bangor, uk, march 5 magnus gimåker - cost...

Production of NFC and its uses at Innventia

Bangor, UK, March 5

Magnus Gimker

www.innventia.com 2013 2

Nomenclature

Microfibrillated cellulose (MFC)

Original name

Nanofibrillated cellulose (NFC)

New name started to be used 4-5 years ago

Nanocellulose

Collective name for all types of nanocellulose. Used for this material the last 6 years.

Other nanocelluloses are NanoCrystalline Cellulose (NCC) and Bacterial NanoCellulose (BNC)

New name Cellulose Nano fibrills (CNF). The name proposed by ISO standardization committee


The start - NFC in the 1980s

NFC

Pulp

Homogenisation

Energy consumption = 30000 kWh/tonne

Source: Turbak, A.F., Snyder, F.W. and Sandberg, K.R. (1983). J. Appl. Pol. Sci.: Appl. Pol. Symp. 37: 815-827. Source: Lindstrm, T. and Winter, L. (1988). Mikrofibrillr

cellulosa som komponent vid papperstillverkning. STFI-meddelande C159 (internal STFI-report)


The key = pre-treatments! Generation 1

Pulp

NFC

Mechanical & Enzyme

treatment

Homogenisation

Energy consumption = 550-2000 kWh/tonne

Energy reduction = 93-98 %

www.innventia.com 2013 5 Mikael Ankerfors, Innventia AB

NFC gen. 1

2 w-%

Example of an NFC gel from Innventia


The Innventia lab-scale nanofacility


Different generations of NFC at Innventia

Generation 0 (ITT-developments in the 80s (+30 000 kWh/ton))

Generation 1 (Enzymatic pre-treat. Innventia, pat.pend, (550-2000 kWh/ton)

Generation 2 (Carboxymethylation, STFI 1987, 500-2000 kWh/ton)

Generation 3 (Tempo-oxidation, 500-2000 kWh/ton)

Generation 4 (Bipolar act. 1 Pat.+ 1 pat.pend) (1000-2000 kWh/ton)

Generation 5 (Cationized, 500-2000 kWh/ton)

Generation 6 (Hydrophobic NFC)


Different generations of NFC at Innventia

Generation 0 (ITT-developments in the 80s (+30 000 kWh/ton))

Generation 1 (Enzymatic pre-treat. Innventia, pat.pend, (550-2000 kWh/ton)

Generation 2 (Carboxymethylation, STFI 1987, 500-2000 kWh/ton)

Generation 3 (Tempo-oxidation, 500-2000 kWh/ton)

Generation 4 (Bipolar act. 1 Pat.+ 1 pat.pend) (1000-2000 kWh/ton)

Generation 5 (Cationized, 500-2000 kWh/ton)

Generation 6 (Hydrophobic NFC)


Paper & paperboard

Barrier films/coatings

Food applications

Hygiene/Absorbent products

Emulsion/Dispersion

Nanocomposites

Textile fibres and carbon fibres

Oil recovery applications

Additive for hydraulic fracturing for oil and gas extraction

Many interesting application areas


Paper & paperboard


Food applications

Hygiene/Absorbent products

Emulsion/Dispersion

Nanocomposites

Textile fibres and carbon fibres

Oil recovery applications

Additive for hydraulic fracturing for oil and gas extraction

Many interesting application areas


Applications in the paper and board area

As a dry strength agent enabling e.g. Increased filler content in publication papers

Weight-reduction in board

As an oxygen barrier material for packaging

As an additive in coatings

As a surface strength agent to reduce linting and dusting


NFC used as dry strength agent old news

Added amount (%)

Tens

ile in

dex

(kN

m/k

g)

NFC wet-end addition to CTMP

Source: Lindstrm, T. and Winter, L. (1988). Mikrofibrillr cellulosa som komponent vid papperstillverkning. STFI-meddelande C159 (internal STFI-report)

C-starch

Fines

NFC


NFC as a commercial dry strength additive?

