Creating business from green chemistry

Innovation leads the way. Innova-tion keeps the companies in pace

with the changing world. Best innova-tions are built in cooperation with best partners.

Tightening competition and pressure from global markets are challenging the companies worldwide. To survive, com-panies must be agile in operations and efficient in their use of energy and ma-terials. Their products and services must be aligned with customer needs, envi-

ronmental legislation as well as public opinion. VTT helps the

companies to face these challenges by being their innovation partner.

Partnering relates to the enthusiastically discussed topic of outsourcing innova-tion. A recent article* highlights three key aspects of successful outsourcing of innovation. Firstly, the strategic fit is a key to long-term success. Secondly, the company can take the advantages of rapid prototyping and piloting. And thirdly, exploiting the partner’s capabili-ties and infrastructure reduces the com-pany’s fixed costs and ads in flexibility. VTT matches up with these elements perfectly. Our partners benefit from our multi-technological abilities, extensive research infrastructures and flexible working models.

With this brochure, we wanted to high-light our services for chemical, water-intensive and mining industries. We have

VTT – your innovation partner

* Tucker, M. & Friar, J. Research-Technology Management Journal, Sep-Oct 2012

also included examples of our advanced biomaterials, seeing that the industry’s renewal through bio-based technologies is a key priority for us. VTT just complet-ed a 100-million euro spearhead program ‘Industrial Biomaterials’ led by Professor Ali Harlin. In the program we developed number of new biomaterial technologies.Please, take a look at the review on the next double page.

To further encourage You to choose VTT as Your innovation partner; we have col-lected some successes stories of our customers that exemplify the benefits of our partnership. We invite You to collabo-rate with VTT to strengthen Your success.

Best regards,

Tuomas MustonenVice President, Chemical industry and EnvironmentTel. +358 50 598 7516tuomas.mustonen@vtt.fi

ContentsIndustrial renewal through bio-based platform chemicals ...4

Sustainable process solutions for chemical industry ............6

Advanced materials .................................................................10

Solutions for water intensive processes ...............................14

Sustainable mining ..................................................................18

VTT – your research and development partner ....................20

Save the globe with intelligent resource usage

Ensure and increase profitable production

Test and pilot new ideas

Develop sustainable materials and products

Optimize your processes

VTT – your innovation partner

VTT’s international research units:VTT/MSI (Berkeley, US), Seoul (South Korea), São Paulo (Brazil).

VTT’s marketing and networkingoffices (FinNode): Shanghai (China), Tokyo (Japan), St. Petersburg (Russia), and Brussels (Belgium).

VTT’s main office in Finland:Tekniikantie 4A, Espoo

The vision is clear: renewable, recy-clable, reusable and responsible. Bio-materials drive away oil dependency and welcome carbon neutrality. VTT is actively building solutions for new, re-newable materials by developing bio-based platform chemicals. Our future synthetic biopolymers are made from non-food raw materials utilising exist-ing industrial infrastructures.

REDucED OIl DEpENDENcE wITh BIOplASTIcSYou can’t replace plastics in many uses, but you can replace its fossil origin by re-newable biomass. Plastics are built from unsaturated hydrocarbons, olefins, such as ethylene and propylene. Olefins form the main petrochemical platform for vari-ous products of which polyethylene (PE) is the best recognized. These plastics can already today be derived also from biomass.

An industrial example of bio-based PE production is at Braskem in Brazil. In re-cent years it began production of bioeth-anol-based polyethylene (PE) derived from farmed sugarcane. This product is identical to oil-based plastic, with the same good performance properties and the same disposal and reuse challenges. Even when bio-based, PE is not readily biodegradable.

100% bio-based polyethylene terephtha-late (PET) is still waiting for a commercial breakthrough. E.g. Coca Cola Company has at present a 30% bio-based Plant-Bottle in the market. They now produce the mono-ethylene glycol (MEG) - the other component of PET - from sugar-cane ethanol. The ultimate challenge is

to bring in a bio-based terephtalic acid (PTA), which makes up the remaining 70% of PET. Bio-based PET has market potential beyond beverage bottles, as PET is also used in deep-drawn packag-ing and textiles.

One bio-based alternative for PET is polyethylene furan (PEF). It is made from sugar, also derived from farmed sugar cane or sugar beet. PEF forms a superior carbon dioxide barrier and has superior stiffness over PET. It seems that the new furan polymer has a potential to take over the market. The problem with PEF is, like with most today’s commercial bioplas-tics, that it is produced from farmland bi-omass, which is competing with food and feed production. We at VTT have decided not to take that path, but to utilise so-called second generation (2G) biomass.

VTT is developing alternative paths to bio-based olefins and bioplastics. Vari-ous paths go via bioethanol from recy-cled pulp, methanol from gasification of organic waste, catalytic cracking of Fischer-Tropsch wax, and hydrodeoxy-genated bio-oils. The foundation of our development work is to utilize feedstock that does not compete with food produc-tion. We are therefore typically utilizing side or waste streams of agriculture or forest industry.

