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Inorganic-organic Nanocomposites & Nanoscale Surface Modification Energy Consumption & Reduced Capital Costs. Ted Wegner USDA Forest Service Forest Products Laboratory June 15, 2007. Nanocomposites. Technical Challenges Understand & control surface chemical reactivity - PowerPoint PPT Presentation
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Inorganic-organic Nanocomposites & Nanoscale Surface
Modification
Energy Consumption & Reduced Capital CostsTed WegnerTed Wegner
USDA Forest Service USDA Forest Service Forest Products LaboratoryForest Products Laboratory
June 15, 2007June 15, 2007
NanocompositesNanocomposites
Global Wood-based Panels Production, 1970-2005
0
50
100
150
200
250
1970
1975
1980
1985
1990
1995
2000
2005
Mill
ion
Cubi
c M
eter
s
.
Global Paper and Paperboard Production, 1970-2005
0
50
100
150
200
250
300
350
400
1970
1975
1980
1985
1990
1995
2000
2005
Mill
ion
Met
ric T
ons
.
Oceania
Latin America
Europe
Asia
Africa
North America
Technical Challenges
Understand & control surface chemical reactivity
Characterization of structures at nanoscale
Measurement of physical properties at nanoscale
Multiple material compatibility
Directed self assembly of nano-components
Focus Area 4: Inorganic-organicnanocomposites nanoscale surfacemodification
Target: Produce nano-compositematerials from forest materials
Strength of Materials: building blocks and interfaces
nacre
dentinbone
enamel
Gecko Feet
Source :K Autumn, PNAS 2006
Source :Gao, Fratzl et al, PNAS 2004
Perceived Issues with Perceived Issues with Wood-based CompositesWood-based Composites
Low strength and stiffness with eventual rheological/creep problems
Poor durability and water-related problems
Limited service life Limited or poor fire performance Requirement for enhanced
performance, durability, fire resistance, and service life in non-residential construction
Nanotechnology Advanced Nanotechnology Advanced Wood-based CompositesWood-based Composites
Natural composite componentsNatural composite components Combined wood and natural biofiber Combined wood and natural biofiber
composites possessing synergistic performance composites possessing synergistic performance and service life using bio-based resins and service life using bio-based resins
Totally bio-based, sustainable composites Totally bio-based, sustainable composites High-performance bio-based composites using High-performance bio-based composites using
inorganic binders or natural bio-based binders inorganic binders or natural bio-based binders such as ligninsuch as lignin
Biomimetic compositesBiomimetic composites Self-healing systems that include resins or Self-healing systems that include resins or
sub-systems that reactivate when they sense sub-systems that reactivate when they sense degeneration of bond properties or mechanical degeneration of bond properties or mechanical displacementdisplacement
Recycled materialsRecycled materials Systems that promote use of recycled materials Systems that promote use of recycled materials Systems that enhance its later recyclabilitySystems that enhance its later recyclability
Nanotechnology Advanced Nanotechnology Advanced Wood-based CompositesWood-based Composites
Smart compositesSmart composites Systems that sense and warn users of mechanical Systems that sense and warn users of mechanical
overloadoverload Systems that sense moisture and warn users of its Systems that sense moisture and warn users of its
presencepresence Systems that sense fungal or enzymatic activity and Systems that sense fungal or enzymatic activity and
react to suppress itreact to suppress it Systems that sense fire and react to suppress and Systems that sense fire and react to suppress and
extinguish itextinguish it Additives (such as wax, preservative chemicals, fire Additives (such as wax, preservative chemicals, fire
retardants)retardants) Systems that enhance bonding by acting as coupling Systems that enhance bonding by acting as coupling
agentsagents Systems that result in water-resistant—even water-Systems that result in water-resistant—even water-
proof—constituent materialsproof—constituent materials BindersBinders
New bio- or synthetic-based binders with enhanced New bio- or synthetic-based binders with enhanced performance performance
Environmentally responsible and sustainable binder Environmentally responsible and sustainable binder systems systems
New Markets Needed !!
Nanotechnology for Reduced Energy Consumption & Reduced Capital Costs
ObjectivesObjectives
Apply nanotechnology and employ Apply nanotechnology and employ nanomaterials in forest products nanomaterials in forest products processing in order to reduce processing in order to reduce manufacturing costs by manufacturing costs by both both reducing the amount of energy reducing the amount of energy consumed during processing and consumed during processing and capital equipment requiredcapital equipment required. .
