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InTechFibres – Plant Chemistry Team
Michel Petit-Conil
Grenoble – Mars 2018
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 2
Who are we ?
InTechFibres Team
Market / Society context …
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 3
• 150 to 200 milliard tons of biomass produced annually, of which 0.5 to 1 milliard tons are wood.
• In 2015, 178.5 million tons of pulp produced in the world, Europe representing 24.5 % and France 1%. This world production is characterised by :
75% of chemical pulps and 25% of mechanical pulps.
A growth of about 1% per year, mainly driven by the Asian demand. Fluff pulp, dissolving pulp and BCTMP will count for the future.
• In 2016, 4.09 million tons of wood were used for the production of panel boards and plywood products in France.
• InTechFibres partnership between CTP (French pulp and paper research
center) and FCBA (French Institute of Technology for forest-based and
furniture sectors) for increasing the forces in plant chemistry.
The addressed Markets
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 4
R&D and Technological Transfert
Consultancy and Expertise
Training
Analyses, Characterisation tests
Paper pulps (chemical and mechanical pulps)
Panels (MDF, insulation, particles, plywood)
Plant Chemistry (natural molecules extraction)
Microfibrillated cellulose
ITF main activities
Specific
markets or
applications
Our objectives … for you
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 5
• Decrease in production costs
(chemicals savings, electrical energy consumption)
• Decrease in environmental impact of processes
• Develop the biorefinery concept into wood-based mills
• Open new markets for fibres and plant molecules
InTechFibres Team
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 6
Domains of competences • Production of virgin fibres from
lignocellulosic materials (wood and annual plants)
• Chemical and mechanical pulping and bleaching
• Panels and insulating products manufacturing
• Testing of new technologies
• Extraction of natural molecules and fibres derivatives from lignocellulosic materials
• Extraction and characterization of plant components (extractives, lignin and hemicelluloses)
• Production of microfibrillated cellulose
• Functionalisation of fibres
• Characterisation of lignocellulosic materials and fibres
• Chemical composition of lignocellulosics
• Morphological and dimensional properties of fibres
• Optical and physical properties of products
• Microscopic examination and analysis
Michel PETIT-CONIL
Team Manager Staff 1 team leader
7 project leaders
8 technicians
Expertise, experience and created value
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 7
Key
Figures
7
publications per year
pilot plants
80%
2
30%
energy savings through enzymes use in pulping and COD reduction in chemical pulp bleaching
book chapters
reduction in formaldehyde emission in panels with biosourced adhesives
30
60 years of expertise in plant processing
5
8
PhD thesis defended with success in 5 years
10 participations in international conferences per year
12 years of partnership
patents in 5 years
8 « InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 9
The Facilities
Laboratories and Pilots
InTechFibres Team
Labo : MorFi, CyberSize, MorFi CWT, Microscopy, Fibrous composition, Immunolabelling Panel density and strengths
Key Technologies
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 10
Plant chemistry
MFC production
Panels production
Products characterization
Extraction/Cooking Pilot Bleaching/Functionalisation Pilot Lignin precipitation Platform Refining Pilot
Mechanical Pulping Pilots
(5 kg/batch and 20 kg/h)
Heated hydraulic press (9 T)
NaMiCell Pilot
Pilot 1 : Cooking/Extraction - Bleaching
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 11
Simulation of chemical pulping, bleaching
and extraction processes
• Cooking of 100 kg of o.d. chips up to
180°C
• Bleaching of 100 kg of o.d. pulp at any
consistency (3-40%), with any bleaching
chemicals, up to 120°C, 2 bar maximum
pressure
• Unique, reliable and flexible tools
• Good simulation of industrial processes
with results easy to transfer to the
industrial unit
• Homogeniser with a maximum flow of 1
m3/h
Maximum pressure: 1500 bar
2 homogenising stages available
Motor of 55 kW
Cooling system at the output
Production capacity: up to 50 kg,
depending on the pulp and the
homogenisation sequence
• Homogeniser with a maximum flow of 50
L/h
Maximum pressure: 1500 bar
Motor of 5.5 kW
Cooling system at the output
Production capacity: up to 7 kg, depending
on the pulp and the homogenisation
sequence
Pilot 2 : NaMiCell
12 « InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
• Simulation of all the refiner pulping processes
RMP & TMP
CTMP, CMP and APP
• Possibility to use a MSD 6’’ Pressafiner for