BIOpOlyMERS FOR pERFORMANcEModified natural polymers - such as hemicellulose extracted from dissolv-ing pulp production - can be used in various applications, including oxygen and grease barriers for food packaging. Natural polymers can well be applied to a variety of products, but they do not

entirely replace oil-based thermoplastic materials. The superior processability and excellent cost-performance ratio are favouring oil-based materials. Oil price increase and growing environmental awareness are likely to alter the aspects soon.

To further amplify economic feasibility and sustainability, VTT is using unexploit-ed side streams of agriculture and for-est industry to develop novel functional polymers. In addition to hemicellulose barriers, we are also developing lignin derivatives to replace phenolic glues or styrene-based coating binders.

Polyglycolic acid (PGA) is an example of a superior performance biopolymer. By its chemical composition it is a close relative to polylactic acid (PLA), but as a material it possesses noticeably higher oxygen barrier and mechanical strength properties than PLA. VTT has developed proprietary technology for the production of glycolic acid and its further polym-erisation to PGA. Our biotechnological production method provides pure mono-mers for demanding applications. More-over, the novel polymerisation method enables rapid and efficient production of high performance polymers. These poly-mers can be used in biomedical fields as well as in food and beverage packaging.

VAluE FROM SIDE STREAMSSide and waste streams can yield re-markable revenue. As an example, we have demonstrated how to recover hy-droxy acids from pulp mill’s black liquor. We have then transformed the hydroxy acids into polymers for sealing and hot melt applications. The concept is espe-

REVIEw OF REcENT DEVElOpMENTS

Industrial renewal through bio-based platform chemicals

4

cially interesting because the raw materi-al is in big amounts available. As much as seven tonnes of black liquor are gener-ated along with one tonne of pulp. Refin-ing even a fraction of that would result in added value production in a very feasible scale. Today most of the black liquor is burned to produce energy.

We have also developed a new method of producing latexes from hydroxy acids. The novel technology enables simpler and more reproducible manufacturing of polymer dispersions than the standard procedure of mixing dissolved or ground polymer into water. The latexes are used in number of applications like in coatings or as cement additives.

BIO-BASED FuTuREIn forward-looking eco-conscious world there is a growing demand for “green” products. We have found that some bio-based raw materials yield even superior performance than existing polymers. To-day the existing production of biopoly-mers is still competing with food and feed production to some extent. In future the emerging technologies will enable the use of second generation feed stocks, including the side- and waste streams of agriculture or forest industry.

AddITIonAl InformATIon

Ali HarlinResearch Professor, Industrial BiomaterialsTel. +358 40 533 2179ali.harlin@vtt.fi

5

Sustainable process solutions for chemical industryWe want to help the chemical companies to assure their global competitiveness while minimiz-ing their environmental impact. focus is feasible and sustaina-ble in the same package. Thanks to recent developments in bio-processing technologies and the increasing use of renewable and recycled feedstocks, new oppor-tunities are here. We have creat-ed novel process alternatives for our customers and will continue to do so.

ENhANcE yOuR pROcESSES Energy efficiency, material efficiency and ever-greater product quality is what you need. We can help you to enhance your chemical conversion and product separation processes to achieve the targets. VTT has over 20 years’ experi-ence in developing processes as well

as building chemical system models based on thermodynamic principles. We can help you to achieve reductions in raw materials and energy consump-tion, improve the production line runna-bility and process control.

At VTT, we have designed our pilot-scale facilities for research and testing of chemical processes. They are cou-pled with cutting edge laboratories and analytical services. The pilot plant can be run with a wide variety of raw materi-als and end products. Our piloting serv-ices include scale-up support and test material production as well as customer specific product manufacturing.

Key assets of our simulation serv-ices are our globally recognized proc-ess simulation software products. The simulation tools effectively predict the chemical process phenomena and their

outcome by combining thermochemis-try and computational fluid dynamics. Simulation tools can be coupled for customized modelling according to our customer’s assets and processes.

GREEN VAluE FROM BIOTEchNOlOGIcAl pRODucTIONVTT is developing novel industrial solu-tions for the production of bio-based products. Biotechnological means can replace traditional petrochemical proc-esses. Renewable biomass - such as the organic waste generated by the agricultural sector and forest industry - contains sugars that, with the help of microbes, can be used as raw material for biochemicals and bioplastics.

