Lignin sources, properties and volumes

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1 Lignin sources, properties and volumes Tom Browne Research Manager, Biorefinery & Bioenergy FPInnovations Pointe-Claire, QC Location: Date: World Bio-Congress, Montreal, QC June 18, 2013

2 Lignin: a complex macromolecule 2 nd most abundant plantderived polymer in the world, after cellulose The only large-scale, biobased source of aromatic functionality Renewable, potentially sustainable Hundreds of millions of tonnes available Realistic volumes are significantly smaller 2

3 Lignin: three basic monomer units 1. Coumaryl alcohol (Ag) 2. Coniferyl alcohol (SW) 3. Sinapyl alcohol (HW) 3

4 Lignin: a complex macromolecule Different types of lignin due to: Feedstock Agricultural, softwood, hardwood Biomass pre-treatment stages Acid prehydrolysis, enzymatic treatments, steam explosion, etc. Lignin extraction process Kraft, sulphite, soda, organosolv, etc. Post treatment processes Finally, how these processes are operated will affect end properties 4

5 Kraft and other processes for making wood pulp Generally, these processes seek to protect the cellulose Lignin is dissolved in a large digester using some form of chemistry Spent cooking chemicals are separated from lignin, and converted back to fresh cooking chemicals, in some form of recovery cycle Lignin is usually burned to drive the recovery reactions, and to generate heat 5

6 Kraft and other processes for making wood pulp Wood Pulping Cellulose Steam, Fresh liquors Lignin, Spent liquors Recovery Excess lignin 6

7 Kraft and other processes for making wood pulp Kraft pulp mills, conventional extraction process: Patents granted in Operated in Cornwall until mid-1960 s Currently operated by MeadWestVaco in Charleston, SC 17 kt/y high ash lignin, used as a dispersant Kraft pulp mills, modified extraction processes LignoBoost (SE), LignoForce (CDN) Pilot plants in operation, reduced ash content 30 kt/y plant currently in startup at Plymouth, NC N.A. mid-term potential: up to 500 kt/y if multiple kraft mills install extraction systems 7

8 Kraft and other processes for making wood pulp Sulfite pulp mills Current 1 Mt/y lignosulfonates produced worldwide Tembec, Lenzing, Borregaard are major vendors Added production is unlikely Other sources GreenValue SA offers 5 kt/y lignin from Indian straw pulp mills Potential exists for larger volumes if demand exists 8

9 Organosolv and other processes for making lignin and sugars Organosolv process uses a solvent, typically ethanol, to separate lignin and cellulose Process originally tried as the AlCell process, New Brunswick Cellulose initially used for papermaking Patents acquired by Lignol Cellulose converted to sugars today Lignin is chemically different from kraft lignin Volumes to be determined pilot plant scale today 9

10 Cellulosic ethanol processes: volumes Generally, pathways to cellulosic ethanol will generate a residue stream Depending on the process, this residue will include: Most of the lignin in the feed Possibly some unconverted carbohydrates Possibly remnants of enzymes or other organisms 1 billion litres of ethanol will generate ~500 kt/y lignin-rich residues Generally this will be burned for heat and power 10

11 Lignin: a complex macromolecule Different types of lignin due to: Feedstock Processes Operating conditions The lignin that works in one application won t necessarily work in the next Tailor the lignin and the process to the enduser s needs 11

12 Lignin in PF resins: not rocket science Copyright FPInnovations Do not reproduce without permission. 12

13 Plywood resin prices vs oil prices (inflation adjusted) 1,500 $ y = 8.28x R² = ,250 $ 1,000 $ 750 $ 500 $ 0 $ 20 $ 40 $ 60 $ 80 $ 100 $ 120 $ Copyright FPInnovations Do not reproduce without permission. 13 Data for 1955, 1960, 1980 ignored in the regression analysis Sources: SRI;

14 Lignin in PF resins: not rocket science But: Not economic when oil is $20 Pilot trials necessary to prove it again Lots of R&D into fossil-based phenols means performance requirements have shifted 70 years of phenol R&D versus 7 years in lignin Partial substitution only at this time 14

15 How much lignin is burned today? 2011 NAFTA kraft pulp production: 34 MT (FAO data) Roughly 17 MT of lignin is burned in parallel 1.7 to 3.4 MT (10% to 20%) could be removed without affecting the recovery process Could more be available? Possibly, but economics would be an issue Fuel to drive recovery, added caustic to replace lost sodium, etc. Caution: Reports of the demise of the paper industry have been greatly exaggerated Newsprint, copy papers in decline Packaging, tissue, hygiene grades are still growing 15

16 Potential volumes, 1-5 year horizon Source Today 5 years Comments Kraft lignin (MWV via 1948, 1952 patents) 17 kt/y 17 kt/y No added capacity likely Lignosulfonates 1 MT/y 1 MT/y No added capacity likely Kraft lignin (LignoForce, LignoBoost) Organosolv lignin Lignin from NAFTA cellulosic ethanol plants 20 kt/y 100 kt/y? Demand will drive growth Pilot scale 100 kt/y? Demand will drive growth kt/y? Low quality, mixed residue product 16

17 Conclusions Lignin properties: a function of species & process Lignin designed for one application won t necessarily work in the next Work with suppliers to tailor lignin to your needs Opportunities will arise as oil prices remain high Look for partial replacement where the existing product depends on oil prices 17

18 Contact FPInnovations Tom Browne Research Manager, Biorefinery and bioenergy 570 St-Jean Blvd. Pointe-Claire, QC H9R 3J9 Phone: Cell: FPInnovations. All rights reserved. Copying and redistribution prohibited. FPInnovations, its marks and logos are registered trademarks of FPInnovations.

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