impregnating the raw material
• Capacity: 5 to 20-25 kg/h in o.d. pulp
• Adjustable speed refiner (up to 5000 rpm)
• Continuous production of the primary refined pulp
• Possibility to use any impregnating chemicals up
to 120°C, including enzymes
• Different chemicals introduction points
Bottom of the reactor
Output of MSD Pressafiner
Eye of the refiner
Pilot 3 : Mechanical Pulping
13 « InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
Pilot 4 : Panels Manufacturing
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• Production of fibres at high temperature and
pressure
• Embedding of particles and fibres with adhesives
and drying
• Panel forming
56 cm x 56 cm frames for panels
2 to 5 plies for plywood
Any thickness and density
• Panel pressing
Weigth : 9.2 T
Maximum temperature: 220°C
Maximum pressure:
Plate size: 60 cm x 60 cm
Adjustable pressing cycles
Lab : Characterisation of fibres
Low consistency refining bench Lignin production platform CyberSize, CyberBond analyser
Light microscopy – Fibre
composition
Immunolabelling MorFi and MorFI
Cell Wall
Thickness
analysers
15
Near IR
Spectroscopy
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 16
Success Stories
Innovations
InTechFibres Team
Ecokraft
17
New bleaching possibilities for producing chemical pulps at
lower costs and environmental impact • Reduction of environmental impact of
bleaching sequence
Reduction of COD by partially replacing NaOH by
MgO
Reduction of scaling problems, especially calcium
oxalate
• A new chlorine dioxide stage in alkaline
medium
Reaction decrease by up to 135 min
No intermediate washing stage
Reduction in COD of 30% and AOX by 70%
Cost savings: 2.8 €/t
Patent pending
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
18
NaMiProd
New mechano enzymatic or chemical pre-treatments for
microfibrillated cellulose production • Mechano-enzymatic pre-treatment
Cellulases treatment after slushing
1st refining stage down to 0.1 Ws/m and 2nd
refining stage down to 0.01 Ws/m to reach a fibre
length < 200 µm
1 to 2 homogenising passes at 3% consistency
40% energy savings
Patented process
Better transparency of MFC films
• Chemical pre-treatment
15% Ozone applied on pulp
6 homogenising passes at 3.5% consistency
25% energy savings
Similar MFC quality
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
19
LigNOFlam®
New biosourced fire-retardant formulation
• Surface treatment of wood-based products
Substitution of bore- or ammonium phosphate-
based formulations
Transparent formulation based on sustainable
resources
Euroclass C obtained for wood fibres panel
Patented formulation
• Potential applications
Insulating products made of synthetic or
lignocellulosic fibres
Process panels
Papers and boards
Textiles for furniture
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
BoostEff
20
Stratified panelboards with lower environmental footprint
• Hardboard with new properties
Fractionation for separation of coarse fibres and
fine fibres from different raw materials
Stratification of the hardboard to improve
properties
Use of paper mill rejects in the panel
• Better control of MDF production
Fractionation and stratification present interesting
results but more difficult to implement
Development of laboratory and online sensors for
controlling the panel surface.
Two sensors installed on a production line and
use in routine
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018
Terpin
Volatile terpenes better recovered and valorised !
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 21
• Development of a method to analyse
terpenes in wood, pulp, liquids and gases
Specific device for sampling terpenes in vapours
Chemical analyses of the terpenes at lab scale
Quantification of terpenes valorisation potential
Expertise developed on site: one chemical pulp
mill and one TMP mill were studied
• On-site mill audit
Identification of terpenes losses into the process
Quantification of terpenes sources not valorised
Better recovery of terpenes and turpentine
Identification of terpenes into liquid effluents
responsible of wastewater treatment plant
troubleshooting
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 22
R&D Projects
Confidential
InTechFibres’ property
InTechFibres Team
2018: On-going projects
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 23
InTechFibres Projects
BenchGlue, OptiBlue, ExtraPulp, Iliqo
InTechFibres Partnership projects
BioPick, Catbiose, Celloglue, Cerise, Disoli, Durlig, IgniboisValo, MicroDES, MobileFlip, NanoXyLi, Phenoliq, PhytoFiber, ProviDES, Syncobio2, 3W, Valonoix, WoodColor, WO3D, Woodens, WoodClick, WoodZymes
Other projects with team involvement
BioExPack, Celical, Dissolucell, Fluco2, Isobiodom, QualiPin, Mars-EV, Matlam, NanoSono, SealFib, Sherpack, TNT
The collaborating companies
« InTechFibres’ property – do not divulgate » - General Presentation/MPC/2018 24