Nanotechnology applications can take the Nanotechnology applications can take the forms of: forms of: nano-catalysts to reduce the temperatures and nano-catalysts to reduce the temperatures and
time needed to delignify wood in pulping; time needed to delignify wood in pulping; low corrosion nano-coatings and nano-materials low corrosion nano-coatings and nano-materials
to prolong the life of capital equipment; to prolong the life of capital equipment; nano-dimensional tags/markers for fiber nano-dimensional tags/markers for fiber
separations; separations; nano-inspired products that help with water nano-inspired products that help with water
removal on paper machines (drainage wires, removal on paper machines (drainage wires, vacuum boxes, wet presses, and dryers), kilns, vacuum boxes, wet presses, and dryers), kilns, and hot presses; and hot presses;
robust nano-dimensional sensors (temperature, robust nano-dimensional sensors (temperature, pressure, tensile/compressive forces, etc.) that pressure, tensile/compressive forces, etc.) that can be used to monitor and optimize processing can be used to monitor and optimize processing conditions as well as reduce/eliminate off conditions as well as reduce/eliminate off specification product productions; etc. specification product productions; etc.
Pulping and Paper/Paperboard Pulping and Paper/Paperboard Production TargetsProduction Targets
Reduce pulping process energy Reduce pulping process energy consumption by at least 33% and produce consumption by at least 33% and produce the same or better quality fiber at 5-10% the same or better quality fiber at 5-10% higher yieldhigher yield
Reduce energy consumed in the process Reduce energy consumed in the process of increasing black liquor solids (kraft of increasing black liquor solids (kraft pulping) by at least 50%pulping) by at least 50%
Develop lower-cost technology to replace Develop lower-cost technology to replace the current (energy and capital intensive) the current (energy and capital intensive) causticizing processcausticizing process
Reduce energy and produce same or Reduce energy and produce same or better-quality paper products by using: better-quality paper products by using: (a) nano-coating pigments and (b) three (a) nano-coating pigments and (b) three times the non-fiber filler contenttimes the non-fiber filler content
Reduce the energy consumed in paper Reduce the energy consumed in paper dewatering, pressing, and drying by at dewatering, pressing, and drying by at least 50%least 50%
Waste Streams/WastewaterWaste Streams/Wastewater develop cost-effective methods to develop cost-effective methods to
reduce or eliminate odorous kraft reduce or eliminate odorous kraft emissions beyond the mill propertyemissions beyond the mill property
Develop alternative methods for Develop alternative methods for wastewater treatment that are less wastewater treatment that are less energy- and capital-intensive than energy- and capital-intensive than current biological effluent current biological effluent treatment systems.treatment systems.
Develop low corrosion nano-Develop low corrosion nano-coatings and nano-materials to coatings and nano-materials to prolong the life of capital prolong the life of capital equipmentequipment
Fiber Recovery and RecyclingFiber Recovery and Recycling Develop functional nanomaterials to enable Develop functional nanomaterials to enable
paper and fiber taggingpaper and fiber tagging Use nanomaterials to facilitate ink removal Use nanomaterials to facilitate ink removal
(i.e. de-inking) and contaminant removal(i.e. de-inking) and contaminant removal Develop low corrosion nano-coatings and Develop low corrosion nano-coatings and
nano-materials to prolong the life of capital nano-materials to prolong the life of capital equipmentequipment
Develop nanomaterials to improve Develop nanomaterials to improve recyclability of paper and paperboard recyclability of paper and paperboard productsproducts
Wood ProductsWood Products Reduce VOC and HAP emissions from Reduce VOC and HAP emissions from
manufacturing wood-based products by manufacturing wood-based products by 90%90%
Use nanoscale materials and technology to Use nanoscale materials and technology to improve conversion efficiencies of wood improve conversion efficiencies of wood productsproducts
Use nano-coatings and nano-catalysis to Use nano-coatings and nano-catalysis to decrease emissions to indoor air from decrease emissions to indoor air from wood-based products by 50%wood-based products by 50%
Investigate ways to use nanotechnology Investigate ways to use nanotechnology and nanomaterials to enhance and and nanomaterials to enhance and increase the efficiency of drying wood and increase the efficiency of drying wood and wood-based materials in kilns and presseswood-based materials in kilns and presses
Increase marketable chemical byproducts Increase marketable chemical byproducts of wood by 10%of wood by 10%
Employ robust nano-dimensional sensors Employ robust nano-dimensional sensors (temperature, pressure, (temperature, pressure, tensile/compressive forces, etc.) to tensile/compressive forces, etc.) to monitor and optimize processing monitor and optimize processing conditions and improve conversion yields conditions and improve conversion yields as well as reduce/eliminate off as well as reduce/eliminate off specification product productions; etc.specification product productions; etc.
Questions