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New Cellulose Products and
Process Technologies
FIBIC annual seminar 20.11.2013
Anna Suurnäkki, VTT, FuBio Cellulose program manager







Kristiina Poppius-Levlin, VTT
Marja Rissanen, TUT
Jaakko Hiltunen, VTT
Jonni Ahlgren, Kemira
Katja Salmenkivi, Pöyry

FuBio Cellulose

Anna Suurnäkki
Forest industry searches for new products

? €
€? ?
€ €?
FuBio Cellulose

Anna Suurnäkki
FuBio Products from Dissolving Cellulose
Main objective
To develop novel, sustainable, and feasible
processes for production of
 regenerated cellulose staple fibres
 novel functional materials based on
cellulose beads, nonwovens or
thermoformable structures

 water soluble cellulose chemicals

FuBio Cellulose

Anna Suurnäkki
FuBio Products from Dissolved Cellulose

Target: value chains novel to forest industry
Technical
textiles

Garments
www.suominen.fi

Water management
chemicals

Hygienic products

Plastic like packaging
FuBio Cellulose

Anna Suurnäkki
FuBio Products from Dissolving Cellulose

Approach
drying

collecting

washing

Fibre spinning

Cellulose
absorbents for
hygiene products

Water soluble
cellulose
chemicals

Chemical
synthesis
Regenerated cellulose fibres for
textiles and nonwovens

Beads manufacturing
FuBio Cellulose

Anna Suurnäkki

Cellulose
beads to
e.g.medical
tableting

Thermoplastic
cellulose to
fibres
5
FuBio Products from Dissolving Cellulose

Foreseen impacts
 Finnish knowledge platform fortified with world class research
and inventions in focus areas
 Business and economy
 Existing value chains equipped with breakthrough technical
tools
 Potential new value chains based on wood cellulose
introduced
 Novel business opportunities for value chain players:
pulp and paper companies, chemical suppliers, engineering
and machinery suppliers, and material converting companies
 Environment, sustainability and safety
 From oil based polymers and unsustainable cellulose sources
to wood cellulose in focus areas
 Future process sustainability and workers safety by replacing
harmful process chemicals (e.g. in staple fibre production)

o
FuBio Cellulose

Anna Suurnäkki
FuBio Cellulose – Result examples

FuBio Cellulose

Anna Suurnäkki
Result example

Synthesis routes for cationic cellulose chemicals
Motivation: Cationic water soluble polymers is a growing market with key application
areas in water treatment, pulp & paper, oil, mining, cosmetics and textile industries
Target: A feasible synthesis route for cationic, water-soluble, cellulose-based flocculant
for paper and water treatment applications

Effect of charge on polymer solubility

Results:
Extensive cationization chemistry mapping carried out
Techno-economic modelling of process concept carried out
Process concept

Qualitative and quantitative
opportunities evaluated

Cellulose

Effect of polymer charge on performance

Activation
Cationization
Neutralization
Separation &
Purification
Drying

Cationic cellulose

FuBio Cellulose

Anna Suurnäkki
Result example

Cellulose beads for medical applications
Results
 New method for producing
cellulose beads developed to kg
scale
 Beads can enable precise,
accurate and individualized dosing
of pharmaceuticals
Drugs were immersed in wet beads and dried

FuBio Cellulose

Anna Suurnäkki
Result example

Water based regenerated fibre production process
Finnish invention Biocelsol process as a basis

Dissolving grade pulp

MERCERISATION, 18wt% naoh
Combined mechanical and enzymatic
treatment

Sulphurisation

 Process more lean and less polluting than viscose
 Machinery the same as in viscose process - enhance
industrial take up of the technology
 Process challenge: Pretreatment time and up-scaling

Aging

Before
project

Results
Dissolving, NaOH
Alkaline slurry is frozen
and thawed

Ripeni
ng

 Feasible, up-scalable
pretreatment process

Mechanical shredding
Pulp consistency
Batch size

Filtration, degas

 Fibres with excellent
water absorption

No emissions

Pulp consistency
Batch size

Regeneration

FuBio Cellulose

Enzymatic treatment

Enzyme dosage, relative

Anna Suurnäkki

After project

5h
20%
0.5 kg
3h

combined
treatment
for 45min
at 30%
consistency,
up-scalable

5%
0.5-5kg
1

0.25
Result example

Novel solvent based regenerated fibre production process

 Novel fibre spinning process based on ionic liquid dissolution of
wood cellulose
 Example of the material demonstration

