RESOURCE EFFICIENCY • Significant resource savings are expected for foam forming technology – The biggest advantage through fiber savings – Less drying energy due to decreased basis weight – Chemical costs are lower due to reduced basis weight and improved retention • Sustainability – Even 40% reduction in carbon and water footprints EffNet 21.11.201 3 Erkki Hellén
  • 6. FOAM FORMING – ENABLING RENEWAL Lightweight structures from novel raw material combinations Foam + Nanomaterials Natural fibres Ultra lightweight materials Regenerated fibres Synthetic fibres EffNet 21.11.201 3 Erkki Hellén Functional chemicals
  • 7. 21/11/2013 7 FOAM FORMING AT VTT’S SUORA ENVIRONMENT
  • 8. MAIN BENEFITS OF FOAM FORMING EXCELLENT FORMATION HIGH BULK ADVANCED RAW MATERIAL COMBINATIONS EffNet 21.11.201 3 Erkki Hellén
  • 9. HIGH BULK -> LIGHTWEIGHT STRUCTURES Operating window for current technology and raw materials 150 Modified Scott Bond [j/m 2 ] 130 110 Not possible with water forming Pilot data water Foam Foam+10%NFC 90 foam+20%NFC 70 50 30 Foam forming 10 -10 0 2 4 6 8 10 12 Bulk [cm 3 /g] • new raw material combinations • raw material savings • usage of materials impossible in water or dry laid technologies EffNet 21.11.201 3 Erkki Hellén
  • 10. SUPERIOR FORMATION INDEPENDENT OF FIBER LENGTH • Strength at low grammages • Utilization of long fibers Tensile Index [Nm/g] 30 3 Specific Beta formation [√g/m] - 69 % 20 + 41% 2.5 + 30% 2 25 - 49 % + 47% 1.5 - 16 % 15 10 Water 0 Foam 15 30 45 60 75 Water Foam 0 Spruce-CTMP EffNet 21.11.201 3 Pine 2 Birch 1 Erkki Hellén 105 Grammage [g/m2] 1 0.5 90 120 13
  • 11. GLOBALLY UNIQUE RESEACH INFRA FROM LAB TO PILOT SCALE Handsheet formers Web speed Amount of fibers Layered products Forming geometry EffNet SUORA research environment A4 & 500*500 mm. Laboratory pressing & drying >Few grams Web width 120 mm. Laboratory pressing & drying 300 m/min (foam) 300 m/min (water) > 5 kg Web width 250 mm. Reeled sample & offline cylinder drying ~1000 m/min (foam) 2000 m/min (water) > 300 kg 1-sided dewatering Sample size Small circulation device ‘ KISU’ 3-layers (foam) Single layer (water) 1-sided dewatering Single layer (foam) 3 layers (water) Fourdrinier / hybrid / gap 21.11.201 3 Erkki Hellén
  • 12. VALUE CHAIN CO-OPERATION: development of binding fillers Biomineral development Kemira, VTT, Aalto Printing KCL, VTT Laboratory sheets VTT, Aalto Pilot calendering Metso Semi-pilot testing VTT, Stora Enso Pilot scale trials VTT, UPM Concept demonstrated by increasing the filler content of paper from 30% to 40% EffNet 21.11.201 3 Erkki Hellén
  • 13. EFFICIENT NETWORKING Environmental management and sustainable use of nanocellulose • National co-operation between two Finnish Strategic Centres for Science, Technology and Innovation (SHOKs) • The Forest Cluster/EffNet program and • The Cluster for Energy and Environment/MMEA Program • Outcome: Finnish perspective on – the most critical product safety, environmental efficiency and regulation challenges of NFC production and the usage of it in intermediate and end-products Report available at: http://www.syke.fi/download/noname/%7B6EB71A59-55F6-4529-AB91-A2D8AB8C3025%7D/29791 EffNet 21.11.201 3 Erkki Hellén
  • 14. FROM NETWORKING TO COMMERCIALIZATION Metso IQ Surface Measurement • Combining the best forces to common goal – – – – – – – – Tampere University of Technology, Department of Automation Science and Engineering Lappeenranta University of Technology, Information technology Metso Automation University of Eastern Finland, Optics University of Helsinki, Department of Mathematics University of Jyväskylä, Department of Physics (P), Department of Information Technology (IT) University of Oulu, Control (C), Optoelectronics (O) UPM-Kymmene • Unique image-analysis based formation measurement • Predicts printability already in paper mill by online and enables the reduction of customer complaints. • Accurate and stable profile measurement for precise control of sheet surface properties in machine and cross directions. For more information see http://www.metso.com/Automation/pp_prod.nsf/WebWID/WTB-120904-2256F-C465D?OpenDocument and for a video http://www.youtube.com/watch?v=xA-RgxPr8Is EffNet 21.11.201 3 Erkki Hellén
  • 15. SCIENTIFIC EXCELLENCE: nanocelluloses Distribution and retention Pumping and mixing Classification Bacterial cellulose Centrifugal pump Size/Dimensions/Branching Scale bar: 20 μm Chain or rod-like structure Nanofibres Nanocrystals All dimensions in nanoscale Nanofibrillated 6 Microfibrillated Ribbon-like structure Overall dimensions in macroscale, fine structure in nanoscale Optimized pipe dimensioning 5 4 New pump type 20 3 2 Branched structure 15 1 Overall dimensions in macroscale, fine structure in nanoscale 10 0 Image area 2x2 μm Image area 1x1 μm Screw pump 5 0 Image area 2x2 μm Image area 2x2 μm Charge/Chemistry Colloidal dispersion Effect of REACH TEM Polyelectrolyte-like Woodfibre like AFM Decreasing surface charge Amount of nanomaterial Basic characterization Visual appearance OM Transmittance SEM Swelling Rheology EffNet 21.11.2013 Viscosity Strength properties Erkki Hellén Preservability Specific surface area Dewatering
  • 16. FUTURE: TOWARDS FOAM TECHNOLOGY PLATFORM EffTech & EffNet 20072013 (FIBIC) • Potential of foam Technology • Demo products • Laboratory and semipilot scale Naseva I & II, 2008-2013 • Stabile foams • Nanocellulose foams • Filters and insulation Jyväskylä Innovation 2011-2012 • Thermoset composites • Decorative products VTT 20112012 • Mouldable and transparent webs • Nonwoven products 1cm EffNet 21.11.201 3 Erkki Hellén KOTVA 20122013 (ERDF) • SUORA scale-up • Foam process development TESTAA 2012-2013 (ERDF) • Added value products • Research infra for SMEs FiFo 20132014 (Academy) • Fibrous foams • Foam rheology
  • 17. Impacts • Competence – To the date 40 peer reviewed articles from the program – Over 100 international conference presentations – 13 MSc thesis finished – 4 PhD thesis finished & 10 PhD thesis ongoing – 4 patent applications – Value of networking: broad insight and expertise within and after the program • Industrial – Unique, national research infra – Foam forming: radical leap in resource-efficiency for packaging board and a new platform for fiber-based products (non-wovens, construction, composites…) – Great potential with micro fibrillated celluloses – New knowledge and novel tools to improve production efficiency – New services, product ideas and technology concepts utilized in company driven product development projects The results provide a solid basis for further development towards efficient industrial solutions, generating value and new business opportunities for the industry. EffNet 21.11.201 3 Erkki Hellén