moving from black to green;...drug delivery results from pfi research has shown e.g.: living cells...

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Moving from black to green;

Development of biorefinery processes and products in Norway

Karin Øyaas, PFI


Agenda

Norwegian green biomass resources

Current status of the Norwegian Forest based industries

PFI research on Biomass Conversion About PFI

Green Chemistry and Innovative processes

Examples of R&D activities

Concluding remarks


Norwegian Forest based Sector History

Forests represent the major green biomass resource in Norway

Ever since the late 18th century pulp and paper production has been central to on-shore value creation, ensuring activities along the whole forest based value chain.

The first Norwegian pulp mill started in 1863, with others following soon after

At the turn of the 18th century the Norwegian pulp and paper industry accounted for up to 60% of Norwegian Industry export value.


Norwegian Oil Industry Sector History

1969: Oil discovered on the Norwegian continental shelf, and since the early 1970s the expanding oil industry has ensured long-term wealth and welfare to the Norwegian society.

Today the petroleum activities represent Norway's largest industry in terms of value, contributing to over 20% of gross domestic product (GDP). In addition, the petroleum sector's share of total export revenues reached almost 50% in 2012.

However, during recent decades, increasing environmental concern has shifted the focus of research and innovation to strengthen the development of novel, environmentally benign processes and products based on biomass (green and blue).


Norwegian forest biomass resources

Forests cover almost 37% of land area Standing woods and annual growth is

increasing (> 50% since 1960) Spruce is the dominant species


Norwegian Pulp and Paper industry status

Declining demand and prices for key end products (e.g. printing paper)

Strong competition from regions with lower production costs

Leading printing paper producers in a difficult market situation - several closures in recent years

TMP, CTMP and sulphite pulp mills – no remaining kraft pulp mills

Borregaard’s diversified biorefinery goes well!


SKOG22 National strategy for the forest based sector

Established by the Ministry of Agriculture and Food, autumn 2013

A broad and cohesive strategy for research, development, innovation and knowledge of forestry and wood industries

Focus on recommendations and measures affecting the foundation for the development of a robust and competitive forestry and timber industry

Contributions from the entire value chain: Forestry, Building sector, Fibre/biorefinery, Energy

Completed January 2015


SKOG22 Main conclusions

Forestry and wood industries can triple turnover

Several growth areas are foreseen, e.g. as building material, as chemistry, as energy.

Measures: High degree of processing in Norway Shift to products with high added value Better the pulp and paper industries; focus on

efficiency, specialization, innovation Product development in areas where Norway

has/may develop competitiveness, e.g. smelting industry, aquaculture, agriculture, oil/gas

Bioenergy to replace a larger share of fossil energy


Established1923

Independent research institute

Member of the INNVENTIA group (S) since 2004 • Innventia group: world-leading research institute

working with innovations based on forest raw materials

PFI has long experience in R&D related to processing of / products based on lignocellulose

• Fibre, pulp and paper • New bio-based materials and chemicals, e.g. bio-

composites, nanocellulose, biochemicals • Biorefining and bioenergy • Raw materials and characterisation

Co-localised with NTNU* in Trondheim Several external PhD-students/postdocs

Paper and Fibre Research Institute (PFI) Key facts

*: Norw. Univ. of Science and Technology


PFI works along the whole value chain

Lignocellulose

Fiber

Biorefinery

Printing paper

Packaging

New biobased materials

Biofuels Biobased chemicals


PFI works closely together with the customers - and brings in the required expertise and partners -

Value-chain mindset


Biorefining and bioenergy

Nanocellulose and carbohydrate polymers

Biocomposites

Fibre and paper

Focus areas at PFI


Focus area Fibre and Paper Selected research topics

Cost- and energy effective production of fibre and fibre based products

Quality improvements of fibre based products New fibre based products, e.g.

Construction materials

Fibre based packaging solutions

Synergy effects - combined production of fibre/ pulp/paper and bioenergy/biochemicals

Innovative and sustainable barrier concepts, e.g. against gas (oxygen), moisture and water

Raw material competence: • The right raw material for the right product • The right processing of the chosen raw material • Characterisation


R&D Example Wood fibre based construction materials

Construction panels Wood fibre based interior panels Wood fibre based facade panels

Wood fibre based insulation Compressible insulation mats Blow-in solutions


New mechanical pulping process developed by PFI, Norske Skog and Andritz

The energy consumption in mechanical pulp production can be reduced by 40% - 50%

Implemented at Norske Skog Pisa. → Costs savings ~7 mill $/ year.