With metabolic engineering we can cre-ate new microbial production hosts that can operate with higher productivity in efficient industrial conditions. Proof-of-

VTT serVices

• ChemSheet®:Accuratethermodynamic modelling of multiphase systems

• KilnSimu:Rotarykilnovenmodelling• Balas®:Steadystateprocess

simulations

PIloT PlAnTS• Processchemistry:scale-upin

multipurpose reactor systems• Fermentationanddownstream

processing• Plasticsprocessingpilots• Surfacetreatmentandcoatingpilots

BIomASS ProCeSSIng• Pre-treatmentandhydrolysis• Fractionationandproductrecovery• Chemicalandenzymaticconversion• Modificationandformulation• Biorefineryconcepts

BIoTeCHnologICAl ConVerSIon• Metabolicengineering• Proteinandenzymeproduction• Molecularandsystemsbiologyof

the cell• Plantbiotechnology• Bioprocessengineering

CHemICAl ConVerSIon• Industrialcatalyticchemistryand

polymerisation• Functionalbio-basedchemicalsand

intermediates• Modificationofbiobasedpolymeric

materials• Productformulation

ConCePT deSIgn And SImulATIon• Advancedprocesssimulationand

modelling techniques • Techno-economicviabilityandLCAof

process concepts

6

Sustainable process solutions for chemical industry

concept can be performed in our versatile pilot facilities, including techno-economic evaluationfromfeedstocksourcingtoplantroutine operation. The extensive technology base of VTT enables us to combine biotech-nological processes with classical chemis-try and e.g. microelectronics in one project.

AddITIonAl InformATIon

Juha HakalaKeyAccountManager,ProcessconceptsTel.+358503389251,juha.hakala@vtt.fi

Antero laitinenKeyAccountManager,ChemicalprocessesandmodelsTel.+358505634109,antero.laitinen@vtt.fi

Jouni AhtinenKeyAccountManager,IndustrialBiotechnologyTel.+358503531145,jouni.ahtinen@vtt.fi

7

cuSTOMER cASE: chEMIGATE

Energy and material savings with a new dry modification process

FEATuRES AND BENEFITS: The new dry modification process provides cost-effective production of new generation starch products for paper and other industries. The continuous dry modification process notably saves costs by excluding the energy-intensive dry-ing step. At the same time the amount of waste water is reducedremarkablycomparedtoconventionalprocess.Inaddition, the modification chemicals are needed in a smaller degree. The process can flexibly utilise various starches from different origins. The process prepares the way for new generation of starch products in paper applications and be-yond.

DEScRIpTION: Thedevelopmentwork of Scirocco,Chemigate’s newdrymodification process for starch, began in close cooperation in2009.Chemigate’scommitmenttothecreationofsustain-able starches plus VTT’s competence on process and starch chemistryledtoafast-trackdevelopment.AlargenumberoftestrunswereperformedatVTT’spilotplantinRajamäki,Finland.Variousproductionrecipeswerescaled-upintrials.Inthespringof2012thedevelopmentworkwassuccess-fullycompletedwhilstChemigatestartedupanewproduc-tionplantinLapua.TheSciroccoplantnowproduceshighquality starch products with the annual capacity of 60 000 tons.Chemigate-VTT–cooperationcontinueswith thede-velopment of new product grades.

The co-operation with VTT has been excellent. I am particularly pleased with VTT’s flexible ap-

proach and the useful combination of skilled research and practical scale-up at the pilot plant.

Seppo lamminmäki,CEOofChemigateOy

Chemigate is a Finnish starch company, with a history in Raisio, Ciba Chemicals and BASF. Present Chemigate Oy was founded in 2010 as the management bought out the starch business from BASF. The company invested right at the start-up in a new dry modification plant in Lapua. With the investments in development Chemigate looks ahead to meet the future demands of their paper customers as well as prepares to diversify into wider markets.

cuSTOMER cASE: uBE INDuSTRIES

Reduced energy consumption by advanced process simulation

FEATuRES AND BENEFITS: A customized simulation tool helps to optimise and control the cement manufacturing process. A model fitted to Ube Industriesshowsthebestoperationpracticesforminimizedenergy consumption and emissions.

DEScRIpTION: VTTworkedwithUbeIndustries,aJapanesecementmanu-facture, to develop an advanced simulation tool for their dry cementprocess.ThepremisefortheworkwastheKilnSimu,a modelling tool developed by VTT. KilnSimu models the chemical reactionsandphasechanges ina rotarykiln,aswellastheirthermalandenergybalances.WithUbeIndus-tries, the simulation was coupled with other modelling tools and fitted to meet Ube’s process parameters and operation-al experience.

The ‘Customized KilnSimu’ was developed. It predictedsuccessfullycementclinkercrystal formationandcompo-sition. It also estimated reliably the circulation of harmfulsulphate and chlorine species both in the precalciner and intherotarykiln.Itshowedhowtocontrolthesecondaryairand fuel inlets tominimize thekiln’senergyconsumption.‘CustomizedKinSimu’nowhelpsUbeIndustriestooptimiseand control their process operations.

For cement manufacturers, improvement of the process’s thermal efficiency is highly desirable.

