VTT - from Forest Bioeconomy Research towards Sustainable Innovations

Transcription

1 VTT - from Forest Bioeconomy Research towards Sustainable Innovations Pia Qvintus Michigan Forest Bioeconomy Conference February 12-13, 2019 Midland, MI VTT beyond the obvious 1

2 VTT beyond the obvious VTT is one of the leading research, development and innovation organizations in Europe. We help our customers and society to grow and renew through applied research. The business sector and the entire society get the best benefit from VTT when we solve challenges that require world-class know-how together and translate them into business opportunities. Established in M Net turnover and other operating income (VTT Group 2017) 2,368 Total of personnel (VTT Group ) Our vision A brighter future is created through science-based innovations. Our mission Customers and society grow and renew through applied research. Owned by Ministry of Economic Affairs and Employment 27% Doctorates and Licentiates (VTT Group 2017) Strategy 36% Impact through scientific and technological excellence. from abroad (VTT Group 2017) VTT beyond the obvious 2

3 VTT s research projects 1 COMMERCIAL PROJECTS Impact: Building competitiveness for VTT s customers through world-class research and innovation services 2 JOINTLY FUNDED PROJECTS Impact: More efficient technology transfer Foundation for new innovations and political decision-making 3 SELF-FINANCED PROJECTS Impact: Developing VTT s own competitiveness and acquiring knowledge and expertise to meet future customer needs VTT beyond the obvious 3

4 VTT s business areas Sensing and integration Connectivity Data-driven solutions National Metrology Institute VTT MIKES Micronova manufacturing services KNOWLEDGE INTENSIVE PRODUCTS AND SERVICES SMART INDUSTRY AND ENERGY SYSTEMS Lifecycle solutions Nuclear safety Smart energy and transport solutions Digital engineering Business innovation foresight Industrial biotechnology and food solutions Biomass processing and products Sustainable energy and chemical technologies SOLUTIONS FOR NATURAL RESOURCES AND ENVIRONMENT VTT beyond the obvious 4

5 Biomass processing and products Development of resource efficient and cost competitive processes and added-value product concepts based on renewable raw materials BIOMASS PRETREATMENT Mechanical, chemical and enzymatic processing of raw materials UPGRADING FRACTIONS Lignin up-grading technologies Recovery of high-value components Sustainable dissolution processes Total 125 experts working in Biomass processing and products WEB BASED FIBRE PRODUCTS Foam forming of thin and thick webs Moldable web NFC films and membranes Barriers and functional coating BIO-BASED HYBRID STRUCTURES Biocomposite production technologies, esp. extrusion Man-made fibres and yarns Biopolymer foams, 3D-structures and functional materials

6 Why forest bioeconomy? Finland is #1 forested country in Europe Annual forest growth 110 million m3, only 60% used Long history in pulp and paper industry research Global big players Stora Enso and UPM in Finland Integration of over 100 years old Pulp and Paper Research Institute (KCL) and VTT in 2009 Identified need of renewal of pulp and paper industry and te long tradition in pulp and paper research have formed a platform for development of new revolutionary bio products VTT beyond the obvious 6

7 The value of forest industry production can be doubled and the climate targets for 2050 can still be obtained FinnCERES project Source: Arasto, Antti; Koljonen, Tiina; Similä Lassi (eds.) Wealth from bioeconomy - Integrated bioeconomy and low carbon economy futures for Finland, VTT Technical Research Centre of Finland Ltd. Comparisons are made to year FinnCERES project by Aalto Universiy and VTT started in /02/2019 VTT beyond the obvious 7

8 VTT-Aalto BIOECONOMY infrastructure co-operation - the national roadmap of research infrastructures Building excellence in research, education and enabling technologies

9 Bioeconomy in Circular Economy Business models of circular economy Product-life extension Product as a service Sharing platform Renewability Resource efficiency and recycling Business Finland launched in the beginning of 2019 Bio and Circular Finland program for innovation funding and development of export activities with budget of 300 million

