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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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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.
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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).
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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!
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
PFI works along the whole value chain
Lignocellulose
Fiber
Biorefinery
Printing paper
Packaging
New biobased materials
Biofuels Biobased chemicals
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
PFI works closely together with the customers - and brings in the required expertise and partners -
Value-chain mindset
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
Biorefining and bioenergy
Nanocellulose and carbohydrate polymers
Biocomposites
Fibre and paper
Focus areas at PFI
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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)?
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
• 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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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)
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
NORCEL Structure
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
• Generic competence is built through the research topic activities. • The competence is directed towards applications of increasing complexity.
NORCEL
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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 (sigurd.r.pettersen@ntnu.no), 8th NTNU NanoLab Symposium, November 12th 2013
NorBioLab The Norwegian Biorefinery Laboratory
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
NorBioLab Structure
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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)
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
NorBioLab Collaboration a central success criterion
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
NorBioLab Catalytic Fast Pyrolysis (CFP) Unit
Unit for Catalytic Fast Pyrolysis Process Development at PFI Scheduled to be in operation by autumn 2016
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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.
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
Characterisation of biomass and products Central tools supporting all aspects of our research
Chemical Physical Thermic Morphological
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
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
Papir- og fiberinstituttet AS Paper and Fibre Research Institute
Follow us on electronic media: www.pfi.no
www.linkedin.com/company/paper-and-fibre-research-institute-pfi-
http://twitter.com/#!/PFI_tweets
Thank you for your attention!
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