VTT Technical Research Centre of Finland Ltd

Transcription

1 VTT Technical Research Centre of Finland Ltd Heli Kangas, Research Team Leader Michigan-Finland Summit on Forest BioProducts, Oct 17-18, #vttpeople

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. Our vision A brighter future is created through science-based innovations. Our mission Customers and society grow and renew through applied research. Strategy Impact through scientific and technological excellence. Established in 1942 Owned by Ministry of Economic Affairs and Employment 258M Net turnover and other operating income (VTT Group 2017) 2,368 Total of personnel (VTT Group ) 36% from abroad (VTT Group 2017) 27% Doctorates and Licentiates (VTT Group 2017) VTT beyond the obvious 2

3 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 3

4 Biomass processing and products Development of resource efficient and cost competitive process and 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 CNF 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

5 Why partner with VTT? Five good reasons to choose VTT as your front-line research and innovation partner: 1 Several strong scientific focus areas create a flexible platform for radically new technology and business development. 2 We have a proven track record: 9% of Fortune Global 500 companies are already our customers. 3 Several world-class research environments and solid IPR assets. 4 Our active network enables the utilisation of the best available knowhow on a global scale. 5 Our skilled and motivated staff guarantees effective and reliable project execution. VTT is ISO 9001 and ISO certified VTT beyond the obvious 5

6 VTT s status as performer of R&D work BASIC RESEARCH Universities APPLIED RESEARCH VTT DEVELOPMENT Industry VTT beyond the obvious 6

7 Fiber web research at VTT VTT beyond the obvious 7

8 Perspective on history of fibre products and processes at VTT

9 Papermaking and foam forming research environment SUORA / Jyväskylä SUORA research infra offers excellent facilities and skilled personnel for development work and scale-up of new technologies, raw-materials, process concepts and chemicals Pilot-scale research environment for papermaking board manufacturing processes and product development Over 600 on-line measurements from the process Stratified foam forming Can be operated with very small amounts of raw material (<50 kg abs dry) The first pilot scale foam forming process and technology infra in the world speeds up to 1000 m/min

10 SutCo surface treatment line / Otaniemi SutCo surface treatment concept offers excellent facilities and skilled, experienced personnel for development work and scale-up of product concepts Modular semi-pilot for evaluation of new product concepts Excellent selection of different coating methods Possible applications Nanocellulose films Non-woven treatment Barrier enhancement of bio based plastics Barrier development Simple electronics Functional surfaces Bioactive functionalities Other customized applications (methods and products)

11 Nanocelluloses: Extensive knowledge from lab to pilot scale VTT offering examples Nanocellulose production concepts tailored for customer s raw materials State-of-the-art characterization and benchmarking from lab to pilots Performance-driven product development Safety and sustainability assessment Innovation and patentlandscapeanalysis Cross-disciplinary competence from several industrial sectors Electronic devices and as components 3D composites Water purification Packaging Optical structures Textiles Stability for Food, Cosmetics and Paints

12 Foam forming platform Over 50 Pilot trials More than 30 publications Over 70 partners & customers Project portfolio ~22 M since 2010

13 Examples of research results 1. Packaging solutions alternatives for plastic VTT beyond the obvious 13

14 BIO-BASED BARRIER SOLUTION FOR SUSTAINABLE PACKAGING 3 LAYER BARRIER FILM STRUCTURE Moisture & water vapour barrier Thermoplastic cellulose Nanocellulose film Thermoplastic cellulose Oxygen, gas & grease barrier Circular Materials Challenge 2018 Award, Ellen MacArthur Foundation Ecopack Challenge 2018 Award, Packaging Innovations in assoc. with Marks&Spencer Sustainability Awards 2018, Finalist Bio-Based Packaging

