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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
www.innventia.com 2013 3
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)
www.innventia.com 2013 4
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
www.innventia.com 2013 6
The Innventia lab-scale nanofacility
www.innventia.com 2013 7
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)
www.innventia.com 2013 8
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)
www.innventia.com 2013 9
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
www.innventia.com 2013 10
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
www.innventia.com 2013 11
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
www.innventia.com 2013 12
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
www.innventia.com 2013 13
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)
www.innventia.com 2013 15
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
www.innventia.com 2013 16
FEX pilot paper machine
Fourdrinier former Shoe presses
Conventional press Roll-blade former
www.innventia.com 2013 17
Tensile index vs. filler content
Source: Ankerfors, Lindstrm, Sderberg. Unpublished.
www.innventia.com 2013 18
TEA vs. filler content
Source: Ankerfors, Lindstrm, Sderberg. Unpublished.
www.innventia.com 2013 19
Large-scale formation vs. filler content
Source: Ankerfors, Lindstrm, Sderberg. Unpublished.
www.innventia.com 2013 20
Z-strength vs. filler content
Source: Ankerfors, Lindstrm, Sderberg. Unpublished.
www.innventia.com 2013 21
FEX trial: Initial wet tensile energy absorption vs. filler content
Source: Ankerfors, Lindstrm, Sderberg. Unpublished.
www.innventia.com 2013 22
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
www.innventia.com 2013 23
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
Water vapour transmission rate (g/m2 day atm)
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
Water vapour transmission rate (g/m2 day atm)
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
Barrier films/coatings
Reference 1 g/m2
Aulin et al., Cellulose 17 (2010) 559
www.innventia.com 2013 25
Present focus: Up-scaling
www.innventia.com 2013 26
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
www.innventia.com 2013 27
The solution A transportable NFC-plant
www.innventia.com 2013 28
Design of a transportable NFC-plant
www.innventia.com 2013 29
Transportation
The plant can be transported on a regular deep loader trailer
www.innventia.com 2013 30
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
www.innventia.com 2013 31
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