KilnSimu is a very powerful and useful tool for analys-ing the whole cement process. With it we can estimate the quantitative effect of process improvements.

dr Yokota, UBE industries

Ube Industries Ltd. is a Japanese chemical company with global diversified industry operations. Its main products are chemicals, pharmaceuticals, cement and energy. Ube Industries has three cement factories in Japan with a com-bined production capacity of nine million tonnes of cement per year. Ube’s Process Technology Research Laboratory now uses KilnSimu to model the whole cement manufactur-ing process from the precalciner subsystem to the rotary kiln and the clinker cooler unit.

8

cuSTOMER cASE: NATuREwORkS

Eco-friendly products with bioplastics

FEATuRES AND BENEFITS: Bioplastics have been developed to create eco-friendly plastic products. Bioplastics are produced from annually renewable plant biomass instead of fossil sources. The performance of bioplastic can be similar to petrochemical plastics, but it was long considered costly to manufacture. The feasibility of production is gained with a new biotechni-cal process that can operate with high productivity and ef-ficiency in industrial conditions.

DEScRIpTION: VTThascollaboratedwithCargill/NatureWorksinthede-velopment of a novel lactic acid production process for bio-plasticrawmaterial.VTTscientistsworkedonthemetabolicengineeringofyeasttomakethelacticacidproductionfea-sible. The developed yeast technology provides microbes thatarenotablystresstolerantandthusworkalsoinindus-trial conditions. The microbes are used in the production of lactic acid from sugars of biomass. NatureWorks usesthe lactic acid to produce their biopolymer, polylactid acid (PLA),whichisfurtherusedtomanufacturebioplastics.

NatureWorks LLC is a leading producer of plant based bio-plastics. NatureWorks is jointly owned by Cargill and PTT Global Chemical Company. NatureWorks possesses the first and the largest PLA facility in the world. The PLA plant is situated in Blair, Nebraska, USA. Their commercial quality polymer (PLA) is marketed under the brand name Ingeo and supplied to markets across the globe. Bioplastics are used in eco-friendly packaging materials, consumer goods and fibre products.

9

Advanced materialsWe develop novel advanced ma-terials at VTT. At the same time, we want to promote the efficient energy and material use, exploi-tation of new raw material sourc-es and utilization of waste flows. Sustainable approach is taking care of the environment and your competitiveness alike. exploit the new technologies and utilize the underused resources for the benefit of the environment and your business.

BIOcOMpOSITES FOR INcREASED EcOEFFIcIENcyNatural materials, like natural fibres,are a logical choice for reinforcement of bioplastics. They form low cost and eco-friendly biocomposites that can replace glass and carbon fibre rein-forced materials. Biocomposites do not require special equipment; they can be produced with normal plastic process-ing technologies. Biocomposites find various application areas in building, transportation and automotive indus-tries, agro- and horticulture as well as consumer goods.

We at VTT have focused on develop-ment of second generation biocom-posites and multilayer structures. Our ambitious target is the production of entirely bio-based material with tech-nical properties similar to the modern engineering plastics, even those with reinforcement. Ultimately, transparent materials with mechanical properties at the level of steel can be expected, e.g.

by a combination of nanoscale cellulose particleswiththerightresin–bothwith100% bio-based content.

Biopolymer foams - as such or as a mul-tilayer composite - present an interest-ing alternative material for example for food trays, car interior parts or insula-tion and structural parts in construction. Biofoams are genuinely eco-friendly alternatives e.g. to expanded polysty-rene. Flexible proof-of-concept trialsare available for our customers as a new tandem extrusion foaming line has been recently installed at VTT’s plastics pilot hall in Tampere. The line is specifi-cally designed for biomaterials.

FuNcTIONAl MATERIAlS, DuRABlE SuRFAcES AND SupERIOR BARRIERSVTT’s solutions for functionality feature unique combinations of material and surface properties. Our solutions re-spond to the demand for high perform-ance, minimized ecological footprint, embedded intelligence, miniaturization of components and features etc. VTT develops functional materials, nanoma-terials and coatings as well as manufac-turing techniques, like roll-to-rollprint-ing and powder metallurgy. Tailored coatings for extreme conditions and other special functionalities are created using various thermal spray-coating methods. Our tribology solutions ad-dress friction, wear and lubrication challenges for a wide scale of materials with a modelling-assisted approach.

Multifunctional surfaces with tailoredsurface properties are based on our sol-gel technology, AddSol®. By applyingsol-gel technology, several functionali-ties, such as dirt repellence, scratch-re-sistance, or anti-ice properties, can be produced. The coatings can be applied onto a wide range of materials includ-ing metal, wood, plastics, fibre products and textiles.E.g. in thepackagingap-plications sol-gel based hybrid coatings provide grease repellency, high oxygen barrier as well as antimicrobial protec-tion.

VTT’s material technologies and serv-ices comprise many industrial and ap-plication areas from manufacturing of concrete products to development of materials for emerging energy technol-ogies.Moreover,versatilecharacteriza-tion techniques are available for both ex-situ and in-situ assessments.

