Resource efficient fibre web technologies

Erkki Hellén, VTT

Scientific coordinator

21.11.2013 FIBIC

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.

21.11.2013

Erkki Hellén

Efficient Networking towards Novel Products and Processes (EffNet)

EffNet 21.11.2013

Erkki Hellén

EffNet - Partners and international networking

• Partners: 8 Research Institutes and universities, 8 companies

• International Networking

• 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)

EffTech (2a) + EffNet (3a): ~4+15M€

EffNet

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

21.11.2013

Erkki Hellén

EffNet 21.11.2013

Erkki Hellén

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 21.11.2013

Erkki Hellén

FOAM FORMING – ENABLING RENEWAL Lightweight structures from novel raw material combinations

Synthetic fibres

Natural fibres

Regenerated fibres

Ultra lightweight materials Functional

chemicals

Nanomaterials

Foam +

7 21/11/2013

FOAM FORMING AT VTT’S SUORA ENVIRONMENT

EffNet 21.11.2013

Erkki Hellén

MAIN BENEFITS OF FOAM FORMING

EXCELLENT FORMATION

HIGH BULK

ADVANCED RAW MATERIAL COMBINATIONS

EffNet 21.11.2013

Erkki Hellén

-10

10

30

50

70

90

110

130

150

0 2 4 6 8 10 12

Mo

dif

ied

Sco

tt B

on

d [

j/m

2]

Bulk [cm3/g]

Pilot data

water

Foam

Foam+10%NFC

foam+20%NFC

HIGH BULK -> LIGHTWEIGHT STRUCTURES

• new raw material combinations

• raw material savings

• usage of materials impossible in water or dry

laid technologies

Not

possible

with

water

forming

Operating window for current

technology and raw materials

Foam forming

EffNet 21.11.2013

Erkki Hellén

0

0.5

1

1.5

2

2.5

3

Spruce-CTMP Pine 2 Birch 1

Sp

eci

fic

Be

ta f

orm

ati

on

[√

g/

m]

Water

Foam

- 69 %

- 49 % - 16 %

02468

1012141618202224262830323436

Spruce-CTMP Pine 2 Birch 1

Dry

ne

ss o

f th

e w

eb

[%

]

Water

Foam

+ 30%

+ 41%

+ 47%10

15

20

25

30

0 15 30 45 60 75 90 105 120 135 150

Ten

sile In

dex [

Nm

/g]

Grammage [g/m2]

Water

Foam

SUPERIOR FORMATION INDEPENDENT OF FIBER LENGTH

• Strength at low grammages • Utilization of long fibers

EffNet 21.11.2013

Erkki Hellén

GLOBALLY UNIQUE RESEACH INFRA FROM LAB TO PILOT SCALE

Handsheet formers Small circulation device

‘ KISU ’

SUORA research

environment

Sample size A4 & 500*500 mm.

Laboratory pressing &

drying

Web width 120 mm.

Laboratory pressing &

drying

Web width 250 mm. Reeled

sample & offline cylinder

drying

Web speed - 300 m/min (foam)

300 m/min (water)

~1000 m/min (foam)

2000 m/min (water)

Amount of

fibers

>Few grams > 5 kg > 300 kg

Layered

products

3 - layers (foam)

Single layer (water)

Single layer (foam)

3 layers (water)

Forming

geometry

1 - sided dewatering 1 - sided dewatering Fourdrinier / hybrid / gap

EffNet

Biomineral development

Kemira, VTT, Aalto

Laboratory sheets

VTT, Aalto

Semi-pilot testing

VTT, Stora Enso

Pilot scale trials

VTT, UPM

Pilot calendering

Metso

Printing

KCL, VTT

VALUE CHAIN CO-OPERATION: development of binding fillers

21.11.2013

Erkki Hellén

Concept demonstrated by increasing the filler

content of paper from 30% to 40%

EffNet 21.11.2013

Erkki Hellén

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

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.

21.11.2013

Erkki Hellén

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

Amount of nanomaterial

SCIENTIFIC EXCELLENCE: nanocelluloses

21.11.2013 Erkki Hellén

Specific surface area

Swelling

Effect of REACH

Strength properties

TEM

Rheology

AFM

SEM OM

Pumping and mixing

Preservability

Centrifugal

pump

Screw

pump

New pump

type

Optimized pipe

dimensioning

Branched

structure

Overall dimensions in

macroscale, fine structure

in nanoscale

Scale bar: 20 μm

Chain or rod-like

structure

All dimensions in nanoscale

Charge/Chemistry

Polyelectrolyte-likeWood-

fibre likeDecreasing surface charge

Nanocrystals Nanofibres

Nanofibrillated

Size/Dimensions/Branching

Ribbon-like

structure

Overall dimensions in

macroscale, fine structure

in nanoscale

0

1

2

3

4

5

6

Bacterial cellulose

Image area 1x1 μmImage area 2x2 μm

Image area 2x2 μm

0

5

10

15

20

Colloidal dispersion

Microfibrillated

Image area 2x2 μm

Basic characterization

Distribution and retention Classification

Dewatering

Visual appearance Transmittance Viscosity

EffNet

EffTech & EffNet 2007-2013 (FIBIC)

• Potential of foam Technology

• Demo products

• Laboratory and semi-pilot scale

Naseva I & II, 2008-2013

• Stabile foams

• Nanocellulose foams

• Filters and insulation

Jyväskylä Innovation 2011-2012

• Thermoset composites

• Decorative products

VTT 2011-2012

• Mouldable and transparent webs

• Nonwoven products

KOTVA 2012-2013 (ERDF)

• SUORA scale-up

• Foam process development

TESTAA 2012-2013 (ERDF)

• Added value products

• Research infra for SMEs

FiFo 2013-2014 (Academy)

• Fibrous foams

• Foam rheology

21.11.2013

Erkki Hellén

FUTURE: TOWARDS FOAM TECHNOLOGY PLATFORM

1cm

EffNet

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.

21.11.2013

Erkki Hellén