Young Researchers: European Paper Industry Innovation Hub 22 November 2016 14h00-18h00
Marc Delgado-Aguilar Dr. Eng. LEPAMAP research group University of Girona
The research in short The purpose: Promoting circular economy in papermaking industry through the use of biotechnology and cellulose nanofibers. The keywords: Cellulose nanofibers, enzymatic refining, recycled pulps, high-yield pulps.
The research in short For how long? Research started in 2012. When do you expect to finish it? Albert Einstein said: If we knew what it was we were doing, it would not be called research. Would it? PhD thesis finished in 2015.
The research- in detail The problems Paper production requires large amounts of cellulosic fibers. World s forested lands and croplands have a finite capacity to supply such resources. Recylcing is becoming a central part of papermaking industry activities. Fibers experience structural and irreversible damages during recycling due to mechanical refining and hornification phenomena. The needs Basis weights must be decreased. Fiber content must be replaced by higher filler content such as calcium carbonate. New chemical-based strategies to enhance bonding within paper and paperboard must be developed. Further progress must be performed considering combined approach: Fiber attributes, nanostructured components, novel concepts in bond formation. Advances in unit operations.
What happens during paper recycling? Paper for application 1 Recycling process without additional treatments Paper for application 1 Paper for application 1 Recycling process without additional treatments Paper for application 2 Loss of properties due to hornification phenomena What happens if we want to produce a paper with the same quality? Paper for application 1 Recycling process Pulp treatment Paper for application 1 Ways to improve the bonding capacity of fibers Modifying the fibrous composition Mechanical refining Dry-strength additives High-yield fibers Secondary fibers from higher grades Innovations
Aims and scope Mechanical properties enhancement of papers from secondary and high-yield pulps. Enzymatic refining. Cellulose nanofibers in bulk. Cellulose nanofibers as coating. Development of low-cost and effective cellulose nanofibers. Reinforcing mechanisms of cellulose nanofibers. Comparative environmental impact assessment of the developed technologies with the existing ones.
What we found? 1. The addition of CNF leads to papers with higher mechanical properties than when they are mechanically refined, if drainage agents are properly added. 6000 Breaking length increase, % 120 100 80 60 40 20 0 3wt% CNF addition BKHP SGW ONP/OMG Substrate pulp Breaking length, m 5000 4000 3000 2000 1000 0 0 0.5 1 1.5 2 2.5 3 3.5 CNF, wt% 2. Enzymatic refining increases the mechanical properties significantly without any effect over the pulp drainability. Good behaviour of CNF after enzymatic refining on ONP/OMG pulps.
What we found? 3. Significant differences between the studied pulps: a. External fibrillation and fines. b. Chemical composition of the pulps. c. Initial relative bonded area (RBA) of the pulps 6000 3wt% CNF addition over screened pulps Breaking length, m 5000 4000 3000 2000 0 20 40 60 80 100 120 140 Screening time, min 0wt% CNF 3wt% CNF
What we found? 4. Lignin-containing CNF seem to be a good alternative: a. Decrease on paper whiteness and brightness. b. Potential application in test-liner/flutting paper grades.
What we found? 5. CNF as coating as a potential use of CNF in paper production. Advantages No effect on pulp drainability. Post-formation treatment. No special equipment is required. Physical and mechanical properties enhancement: Surface roughness. Brightness. Tensile strength. Challenges Coating formulation viscosity. CNF retention on paper surface. Interaction with other coating formulations. Potential application for active, intelligent and interactive packaging. Barrier properties. Functional and sensitive surfaces.
What we found? 6. Environmental impact assessment 180.0% 160.0% 140.0% 120.0% 100.0% 80.0% 60.0% 40.0% 20.0% 0.0% CNF Base Sc. CNF Sc.1 CNF Sc.2 CNF Sc.3 CNF Sc.4 Sulfphite instead of kraft 30% of energy improvement on LCNF production Combination of Base and 1 Hydropower electricity Combination of Base, 1 and 3
Why it is innovative What is so innovative about it? - Enzymatic refining is currently used for some papermakers with the purpose of reducing energy consumption during refining: - Using the conditions we used, mechanical refining can be completely replaced by enzymatic. - There is a lot of information regarding the use of CNF in papermaking. None of the published works deal with real suspensions, nor process waters. - Cellulose nanofibers as coating are used as reinforcement. Zero effect on pulp drainability. - Findings on the key parameters of CNF production.
Why it is innovative What good will it bring to the pulp and paper industry market? Higher life span of paper products. Basis weight reduction. Higher filler content in paper. Improved surface properties: barrier, hydrophobicity Functional papers. Versatility. CNF can be easily modified: Several properties in one paper: Grease resistance. Hydrophobicity. Oxygen barrier. Water vapour barrier. Antimicrobial. Strength. Thermo-sealing. AND IT IS STILL PAPER Well, it can even be RECYCLED PAPER
What it will bring - Raw material efficiency. - Improved properties: - New markets with higher requirements can be achieved. - High-value added products. - Substitution of current plastic products by paperbased products. - More energy-efficient processes. - Higher quality of recycled fibers. - Improvement on surface properties.
More information? 1. Delgado-Aguilar, M., et al. (2015). Cellulose 22(1): 789-802. 2. Delgado-Aguilar, M., et al. (2015). BioResources 10(3): 5345-5355. 3. Delgado-Aguilar, M., et al. (2015). Maderas. Ciencia y tecnología 17(2): 293-304. 4. Delgado-Aguilar, M., et al. (2015). Environmental Science & Technology 49(20): 12206-12213. 5. Delgado-Aguilar, M., et al. (2015). BioResources 10(3): 5730-5743. 6. Espinosa, E., et al. (2016). Cellulose 23(1): 837-852. 7. Delgado-Aguilar, M., et al. (2016). Industrial Crops and Products 86: 295-300. 8. Tarrés, Q., et al. (2016). Cellulose 23(2): 1433-1445. 9. Tarrés, Q., et al. (2016). Cellulose. Article in press. Dr. Marc Delgado-Aguilar m.delgado@udg.edu
Thank you