MATERIAl TEchNOlOGIES ENABlE INTEGRATION OF pRINTED ElEcTRONIcSPrinted electronics – or printed intel-ligence – is an industry branch in itsearly promising stages. It is expectedtoinducemarketdisruptionsinvariousbusiness arenas. Printed electronics utilizes printing technologies as a mass production method to create new func-tionalities for products, including trans-mitters, reactive thin film layers and di-agnostic features. Possible applications for the technology are in home diagnos-tics, dispersed energy production, elec-tronic products, intelligent packaging

VTT SERVICES

PACkAgIng mATerIAl SoluTIonS• Repulpabledispersionbarriers• HighperformancePGA• Biobasedhotmelts• Foodqualityindicators• Printeddigitalmediainteraction

BIoBASed ProduCT formulATIon• Biopolymers,bioplasticsand

biofoams • Nano,woodandnaturalfibre

composites• Biobasedflameretardantadditives• Bioadhesives,bio-baseddispersions• Barriers,coatings,pigments,films

AdVAnCed mATerIAl TeCHnologIeS• Nanomaterialsandproduction

methods of nanoparticles• Lowwearandfrictioncoatings• Powderdevelopmentandmetallurgy• Materialdevelopmentandintegration

of printed electronics

10

and intelligent environments. Already known examples of printed electron-icsareOLEDscreensandorganicsolarpanels.

VTT’s researchers have developed nov-el materials and processing techniques with wider applicability for printed elec-tronics. Roll-to-Roll manufacturing is in central roll to enable feasible mass pro-duction of products being developed. VTT has demonstrated technologies and concepts for organic electronics, hybrid systems and polymer integra-tion. Also newmetal inks for cathodeapplications are ready for commerciali-sation.These inkspossess lowerturn-onvoltagesforOLEDsandoffersignifi-cant cost advantages over traditional silver-basedinks.

At VTT, we serve our customers in large-scale commercialisation collabo-rations as well as customer-proprietary product development and production up-scaling projects. At our pilots, you can e.g. manufacture flexible and freely formable plastic-integrated electronic products. In our premises in Oulu, wehost a pilot factory, PrintoCent, whichis a VTT-led consortium with local uni-versities and municipality coupled with strong industrial involvement. Printo-Cent features the most advanced in-dustrialisation capability and service for the printed intelligence in the world. We want to offer you a genuine disruptive innovation route, not just an update to any old production technology.

Advanced materials

PIloT ProCeSSIng• Polymerisation,compounding,blending• Injectionmoulding,micropelletising,

extrusion, incl. foam extrusion• Fibretreatmentsandmodificationsfor

composites• Advancedcoatingtechniques:Sol-gel,thermalspray,laser,metalizing,ALD

• Foamformingandfoamcoating

AddITIonAl InformATIon

Jouni lattuManager,BusinessDevelopmentTel.+358407288519,jouni.lattu@vtt.fi

outi HärkkiTeamLeader,FunctionalplasticsTel.+358401647647,outi.harkki@vtt.fi

kalle nättinenTeamLeader,BiomaterialsandprocessingTel.+358405342974,kalle.nattinen@vtt.fi

11

cuSTOMER cASE: puuSTEllI

Pioneering eco-friendly kitchen with biocomposites

FEATuRES & BENEFITS:Puustelli’seco-kitchen isaground-breaking innovation. Itsevery detail has been selected on ecological grounds. The newkitchenconceptfeaturesbiocompositesinthefurnitureframework.Thenewmaterialisalmostbythirdlighter,andstill significantly stronger than chipboard. The new biocom-posite reduces raw materials consumption up to 30% and the carbon footprint of the furniture production by almost 50%. The end users appreciate also the fact that the furni-ture’s formaldehyde discharge is clearly diminished.

DEScRIpTION:Puustelli wanted to build a kitchen concept that wouldminimize the environmental burden and carbon footprint of the kitchen during its life cycle. VTTwas selected as oneof the co-operation partners in the technological develop-ment work. VTT’s researchers developed an eco-friendlybiocompositematerialforthefurnitureframework.Thisbio-composite contains plastic polymers reinforced with natural fibres. The new material is almost by third lighter, and still significantlystrongerthanchipboard.Italsohasanexcellentmoisture resistance. The new material reduces significantly raw materials consumption and the carbon footprint of the production. Also the furniture’s formaldehyde discharge is clearly diminished. This is a generational shift in furnish products that revolutionizes both manufacturing techniques and the design.

VTT’s role in the development of our new eco-friendly kitchen concept was significant. We

wanted to replace traditional chipboard as the furniture framework material. VTT developed several formulas of biocomposite alternatives. VTT conducted various proof tests to verify their functioning in kitchen furniture. Based on the research results we were able to select the most fitting material to our new Puustelli Miinus kitchen concept. Without VTT’s expertise we wouldn’t have yielded the breakthrough in our project.