Other mills are currently investigating the possibility for investing in the new technology.

R&D Example Development of the ATMP process


Focus area Nanocellulose and carbohydrate polymers

Production Raw materials Pre-treatments (mechanical, enzymatic, chemical) Fibrillation processes (e.g. milling, homogenization) Concentration / drying

Modifications / conversion Applications

Reinforcement - nanocomposites Improved paper qualities (e.g. strength, surface prop.) Viscosifiers Innovative and sustainable barrier concepts Stabilization of emulsions, e.g. in paint Carriers of specific components (e.g. antimicrobial) Membrane and filter applications Health applications, e.g. regenerative medicine, wound

healing and biomaterials for medical devices Applications for the oil field industry


Nanocellulose

Fibre

Wood

Nanocellulose (or microfibrillar cellulose) is composed of thin particles, often with a diameter less than 100 nm, produced from biomass

Artwork by Mark Harrington, Univ. Of Canterbury (1996)

SEM

-pic

ture

s: P

FI

What is nanocellulose (NFC)?


R&D Example Biomedical applications based on nanocellulose (NFC)

NFC has many potential biomedical applications, including: Tissue scaffold Advanced materials for wound healing Biosensors Drug delivery

Results from PFI research has shown e.g.: Living cells can grow and divide on nanocellulose Compressible hydrogels produced by crosslinking of

NFC and other materials (e.g. marine biopolymers) pH-responsive NFC hydrogels designed Selected NFC qualities can function as barriers

against bacteria in wounds

Phot

o: G

ary

Chi

nga

Car

rasc

o, P

FI


• Development of novel functional chemicals to be used in central technologies related to off-shore activities, e.g.

R&D Example Use of nanocellulose in enhanced oil recovery (EOR)

Phot

o: H

åkon

Thi

ngst

ad

− enhanced oil recovery

− drilling fluids − other “green”

oilfield chemicals


R&D Example Hemicellulose and dissolved sugars – use in Norwegian

aquaculture industry and Norwegian feed production

• Dissolved sugars can be used in production of single cell proteins for fish fe

• Hemicelluloses can be used as binder in feed pellets

• Hemicelluloses can be used as binder and nutrient in animal feed

Photo: Harald Groven


NORCEL Norwegian Nanocellulose Technology Platform

One of five main research projects in the national NANO2021 program (Research Council of Norway). Managed by Paper and Fibre Research Institute (PFI).

Three application areas in focus: • Paper and packaging • Petroleum industry (enhanced oil recovery,

EOR) • Tissue engineering

Strong consortium of national and international partners with complementary competences:

NTNU, UoB, UoS, Østfold Research, NORUT, Innventia (S) and CNR-ISTEC (It)


NORCEL Structure


• Generic competence is built through the research topic activities. • The competence is directed towards applications of increasing complexity.

NORCEL


Focus area Biocomposites

New wood fiber reinforced composite materials with fossil-based or bio-based matrix materials

Strategies for mixing of fibres and matrix material Strategies for achieving good compatibility between

fibres and matrix material Characterisation of composite structures Development of wood fibre granules for further

processing Nanostructured biocomposites Examples of applications: Building and construction materials Decking materials Automotive parts Flexible biocomposites, e.g. for packaging Biomedical applications

http://www.google.no/url?sa=i&rct=j&q=automotive+biocomposite&source=images&cd=&cad=rja&docid=MMET7A7_sQSd1M&tbnid=lMTdfu2cSOrtzM:&ved=0CAUQjRw&url=http://www.naturalfibersforautomotive.com/?cat=3&ei=rkBkUYH2B4it0QWxtIDQCg&bvm=bv.44990110,d.d2k&psig=AFQjCNGfk8wiCfaWgo5QSIuuNiCinqImGQ&ust=1365611028184303


R&D Example Norwegian biocomposite technology platform

Develop the technology platform for establishing production of next generation biocomposites in Norway, using wood fibres or microfibrillated fibres (MFF) as reinforcement components.