10 VTT Ventures and VTT Launch pad VTT

11 1) Biocomposites 2) Biopolymers 3) Textiles VTT beyond the obvious 11

12 Why Biocomposites? There is increasing need in consumer goods, transportation, packaging's and construction for materials with low carbon footprint, replacement of oil based materials sustainable end of life natural aesthetic look and haptics combined with easy processing enabling diverse shapes development of strong lightweight composite materials made of (bio)polymers and cellulosic fibers which can be composted or recycled

13 Foaming of biocomposites combines advantages of Thermoplastic foams Natural fibers Light weight Low material usage Energy and cost savings Certain properties improved High strength High stiffness Non-abrasiveness Easy availability Sustainable VTT beyond the obvious New business opportunities Application areas e.g. packaging, construction, transportation Sustainable light-weight products with cellular structure 13

14 Thermoforming of biocomposite films combine the properties of both plastic and cardboard. It can be moulded as plastic having at the same time high natural fibre content New business opportunities Application areas e.g. packaging, construction, furniture, transportation 19/02/2019 VTT beyond the obvious 14

15 Potential use of paper industry side streams in composites Project : EU- Reffibre Significant amounts of valuable components such as fibres and mineral fillers are lost in the form of side streams. Global demand for sustainable products is steadily increasing and new environmental concerns and waste disposal laws are pushing the industry to find new and alternative uses for waste residues. improved composite properties decreased waste generation improved resource efficiency reduced environmental footprint add value of the side streams Realised Side streams from the paper production Pretreatments e.g. grinding, drying Melt compounding + Additives Side stream Injection moulding or extrusion Side streams from paper industry successfully demonstrated as raw material in injection moulded and extruded products Granulates Thermoplastic polymer Products The research leading to these results has received funding from the European Community's Seventh Framework Programme VTT beyond the obvious under grant agreement n

16 Totally biobased injection moulded chair Material development was performed by VTT as a part of ACel program in the Clic Innovations Ltd (TEKES). Biobased injection mouldable thermoplastic composite material with the focus on high cellulose fibre content, good visual look, improved material performance and competitive price. VTT developed totally biobased composite material which were demonstrated in injection moulded chair together with KO-HO Industrial design and Plastec Finland Oy. No petroleum based raw materials New additives improves the material properties enabling to meet the material performance targets Material demonstrated in injection moulded end products 100% Biobased 30% cellulose VTT beyond the obvious 16 Lisa Wikström, VTT

17 Paptic fibre composite material to replace plastic A bioplastic composite paper combining the benefits of paper, plastics and textiles Certified pulp as raw material Recyclable in cardboard recycling system VTT beyond the obvious 17

18 Biopolymers Lignin Cellulose VTT beyond the obvious 18

19 Lignin VTT beyond the obvious 19

20 Higher Value from Lignin VTT research activities Phenolic resins for wood products CatLignin technology for highly reactive lignin Solvent fractionation Biotechnical activation Fuels & chemicals HTL Pyrolysis Solvolysis LIGNIN Kraft Soda Organosolv Hydrolysis residue Surface active agents Thermoplastic materials LigniOx technology for versatile dispersants Concrete and gypsum plasticizers Dispersant for inorganic fillers/pigments Thermoplastic matrix polymer for composites Tackifier for hot melt adhesives Coatings Carbonised materials Carbon black by HTC Activated carbon: water purification, energy storage, catalysis Rubber and plastic products Reinforcement fillers Antioxidants Fire retardants

21 VTT Patent Applications: US , WO2015/049424, WO2017/ LigniOx technology based on alkali-o2 oxidation for versatile lignin dispersants High performance concrete plasticizers Higher performance compared to lignosulfonate admixtures and most of the synthetic plasticizers Gypsum plasticizer & setretardant Comparable to commercial plasticizers No plasticizer Superplasticizer, 0.2% Dispersant of various pigments for paints, inks and coatings TiO 2, CaCO 3 and kaolin dispersion close to commercial synthetic dispersant Carbon black dispersion better than commercial synthetic dispersant Lignosulfonate, 0.4% LigniOx lignin, 0.4%