Jussi Aine,CEOofPuustelliGroup

Puustelli Group Oy is a leading kitchen furniture manufac-ture in Finland with over 90 years of proficient woodworking history. Puustelli is growing internationally with exports to Russia, Sweden and Baltics. Innovation and environmental consideration has always been important at Puustelli. In the beginning of 2013 Puustelli launched the Puustelli Miinus –kitchen concept that is designed to minimize the environ-mental burden and carbon footprint of the kitchen during its life cycle.

cuSTOMER cASE: IScENT

Eye-catching, ecological packaging by surface modification

FEATuRES & BENEFITS:Shiningandglimmeringpackagedoesno longermeanen-vironmentally burdening metal additions, extra lacquers or lamination. The new film surface modification technology produces holograph-like images directly onto plastic andfibre-based materials. The method is based on thermo me-chanicalsurfacemodification.Itissuitableformassproduc-tion and it can be integrated into existing printing presses. Printers can even save by reduced use of inks with thismethod. This is a cost effective and eco-friendly way to createstrikingpackagesordecorationandanti-counterfeitbrand products.

DEScRIpTION:VTThasdevelopedaprintableholographic-likefilmtechnol-ogy. The new light scattering method needs no extra ma-terials; the glittering rainbow colours are generated simply by altering the topography of the plastic or paper surface being treated. The thermo mechanical surface modification can be produced on films, papers and labels, as well as lami-natedand thermoformedstructures. Inaddition tostraightforwardpackagingapplicationsthetechnologyissuitedforin-mould-effects in consumer electronics, leisure products and interiordesign.Thepromisingbusinessoutlookof thetechnologyresultedinspinoffofIscentOywhichcommer-cialises the technology jointly with VTT.

The support of VTT’s knowledge and problem solving are highly respected, especially in crea-

tion of new solutions to Iscent unique thermo mechani-cal on-line printing process. VTT’s network and visibility internationally linked to the new technology develop-ment is important and has been significant for Iscent as a start-up company.

Jaakko Raukola,CEOofIscent

Iscent Oy is a Finnish start-up company based on VTT tech-nology. Iscent supplies innovative film materials for specific customers and licenses the technology to large scale pro-ducers. In the end of 2012, Iscent made a significant invest-ment in a wide web (1,200 mm) roll-to-roll production line that uses the film surface modification technology. Iscent plans to go global and anticipates several production sites in international packaging and printing houses within the next few years. Iscent’s focus markets are Europe, Russia, the USA and Japan.

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13

Solutions for water-intensive processesVTT develops industrial water efficient processes for virtually all water-intensive industries: mining, energy production, food processing and forest industry. our water related technologies build process steps in produc-ing drinking water, recycling and purifying process water as well as producing energy and materi-als from sludge.

wATER MANAGEMENT SOluTIONSOur water solutions include innovative reuse and purification technologies.

VTT’s sustainable water management solutions are built on accumulated experience in optimisation of industrial processes, water cycles and sludge

management. We combine research with sound process technology assessment methodologies stretching from laboratory-scale via pilot to pro-duction scale.

VTT’s strength lies in our ability to develop new solutions by combining diverse technological competencies. Forexample,wedevelopseparationandfractionationtechnologiesmakinguseofour advanced biotechnological, chemi-cal and electrochemical competence for wide range of water-related challenges.

pROcESS DIAGNOSTIcSVTT makes use of advanced onlinemonitoring and process control sys-tems, to ensure efficient sidestream recovery and uncompromising quality control of recycled water. Our techni-

cal innovations, concepts and systems include both developed online monitor-ing technologies, sensors and water quality indicators.

We develop solutions for the production of clean and safe water as well as the efficient recycling and reuse of indus-trial water.

lIFEcyclE MANAGEMENTWe at VTT consider the integration of lifecycle thinking as an essential partof all our development work. We alsouse various environmental assessment techniques including lifecycle assess-ment (LCA) and water and carbonfoot print calculations. With the assess-ments we can ensure the sustainability of our technical solutions, concepts and systems.

VTT SERVICES

AdVAnCed WATer TreATmenT• Removalandrecoveryof

impurities from industrial water • Biomimeticsolutionsandtailored

enzymes• Modificationofnaturalpolymers

for water treatment chemicals

ProCeSS dIAgnoSTICS And oPTImISATIon• Processanalysis,datamining• Modellingandsimulation• On-linewatermonitoringand

solutions for micropollutant detection

• LCAandwaterfootprint

memBrAne TeCHnologIeS• Materialsforantifoulingand

maximised flux • Developmentofcostandenergy

efficient industrial applications• Biofilmmanagement

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Sludge And ConCenTrATeS • Solutionsforenergyefficient

dewatering• Nutrientandmineralrecoveryfrom

liquid waste • Energyandmaterialproductsfrom

sludge

AddITIonAl InformATIon

Jani kiuruKeyAccountManager,FibreprocessesTel.+358405431928,jani.kiuru@vtt.fi

mikko JuutiKeyAccountManager,MeasurementsolutionsTel.+358404858826,mikko.juuti@vtt.fi

mona Arnold ProgrammeManager,GreensolutionsforwaterandwasteTel.+358405681222,mona.arnold@vtt.fi

15

cuSTOMER cASE: TAlVIVAARA

Efficient selection and implementation of water purification system

FEATuRES & BENEFITS:Inafast-trackcooperationproject,themostfeasiblewatertreatment solution was found for Talvivaara’s sulphate con-taining mine waters. Based on VTT’s technical and econom-ic feasibility study Talvivaara was able to select and adopt quicklyasolutiontotreattheirprocesswaters.Theirchoicewas a new VTT membrane technology which was seen as the most responsible, practicable and economical solution.

