Opportunities for Nanotechnology in Advancing Agenda 2020 Technology Platforms. Breakthrough Manufacturing
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1 Opportunities for Nanotechnology in Advancing Agenda 2020 Technology Platforms Breakthrough Manufacturing D. E. White April 26, 2006
2 O 2 Agenda 2020 Focus for the Future CO 2 Meeting the Challenge of Deployment Positively Impacting the Environment Significant Reduction in Greenhouse Gases Decreased Ecological Footprint Next Generation Fiber Recovery and Utilization Recycled Fiber Indistinguishable from Virgin Fiber Advancing the Forest Bio-refinery Sustainable Forest Productivity Extracting Value prior to Pulping New Value from Residuals & Spent Liquors Technologically Advanced Workforce Breakthrough Mfg. Technologies Major Manufacturing Cost/Capital Reduction Significant Enhancement in Product Properties with Existing Assets Substantial Improvement Advancing the Wood in Energy Efficiency for Products Revolution Existing Processes Improved Building Systems Reduced System -2- From Workforce to Knowledge Workers in 7 years Costs6
3 Breakthrough Goal and Objectives Utilize new/emerging technology to achieve a 35% reduction in manufacturing cost through a focus on significant process change that reduce material and energy costs including Reducing raw materials and fiber use by up to 33% Reducing energy use by up to 50% Enhancing fiber functionality by up to 50% -3-
4 Focus Areas 1. Reduced Energy in Paper Dewatering / Drying Reduce process energy consumption by at least 33% and/or produce same or better quality fiber at 5-10% higher yield 2. Reduced Energy for Causticizing Develop lower-cost technology to replace the current (energy- and capitalintensive) causticizing process 3. Reduced Energy for Black Liquor Concentration Reduce energy consumed in the process of increasing black liquor solids by at least 50% -4-
5 Focus Areas 4. Increased Filler/Sustainable Cost-Effective Pigments Produce same or better-quality paper products with three times the non-fiber filler content and using coating pigments derived from lower-cost, renewable raw materials 5. Sheet Property Development Using less Energy and Materials Reduce energy consumed in the paper machine wet end by at least 33% and/or lower sheet basis weight by 15-20% while producing same or betterperforming products 6. Next Generation Technologies for Pulping and Bleaching Reduce process energy consumption by at least 33% and/or produce same or better quality fiber at 5-10% higher yield -5-
6 1 Reduced Energy in Use a better understanding of sheet dewatering to Paper Dewatering/ cost-effectively increase solids before drying to the Drying theoretical limit without compromising sheet structure Alternatives to press dewatering Avoids re-uptake of water (e.g., one-way press, improved felt design) Extend Current Pressing Limits Alternatives to vacuum technology to achieve pressure drop Interaction of water and fibrils at nano-scale - use and apply nanofibrils / nanomaterials to provide breakthroughs in reduction of energy consumption Hydrophilic to hydrophobic switch Nano filtration media for press felts Novel wood-based and non-wood-based nanoscale materials with enhanced properties (e.g., fillers, films, coatings, matrices, pigments, additives) to provide breakthroughs in use of fillers and coatings. -6-
7 2 Reduced Energy in Paper Dewatering/ Drying Develop next-generation technologies that improve energy transfer to the sheet for drying Improve mass transfer Increase cross direction moisture uniformity Understand interaction of water and fibrils at nano-scale - use and apply nanofibrils / nanomaterials to provide breakthroughs in reduction of energy consumption Develop and use novel wood-based and non-woodbased nanoscale materials with enhanced properties (e.g., fillers, films, coatings, matrices, pigments, additives) to provide breakthroughs in use of fillers and coatings -7-
8 3 Next Generation Technologies for Pulping and Bleaching Develop novel variations on the sulfur chemistry of the traditional Kraft process, especially as facilitated by black liquor gasification. Polysulfide pulping Splitting of sodium and sulfur Tradeoffs between time, temperature, capital cost, and concentration during cooking Explore fiber dewatering and quality of paper products manufactured with higher yield process Explore potential for black liquor gasification with sulfite pulping to replace current causticizing process Use of nanoscale materials and nanotechnology to improve conversion efficiencies of wood and woodbased materials to final products o Highly selective nanostructured catalysts to delignify or separate wood into its fundamental units in environmentally preferable ways o Sequestration of sulfur o Nano catalysts for bleaching Separation of cell wall constituents without altering native structures o Separation / extraction of chemicals from pulping -8-