15 Transparent pouches for dry food 100 % RENEWABLE CUSTOMIZABLE 3 layer barrier film structure HEAT SEALABLE Moisture & water vapour barrier Thermoplastic cellulose Cellulose nanofibril (CNF) film Thermoplastic cellulose Oxygen, gas & grease barrier RECYCLABLE by EXTRUSION Accepts MULTIPLE BIOBASED RAW MATERIALS use of local resources Processable with EXISTING MACHINERY VTT

16 Bio-based packaging film Customer: Welmu International Oy New bio-based and/or renewable material to replace plastics and to produce clear and biodegradable films in packaging applications. VTT designed material combinations which were tested in pilot environment. A set of prototype films with alternative properties were manufactured. Development of novel material with great opportunities on packaging film markets. Decrease amount of plastic waste with nonplastic wrapping film. We chose the unconventional way to do R&D and outsourced it entirely to VTT. It has turned out to be a great decision as we are now on the brink of commercializing our new, revolutionary film material. Jaakko Kaminen CEO Welmu International Oy. Our wood based biowrap is the future of packaging Welmu Int.

17 Lightweight inner packages Light and soft fibrous cushioning element that protects the product from impacts Product shape made in manufacturing phase Foam formed inner packages Photos: Harri Kiiskinen and Juha Hakulinen VTT Kiiskinen H., Torniainen E., Kinnunen K., Method of forming a fibrous product, WO 2015/ A1

18 Material replacing paper and plastic PAPTIC LTD., A VTT SPIN-OFF COMPANY. The novel wood fibre-based material PAPTIC combines the renewability of paper with the resource efficiency and functionality of plastics. Biobased product of the Year Europe 2017

19 2. Biopolymerfibre composites VTT beyond the obvious 19

20 Cellulose fibre reinforced thermoformable materials Decrease the use of oil based raw materials Increase the use of cellulose based materials Improved stiffness Sustainability by replacing fossilbased plastics Up to 100% bio-based compositions Light-weight Applications in packaging, construction and transport Combination of light- weight and cellulose fibre reinforced biocomposite material For honeycomb cores and thermoformable packaging

21 Potential use of paper industry side streams in composites 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. Side streams from the paper production Pretreatments e.g. grinding, drying improved composite properties decreased waste generation improved resource efficiency reduced environmental footprint added value for the side streams Melt compounding Injection moulding + or extrusion Additives Side stream Granulates Project : EU- Reffibre The research leading to these results has received funding from the European Community's Seventh Programme LisaFramework Wikström, VTT under grant agreement n Thermoplastic polymer Products Realised Side streams from paper industry successfully demonstrated as raw material (30 50 wt-%) in injection moulded and extruded products

22 Totally bio-based injection moulded chair Bio-based injection mouldable thermoplastic composite material with the focus on high cellulose fibre content, good visual look, improved material performance and competitive price. 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 VTT developed totally bio-based composite material which were demonstrated in injection moulded chair together with KO-HO Industrial design and Plastec Finland Oy. 100% Bio-based 30% Cellulose Material development was performed by VTT as a part of ACel program in the Clic Innovations Ltd (TEKES).

23 3. Value from Lignin VTT beyond the obvious 23

24 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 LigniOx technology for versatile dispersants Concrete and gypsum plasticizers Dispersant for inorganic fillers/pigments Thermoplastic materials 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

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

26 CatLignin Highly reactive lignin by thermal treatment Reactive sites for PF resins Tailor-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 Birchplywood strength 50% phenol substitution VTT Patent Applications: WO , WO

27 VTT s R&D infrastructure an essential part of the national research infrastructure VTT beyond the obvious 27

28 Thermochemical conversion routes RESOURCES COMPETENCES PRODUCTS CO 2 REUSE CATALYTIC PROCESSING PTX C1 ECONOMY GASIFICATION SNG PYROLYSIS BTL UPGRADING FUELS DIRECT LIQUEFACTION, HTL CHEMICALS HYDROTHERMAL CARBONIZATION BIOCHAR 30/10/