DEScRIpTION:Inspring2011Talvivaara,aFinnishbasemetalsproducer,began the search for a technical solution to treat sulphate containing process waters. The company contracted VTT to conduct an extensive assessment of alternative sulphate removal methods. A preliminary screening step of several promising technologies was followed by a detailed explora-tion to find the treatment method that was technically and economicallythemostviable.Membranefiltrationwasulti-mately selected as the best option. The experiments showed thatitworkedwellforthespecificusecaseandcouldeasilybe adapted for the mining waste water treatment.

Our cooperation with VTT quickly resulted in a new concept for treating elevated levels of so-

dium sulphate in process waters. Based on VTT’s tech-nical and economic feasibility study, we at Talvivaara came to the conclusion that membrane filtration tech-nology could be adopted most quickly, and would be the fastest way of purifying the process waters.

leif rosenback,CTOatTalvivaara

Talvivaara Mining Company Plc. is an internationally signifi-cant base metals producer with its primary focus on nickel and zinc. Talvivaara´s main asset is the Talvivaara nickel mine in Sotkamo, Finland. The Group supplies metal inter-mediaries to companies with metal refining operations.

cuSTOMER cASE: STORA ENSO

Significant cost savings with advanced process analysis

FEATuRES & BENEFITS:StoraEnso’sVarkauspapermillachievedsignificantsavingsin production costs by diminishing and eliminating process fluctuations. The causes for fluctuations were revealed by VTT’sprocessdiagnosticsteam.Thankstonewstabilityinproduction processes the mill was able to decrease the use ofdefoamingagentby75%.Inadditiontheuniformqualityof the paper product was secured with the improved proc-ess control.

DEScRIpTION: Stora Enso was facing process control challenges in its Var-kausMill.AtPM3,afinepapermachine, theprocesswasfoaming excessively and needed high amounts of defoam-ingagent.Itwasthoughtthatthedefoamingchemicalwouldinfluence the performance of other process chemicals and ultimately cause problems with the paper product.

VTT’s process diagnostics team installed instruments to complement the mill´s fixed instruments and monitored the watercyclesatthePM3.Themonitoringperiodlastedsev-eral months. Based on the measurements VTT performed a multivariate analysis and provided the mill manages a list of recommendations. After applying some of the recom-mended changes the mill was able to decrease the use of defoamingagentbyapproximately 75%. In addition, sev-eral process fluctuations were detected and found to be the result of faulty pumps or problems with controls. Solving these problems resulted in significant cost savings and se-cured the uniform quality of the paper product.

The co-operation with VTT brought us great ex-pertise and greatly facilitated problem solving.

Juha Hulkkonen, production manager StoraEnso’sVarkausfinepapermill

Stora Enso Oyj is one of world’s largest paper manufac-turers. Its main products are publication and fine paper, packaging board, and wood products. Stora Enso employs 28 000 people worldwide, and is a publicly traded company listed in Helsinki and Stockholm. Stora Enso’s commitment is to be the global rethinker of the paper, biomaterials, wood products and packaging industry.

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Sustainable miningSince the early 2000s the min-erals sector has experienced a powerful global upswing. In-creasing demand for metals has boosted exploration and min-ing in finland and around the world. modern mining and min-

eral processing require a broad variety of high tech solutions. Sustainability aspects are pre-eminently emphasized since the mineral extraction industry has a remarkable impact on surround-ing environment and community.

VTT SERVICES

InTellIgenT mInIng• Sensorsandsensornetworks• Advancedonlinemonitoringand

data management systems• Intelligentandenergyefficient

mining equipment

WATer And WASTe• Chemical,biologicalandmembrane

water treatment• Waterefficiencymodellingand

optimisation• Wastecharacterisationand

utilisation• Safedisposalandstorageofmine

waste• CO2stabilisationinminerock

reCoVerY• Recoveryofmetalsfromsecondary

resources• Bioleachingwithpre-andpost-

treatment methods• Identificationofpotentialmetal

extraction sources• Optimisedseparationsolutions• Geoenergyfrommines

VTT offers a broad selection of min-ing and mineral-related technologies and services. For example, we haveadvanced on-line monitoring and data management systems to support the mining operations and emission con-trol. We can also offer you technologies for the recovery of metals from solid and aqueous industrial waste streams, as well as technologies for purification, recycling and reuse of mine waters. Or maybe you want to benefit from our ex-pertise in developing safe and energy efficient equipment for mine operations.