9 4 Sheet Property Development Using Less Energy and Materials Develop alternative to refining as a way to generate bond strength that is more energy efficient and costeffective, without compromising drainage or formation Effects of extractable wood constituents on paper forming, fiber bonding, etc. -- e.g., by extracting hemicellulose prior to pulping (for increased cellulose yield) and reintroducing hemicellulose at the wet end to increase bond strength. Modification of fiber surfaces with additives or enzymes Technologies to modify fibers and fiber surfaces using biological or chemical treatments Alternative materials to cellulose fibers Modification of fibers to enable higher filler levels Increase the modulus of elasticity Bonding of fibrils without compromising drainage or formation o Reduce wood fiber mechanical refining energy and fiber usage Assemble fibrils into useful structures Nano-composite Structures with other materials Nano-sensors built into sheet Hygro-expansivity control Use of novel wood-based and non-wood-based nanoscale materials with enhanced properties (e.g., fillers, matrices, additives, and fibers) to provide breakthroughs in paper forming, fiber bonding, etc. -9-
10 5 Increased Filler / Sustainable Cost- Effective Pigments Develop novel materials and material additives that deliver strength and optical properties at lower cost that fiber (better filler / improved pigments) Innovative, low-cost materials and/or processes to improve filler fiber bonding Innovative, low-cost materials and/or processes to improve pigment-coating bonding Bio-based pigments and coatings Develop and use novel wood-based and non-wood-based nanoscale materials with enhanced properties (e.g., fillers, films, coatings, matrices, pigments, additives) to provide breakthroughs in use of fillers and coatings. - improve filler-fiber bonding - improve pigment-coating bonding - develop bio-based pigments and chemicals Create novel, functional self-assembling surfaces on existing lignocellulosic substrates -10-
11 6 Reduced Energy for Causticizing Develop full auto-causticizing technology: Better fundamental understanding of physical chemistry and thermal properties of auto-causticizing re-agents Concept definition studies New methods to increase concentration of alkali (white liquor) stream Fossil Fuel Alternatives Pilot-plant demonstrations Develop and employ highly selective nanostructured catalysts -11-
12 7 Reduced Energy for Black Liquor Concentration Evaluate a process approach that would integrate multi-technology selective separation processes Electromechanical separations Mechanical or membrane separations for partial dewatering Liquid-liquid separations Thermal separations Lignin separation earlier in the process (methods to remove high molecular weight components from BL) Identify new techniques for separating cell wall constituents without altering native structures Develop rugged, robust sensors to monitor processes at the nanoscale -12-
13 8 Next Generation Technologies for Pulping and Bleaching Develop energy-efficient mechanical defiberization processes, including radical alternatives (e.g. microwave, ultrasonic) Develop nanotechnologies to modify fiber surface nanostructure and fiber-fiber network bonding ability so wood fiber mechanical refining energy can be significantly reduced. -13-
14 9 Sheet Property Development Using Less Energy and Materials Develop papermaking approaches (new/modified refining and forming processes) to better control fiber network structure and improve web drainage properties Develop and use of novel wood-based and non-woodbased nanoscale materials with enhanced properties (e.g., fillers, matrices, additives, and fibers) to provide breakthroughs in paper forming, fiber bonding, etc. Develop and use functional nanomaterials (sensors, etc.) to provide breakthroughs in product value and performance Use and apply nanofibrils / nanomaterials to provide breakthroughs in operations such as water removal -14-
15 10 Next Generation Technologies for Pulping and Bleaching Develop application of non-sulfur chemistries, such as enzyme pretreatment, soda-aq, chemical (e.g., solvents), biological and borate Utilize, develop, and investigate use of nanoscale materials and nanotechnology to improve conversion efficiencies of wood and wood-based materials to final products o Develop and employ highly selective nanostructured catalysts to efficiently and effectively delignify or separate wood into its constitutive components in environmentally preferable ways. Identify new techniques for separating cell wall constituents without altering native structures -15-
16 11 Next Generation Technologies for Pulping and Bleaching Develop simplified, energy-efficient bleaching process (e.g., in chemicals used) Utilize, develop, and investigate use of nanoscale materials and nanotechnology to improve conversion efficiencies of wood and wood-based materials to final products o Develop and employ highly selective nanostructured catalysts to efficiently and effectively delignify or separate wood into its constitutive components in environmentally preferable ways. Identify new techniques for separating cell wall constituents without altering native structures -16-
17 Acknowledgements Lori Perine, Executive Director, Agenda 2020 Technology Alliance Gerard Closset, Consultant, Agenda 2020 David Turpin, Co-Chair, Breakthrough Manufacturing Task Group, Agenda 2020 Ron Brown Nanotechnology for the Forest Products Industry Vision and Technology Roadmap, Oct.,
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