Focus on technical challenges, including: • Fibre/MFF

production and modification

• Feeding and mixing • Compatibility • Homogeneity • Reduced fibre

shortening • Moisture resistance


Focus area Biorefining and bioenergy

Pretreatment and separation of lignocellulose based materials for production of biofuels and chemicals

Utilization of process flows (e.g. side streams) for production of biobased chemicals

Conversion of lignocellulose to chemicals and biofuels; thermochemical and biochemical conversion routes

Production of bio-oils by pyrolysis

Upgrading of bio-oil, for further refining into fuels (e.g. for ship transport) and biobased chemicals

Torrefaction Torrefied pellets Intermediate product in gasification processes


R&D Example Renewable wood-based biofuels for shipping

Need for low-sulphur alternatives to conventional shipping fuels due to new EU regulations in Sulphur Emission Control Areas (SECAs) since Jan 2015 and coming limits in other sea areas from Jan. 2020.

Need for low- sulphur alternatives to conventional bunker oils

Project objective: Develop alternative low-sulphur bio-based transportation fuels based on upgraded fast pyrolysis oils

Project partners, R&D: PFI (project owner/ coordinator), Aston University (UK), NTNU

Industry partners along the whole value chain (forest - fuels – shipping – engine production)

Partly financed by the Research Council of Norway


National research infrastructure funded by the Research Council of Norway (37,5 mNOK; ~4 m€)

2014 - 2021

Managed and coordinated by PFI. Collaborating partners: SINTEF, NTNU and NMBU

The laboratory is investing in new, advanced research infrastructure – tools for: • Developing new processes and

products based on biomass • Verifying new technological processes

before further implementation

Sigurd Rolland Pettersen ([email protected]), 8th NTNU NanoLab Symposium, November 12th 2013

NorBioLab The Norwegian Biorefinery Laboratory


NorBioLab Structure


NorBioLab C6 and C6/C5 sugar platform: • Autoclave reactor lab with acid proof

autoclave units and EX-protection. • Rapid heating displacement reaktor. • Unit for enzyme production and enzymatic

hydrolysis • Reactor for high dry matter and high viscosity

fermentation with in-situ product separation system

• Multiple autoclave system for catalyzed reactions in liquid phase

Biogas platform: • Dolly reactors and anaerobic cabinet to complete previous

investments at the biogas laboratory

Syngas platform: • Entrained Flow (EF) reaktor (gasification)

Pyrolysis oil platform: • Fast pyrolysis pilot plant for pyrolysis oil production • Reactor for production of hybrid bio-fossil fuels through co-

processing in Fluidized Catalytic Cracking (FCC)


NorBioLab Collaboration a central success criterion


NorBioLab Catalytic Fast Pyrolysis (CFP) Unit

Continuous, flexible bubbling bed reactor with in situ and ex situ catalytic upgrading

Suited for production of liquid fuels and biochemicals from different biomass feedstocks

Unique characteristics: • Catalyst can be exchanged during trial →avoid rapid catalyst deactivation • Upgrading conditions can be adjusted separately • Ex situ CFP: Char separated

(cyclones) prior to vapor feeding to upgrading unit → Improved control of vapor phase reactions; Generally challenging in lab scale

• No similar system exists in Europe


NorBioLab Catalytic Fast Pyrolysis (CFP) Unit

Unit for Catalytic Fast Pyrolysis Process Development at PFI Scheduled to be in operation by autumn 2016


NorBioLab High Pressure Rapid Heating Displacement Reactor

Unique tool for developing new biomass conversion processes (e.g. pretreatment, separation).

Suitable for organic solvent based extraction of wood polymers at high temperature / short retention time.

Will be in operation at PFI during 2016.


Characterisation of biomass and products Central tools supporting all aspects of our research

Chemical Physical Thermic Morphological


Concluding remarks

Innovative process development and green chemistry development are receiving increasing attention in Norway

Forests represent the dominating green biomass resource

PFI is a central R&D stakeholder devoted to conversion of green biomass resources/biorefining, including: Pulping, paper and packaging Biocomposites Nanocellulose and carbohydrate polymers Biorefining and bioenergy production

and coordinates central national R&D and infrastructure projects in the biorefinery area


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Thank you for your attention!

http://www.pfi.no/

moving from black to green;...drug delivery results from pfi research has shown e.g.: living cells...

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