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enVIronmenTAl mAnAgemenT• Holisticsustainabilityandeco-

efficiency management • Safemanagementofchemicalsand

chemical products• Riskmanagement• LCAforecologicalandeconomical

concept design

noISe mAnAgemenT• Predictionofnoisegeneration• Low-noisedesignformachineryand

equipment• Predictionofnoisepropagationand

environmental impact• Noisecontroldiagnosticsand

solutions

AddITIonAl InformATIon

esa mäkeläKeyAccountManagerTel.+358405069089,esa.makela@vtt.fi

rainer raitasuoBusinessDevelopmentManagerTel.+358408675257,rainer.raitasuo@vtt.fi

olli SalmiResearch Professor, MaterialsandbuiltenvironmentTel.+358407342154,olli.salmi@vtt.fi

cuSTOMER cASE: AGNIcO EAGlE FINlAND

Solutions for disposal and treatment of mine waste

FEATuRES & BENEFITS:Agnico Eagle has gained useful tools to reduce the mine’s burden on the environment. Mine waste characterizationwith developed tools is necessary to define the proper waste treatment and final disposal conditions.Measuringtechnologies have been developed also for air emissions and control of nitrogen and arsenic discharges.

DEScRIpTION:AgnicoEagleFinlandandVTThavebeenworkingtogethersincethecompany’sFinnishgoldmineopenedin2008.Theco-operation has enabled the company to conduct useful environmental research and to gain necessary tools to bet-ter control its operations and reduce the mine’s burden on the environment. One collaboration area has been the char-acterization of mine wastes and thus defining their proper finaldisposalconditions.Anotherjointworkareahasbeenthe development of measuring techniques for air emissions. VTT has also developed solutions for Agnico Eagle to con-trol the nitrogen and arsenic discharges from the mine.

Agnico-Eagle is a Canadian based gold producer with mines and exploration properties in Canada, Finland, Mexico and the US. Agnico-Eagle has a strong record of delivering qual-ity growth and low-risk to gold business. The company’s Kit-tilä plant in Finland is run by its subsidiary Agnico Eagle Fin-land Oy. Kittilä mine consists of open-pit and underground operations. It is one of the largest known gold deposits in Europe.

cuSTOMER cASE: METSO MINERAlS

Dusting in control by advanced suppression system

FEATuRES & BENEFITS:VTT’s R&D work on dust control with Metso Mineralshas brought new insight on the rock crushing process.

DEScRIpTION:Dusting is a significant environmental and work safetychallenge associated with rock crushing processes, andMetsoMineralswasseekingwaystoimprovethequalityoftheworkingenvironment.VTT’scontract research, fundedalso by The FinnishWork Environment Fund, focused onmodel-basedassessmentofdustdispersionaroundMetsoMineral’s conveyor belts aswell as on thebest practicesfordustcontrolincrusherdevelopment.Inthelatter,threeoverall dust control methods were tested and ranked atthe Metso Mineral’s new testing facility. The use of thetesting facility provided outstanding conditions for control-led measurements. Based on the experimental results and computational modelling the optimal dust control methods were determined.

Metso Minerals Oy is a part of the corporation company Metso, an international technology and service provider. Metso Minerals belongs to one of Metso’s three business areas, Metso Mining and Construction. It supplies tech-nology, processes, machinery and services for aggregates production, construction, mining and minerals processing.

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VTT Technical Research Centre of Finland is a customer-oriented multitech-nological applied research organization. With a staff of over 3,000, unique research facilities and a global research and industry network, we provide cutting-edge technological solutions and innovative services worldwide.

We work to enhance our customers’ competitiveness and expertise, creating the basis for sustainable development, employment, and a high quality of life for society. VTT’s research and innovation activities focus on creating value from sustainability in selected key areas. VTT’s technologies address societal challenges while focusing on new business opportunities.

Five good reasons why to partner with VTT:

• Wedevelopradicallynewtechnologiesandcreatebusiness opportunities for you.

• Proventrackrecord:10%ofGlobalFortune500companies are VTT customers.

• Solidintellectualpropertyportfolio.• Astrongpartnernetworkgrantsaccesstothebest

global know-how.• Effectiveprojectexecutionandreliableoperations

verifiedbyISO9001-certificate.

Technology and market foresight • Strategic research • Product and service development • IPR and licensing • Assessments, testing, inspection, certification • Technology and innovation management • Technology partnership

Readmore:www.vtt.fi/chemind

VTT – your research and development partner

VTT TEchNIcAl RESEARch cENTRE OF FINlANDTekniikantie4A,EspooP.O.Box1000,FI-02044VTT,FinlandTel.+35820722111,Fax+358207227001www.vtt.fi

PEFC/02-31-135

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