22 LigniOx commercialisation LigniOx BBI Innovation Action (05/ /2021, 5.6 M ) Main activities : Oxidation concepts for various technical lignins Scale-up and construction of mobile pilot unit Integration to biorefineries Product formulation & prototype for concrete plasticizers Demonstration of process and product performance at industrial conditions Techno-economic and environmental assessments Regulatory issues for market uptake 19/02/2019

23 CatLignin Highly reactive lignin by thermal treatment Reactive sites for PF resins Taylor-made kraft lignin properties by thermal treatment of black liquor at pulp mill Lignin with high number of phenolic functionalities & adjusted Mw Increased reactivity for resins Improved antioxidative properties e.g. for composites Improved adhesion in HMAs Proven in lab and small pilot scale for industrial SW & HW black liquors Birch plywood strength 50% phenol substitution VTT Patent Applications: WO , WO

24 Lignin for thermoplastic materials Lignin use potential in several thermoplastic endproducts as such or after chemical modification Plastic composites Coatings Hot melt adhesives (HMA) Lignin can provide in thermoplastic materials cost savings with additional functionality, e.g. Reinforcement Antioxidativity UV-protection Fire retardancy Adhesion VTT Patent Application: FI

25 Tannin polyphenols Tannins are currently produced from the bark and wood of certain southern tree species Acacia (wattle, mimosa, bondtite), Schinopsis (quebracho), chestnut, t/a production Tannin polyphenols + starch derivative as glues for laminates and vaneer based products 1 Estimated 1 Mt/a (d.m.) spruce and 2 Mt/a (d.m.) pine bark produced in wood working industry in Finland Condensed tannins are the main components of softwood bark extractives (Mw = Da) High reactivity towards aldehydes Hot water extraction demonstrated in pilot scale (raw tannin extracts in multi kilo scale) Pine tannin PF resin (30% substitution) displays similar results to commercial reference PF resin Tannin containing insulation foams display promising properties, yet not commercial quality Condensed tannin Tannin PF resin / shear strenght VTT beyond the obvious 25 1 WO 11/ Adhesive agent, a manufacturing method and the use of said agent

26 Cellulose VTT beyond the obvious 26

27 VTT s Thermocell Cellulose Molar mass adjustment Functionalization Pelletization Applications 100% BIOBASED MATERIALS WO A1 and FI VTT beyond the obvious 27

28 Global bioplastics demand by type (metric tons) PBS polybutylene succinate PE polyethylene PHA polyhydroxyalkanoate PLA polylactic acid PP polypropylene PTT polytrimethylene terephthalate PVC polyvinyl chloride Source: Global Markets and Technologies for Bioplastics, BCC Research, Jun. 2016, #PLS0550D 28

29 VTT s Thermocell Circular Materials Challenge 2018 Award, Ellen MacArthur Foundation & & Ecopack Challenge 2018 Award, Packaging Innovations in assoc. with Marks&Spencer Finalist for Sustainability Awards 2018, Packaging Europe VTT beyond the obvious 29

30 Textiles VTT beyond the obvious 30

31 Introduction The global situation of textile fibres Total Synthetic (polyester, nylon, acrylics) Natural (cotton, wool, silk) Cellulosic (regenerated) 6% 31% 62% World fibre market 2017 World fibre consumption, million tonnes Year Figures illustrated based on data from The Fiber Year 2018 January 16, 2019 Hanna Hörhammer and 31 World population, billions

32 Textile fibre research at VTT Regenerated fibres Cellulose derivatives Viscose Cellulose Carbamate, spinned off to IFC Wood Cellulose pulp Ioncell-F (Aalto University, Helsinki University) BioCelSol (TUT, VTT) No dissolution Paper, carton board Paper yarn, spinned off to Spinnova DES-yarn (VTT) VTT beyond the obvious 32