Processing issues?

www.innventia.com 2013 14 2013-02-19 Mikael Ankerfors, Innventia AB 14

Innventias new pilot plant for nanocelllulose production (100 kg/day)


FEX Pilot trial outline

Goal Use NFC as additive in the FEX-system in order to identify possible

weaknesses/needs

Set-up Fine paper pulp composition 80/20 (short/long) STFI-former (roll-blade) Valmet 7-row headbox Speed 600 m/min and slice opening 14 mm Press loads 60/500/700 kN/m Innventias pilot NFC generation 1 PCC as filler @ 20%-35% Retention system from Eka


FEX pilot paper machine

Fourdrinier former Shoe presses

Conventional press Roll-blade former


Tensile index vs. filler content

Source: Ankerfors, Lindstrm, Sderberg. Unpublished.


TEA vs. filler content



Large-scale formation vs. filler content



Z-strength vs. filler content



FEX trial: Initial wet tensile energy absorption vs. filler content



Conclusions

No major processing issues!

Positive effects can be seen

In order to perform trials and compare effects to what can be achieved by chemical additives:

Dosage strategy should be developed

Effects of process units (screens, pumps, pipes etc.) need to be considered since the physics will be different compared to polymer additives

Innventia is equipped to study these effects


0,1

1

10

100

1 10 100 1000Oxy

gen

tran

smis

sion

rat

e(c

m3 /m

2da

y at

m)

Water vapour transmission rate (g/m2 day atm)

NFC coatings on board (6 g/m2)

NFC films (8 g/m2)

NFC in a laminated structure (6 g/m2 NFC followed by PE-lamination)

Commercial PET/EVOH/PE packaging

Commercial PET/PE packaging

Comparison OTR and WVTR

Industrial criteria liquid board

Diagram4

280

20

300

6

4


Oxygen transmission rate(cm3/m2 day atm)

56

4

8

20

1

Blad1

WVPOP

mfc carb0.93.80.9

ps9870.5987

amylose71197

aymylopectin1414414

LDPE19000.071900

Cellopahne956.995

acetylgalactoglucomann22.32

PVDC0.10.00073

beeswax15400.061540

chitosan15.513

whey protein6240

pVOH0.2

PP0.05500

PVC0.06820

EVOH0.1

HDPE0.0175427

PLA9.63160

PET5.710

arabinoxylans182

Glucroxylan0.21

Blad1

Water vapour permeability * 10-11 g/(m s Pa)

Oxygen permeability (cm3 m)/(m2 day kPa)

Blad2

OTRWVTR

MFC caotings56280

MFC caotings + PE420

MFC films8300

Stora Enso krav

PET/PE206

PET/EVOH/PE14

indust general

Blad2


Oxygen transmission rate(cm3/m2 day atm)

Blad3

www.innventia.com 2013 24 2017-07-13 24

2010-05-26 Mikael Ankerfors, Innventia AB

24


Reference 1 g/m2

Aulin et al., Cellulose 17 (2010) 559


Present focus: Up-scaling


Full-scale trials at paper mills

Very large interest from paper manufactures to test the concept

However, difficult to justify investment in a full-scale NFC production without prior full-scale trials on a paper machine

The next step


The solution A transportable NFC-plant


Design of a transportable NFC-plant


Transportation

The plant can be transported on a regular deep loader trailer


Preliminary design finished

Production capacity: 100 kg dry NFC per hour

Intermediate storage of NFC prior to paper machine trial

A few days of NFC production will be necessary for a full day trial on a typical paper machine (50 ton/h production)

Business model and financing possibilities for building the NFC-plant is under investigation

Status at present time


Design of a transportable NFC-plant

Production of NFC and its uses at Innventia NomenclatureThe start - NFC in the 1980sThe key = pre-treatments!Generation 1Example of an NFC gel from InnventiaThe Innventia lab-scale nanofacilityDifferent generations of NFC at InnventiaDifferent generations of NFC at InnventiaMany interesting application areasMany interesting application areasApplications in the paper and board areaNFC used as dry strength agent old newsNFC as a commercial dry strength additive?Innventias new pilot plant for nanocelllulose production (100 kg/day)FEX Pilot trial outlineFEX pilot paper machineTensile index vs. filler contentTEA vs. filler contentLarge-scale formation vs. filler contentZ-strength vs. filler contentFEX trial: Initial wet tensile energy absorption vs. filler contentConclusionsComparison OTR and WVTRBarrier films/coatingsPresent focus: Up-scalingThe next stepThe solution A transportable NFC-plantDesign of a transportable NFC-plantTransportationStatus at present timeDesign of a transportable NFC-plant

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