FuBio Cellulose

Anna Suurnäkki

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New Cellulose Products and Process Technologies, Anna Suurnäkki

  • 1. New Cellulose Products and Process Technologies FIBIC annual seminar 20.11.2013 Anna Suurnäkki, VTT, FuBio Cellulose program manager      Kristiina Poppius-Levlin, VTT Marja Rissanen, TUT Jaakko Hiltunen, VTT Jonni Ahlgren, Kemira Katja Salmenkivi, Pöyry FuBio Cellulose Anna Suurnäkki
  • 2. Forest industry searches for new products ? € €? ? € €? FuBio Cellulose Anna Suurnäkki
  • 3. FuBio Products from Dissolving Cellulose Main objective To develop novel, sustainable, and feasible processes for production of  regenerated cellulose staple fibres  novel functional materials based on cellulose beads, nonwovens or thermoformable structures  water soluble cellulose chemicals FuBio Cellulose Anna Suurnäkki
  • 4. FuBio Products from Dissolved Cellulose Target: value chains novel to forest industry Technical textiles Garments www.suominen.fi Water management chemicals Hygienic products Plastic like packaging FuBio Cellulose Anna Suurnäkki
  • 5. FuBio Products from Dissolving Cellulose Approach drying collecting washing Fibre spinning Cellulose absorbents for hygiene products Water soluble cellulose chemicals Chemical synthesis Regenerated cellulose fibres for textiles and nonwovens Beads manufacturing FuBio Cellulose Anna Suurnäkki Cellulose beads to e.g.medical tableting Thermoplastic cellulose to fibres 5
  • 6. FuBio Products from Dissolving Cellulose Foreseen impacts  Finnish knowledge platform fortified with world class research and inventions in focus areas  Business and economy  Existing value chains equipped with breakthrough technical tools  Potential new value chains based on wood cellulose introduced  Novel business opportunities for value chain players: pulp and paper companies, chemical suppliers, engineering and machinery suppliers, and material converting companies  Environment, sustainability and safety  From oil based polymers and unsustainable cellulose sources to wood cellulose in focus areas  Future process sustainability and workers safety by replacing harmful process chemicals (e.g. in staple fibre production) o FuBio Cellulose Anna Suurnäkki
  • 7. FuBio Cellulose – Result examples FuBio Cellulose Anna Suurnäkki
  • 8. Result example Synthesis routes for cationic cellulose chemicals Motivation: Cationic water soluble polymers is a growing market with key application areas in water treatment, pulp & paper, oil, mining, cosmetics and textile industries Target: A feasible synthesis route for cationic, water-soluble, cellulose-based flocculant for paper and water treatment applications Effect of charge on polymer solubility Results: Extensive cationization chemistry mapping carried out Techno-economic modelling of process concept carried out Process concept Qualitative and quantitative opportunities evaluated Cellulose Effect of polymer charge on performance Activation Cationization Neutralization Separation & Purification Drying Cationic cellulose FuBio Cellulose Anna Suurnäkki
  • 9. Result example Cellulose beads for medical applications Results  New method for producing cellulose beads developed to kg scale  Beads can enable precise, accurate and individualized dosing of pharmaceuticals Drugs were immersed in wet beads and dried FuBio Cellulose Anna Suurnäkki
  • 10. Result example Water based regenerated fibre production process Finnish invention Biocelsol process as a basis Dissolving grade pulp MERCERISATION, 18wt% naoh Combined mechanical and enzymatic treatment Sulphurisation  Process more lean and less polluting than viscose  Machinery the same as in viscose process - enhance industrial take up of the technology  Process challenge: Pretreatment time and up-scaling Aging Before project Results Dissolving, NaOH Alkaline slurry is frozen and thawed Ripeni ng  Feasible, up-scalable pretreatment process Mechanical shredding Pulp consistency Batch size Filtration, degas  Fibres with excellent water absorption No emissions Pulp consistency Batch size Regeneration FuBio Cellulose Enzymatic treatment Enzyme dosage, relative Anna Suurnäkki After project 5h 20% 0.5 kg 3h combined treatment for 45min at 30% consistency, up-scalable 5% 0.5-5kg 1 0.25
  • 11. Result example Novel solvent based regenerated fibre production process  Novel fibre spinning process based on ionic liquid dissolution of wood cellulose  Example of the material demonstration FuBio Cellulose Anna Suurnäkki