33 Biocelsol technology for regenerated fibres Value proposition: Regeneration of cellulosic fibres in a sustainable way - using abundant cellulose raw material and applying environmentally sound technologies. Competitive edge: The sustainable Biocelsol technology produces staple fibres with excellent physical and chemical characteristics. VTT has long experience and outstanding knowledge in the field of cellulose valorization. Offering: Purification and regeneration of cellulosic based material (both virgin and recycled fibres) and production of functionalized textile staple fibres in scales from bench to pilot. Outcome: Concept and input to R&D. Production and testing of textile staple fibres. Process optimization and concept evaluation. Photo (ensure we have rights to publish) Process: Cellulose purification Pretreatment Dissolution Wet spinning Textile staple fibres January 16, 2019 Hanna Hörhammer 33

34 Introduction Fibre regeneration/manufacturing technologies IFC S Technology Dissolution Regeneration Status Comment Viscose Pretreatment: NaOH Derivatisation: CS 2 -> Cell. xanthate Dissolution: NaOH, 8-12 C Wet spinning (H 2 SO 2, Na 2 SO 4, ZnSO 4 ) Lyocell Diss.: Direct, NMMO, C Dry-jet wet spinning (NMMO, H 2 0) Carbamate Pretr.: NaOH Deriv.: Urea -> CCA Diss.: NaOH, Zn < 0 C? Wet spinning (H 2 SO 4, Na 2 SO 4, Al 2 (SO 4 ) 3 ) Spinnova No dissolution Orientation of fibres in multiphase flow Dominant commercial Commercial Start-up Pilot Start-up Pilot Toxic compounds (CS 2 )! NMMO instable. NMMO recovery critical. Demonstrator dress Fashion Show 2018 First demonstrator garments produced 2016 VTT Biocelsol Pretr.: Enzymes, mechanical Diss.: Direct, NaOH, Zn < 0 C Wet spinning (H 2 SO 4, Na 2 SO 4 ) Research Zn recovery challenge Ioncell Diss.: Direct, ionic liquid IL ([DBHN][OAc]), 80 C Dry-jet wet spinning (H 2 0) Research IL recovery critical. Deontrator dress 2018 Metsä Spring building the pilot Cold alkaline Pretr.: NaoH Diss.: Direct, NaOH, Zn < 0 C Wet spinning (H 2 SO 4, Na 2 SO 4, Na 2 CO 3 ) Research Similar to Biocelsol. Other: Nitrocellulose, January 16, Alceru, 2019 Hanna Cocel, Hörhammer Cupro, DMAc/LiCl 34

35 European developers of cellulose based fibres Actors Technology Scale of equipment Lenzing Viscose, NMMO Viscose: t/year NMMO: t/year IFC Carbamate Pilot (Bioruukki), tons/a MetsäSpring Ioncell Demo plant under construction (Äänekoski), capacity 500 tons/a Spinnova Spinnova Demo plant sarted production in 12/18, up to 300 tons/a VTT Biocelsol Bench: -> 1 kg/d (Bioruukki) Pilot: -> 60 kg/d (Bioruukki) Rebuild and automised industry pilot SciTech Viscose Bench (Bioruukki) Aalto Ioncell Bench: ~100 g/d (Otaniemi) RISE (incl. Swerea) Cold alkaline Lab (Stockholm) Bench: ml dope/h = 330 g/h (Mölndal) Pilot: 150 kg dope/h = par. 10kg/h (Mölndal) Fraunhofer January 16, 2019 Viscose, NMMO, carbamate Other: MoRe, TITK, IBWCh, Sniace Hanna Hörhammer Adjustable wet spinning lines; filaments (Potsdam) Lab > Bench > Pilot > Demo > Commercial 35

36 Spinnova textiles from wood pulp Certified pulp as raw material Controlled rheology of multiphase flow of fibers in water to extrusion No harmful chemicals Minimal water usage VTT beyond the obvious 36

37 Infinited Fiber Company regenerated fibres from textile wastes or dissolving pulp Post consumer textile waste or dissolving pulp as raw material Non-toxic cellulose carbamate process VTT beyond the obvious 37

38 76 years of innovations Read more: VTT beyond VTT beyond the obvious the obvious 38

39 World Circular Economy Forum VTT beyond the obvious 39

40 World Circular Economy Forum 2019 Venue: Finlandia Hall, Helsinki Wellcome! VTT beyond the obvious 40

41 #VTTbeyondtheobvious