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Advanced Materials for the Advancing Bioeconomy
Kim Nelson, PhDVP Nanocellulose Technology
American Process Inc.
March 11, 2015
• Vice President, Nano-cellulose Technology, American Process, Inc.
• Nanocellulose technology development and R&D
• Creator of API’s nanocellulose production process demonstration line, commercialization, and partnerships
• MS, IPST; PhD Chemical Engineering, Georgia Tech
Kim Nelson
American Process Inc.
1995Process Integration
Studies
2011Biorefinery Operations
2013Global Partnerships
and Licensing
2009 Biorefinery
Engineering & Construction
2005Biorefinery
R&D
2015BioPLus Nanocellulose Launch & Commercial
Plant Engineering
Over 150 patents pending, 18 grantedGreen Power+™ and AVAP™ Patented Technologies
Two biorefinery demonstration plants in USAFunding from DOE, State of MI, New Market Tax Credits, P3Nano
Offices in GA, MI, Greece, Brazil, and Romania
CONFIDENTIAL MATERIAL 4
Alpena Biorefinery : First Sale of Cellulosic Ethanol in US from Woody Biomass – April 2014
Desalination
Alpena BiorefineryCo-located hardboard facility steam extracts 10% of wood as sugars and lignin to waste stream
EXISTING DPI PLANT
Waste Stream:23 BDT Hemicelluloses and lignin Waste Water
Treatment Plant
Wood chips:325 BDT/D
Treated water back to lake
Board:293 BDT/D
Steam and Electricity
AlpenaBiorefinery
23 BDT/d of hemicelluloses feedstock
Thomaston Biorefinery
Lignocellulosic sugars (low cost & clean)LigninNanocelluloseBiofuelsBiochemicals
Thomaston Biorefinery
Fractionation and Cellulose Separation
Biomass
Was
hed
Regenerated Solvent, SO2
Liquor (hemicelluloses solvent, SO2, lignin)
Enzymatic Hydrolysis
Glucose to chemicals conversion Hemicelluloses Sugars
to Ethanol / Butanol
Lignin to energy and chemical applications
Hemicelluloses Auto Hydrolysis
Chemical Regeneration
Cellulose products
BioPlus™ Nanocellulose
• Versatile morphology• cellulose fibrils and crystals
• Versatile surface chemistry• hydrophilic and hydrophobic
varieties• Low cost
• equivalent to conventional polymers
• High temperature stability• 50-100°C higher than other
nanocellulose
336
238
349
293
0
50
100
150
200
250
300
350
400
AVAP CNF Mechanical CNF AVAP CNC Sulfuric Acid CNC
Ons
et o
f Dec
ompo
sitio
n Te
mp,
o C
TEMPO CNF
Cellulose
Covalently bonded lignin
Adsorbed lignin
DMSO, stirring
+ExtractionCentrifugation
L-CNC ExtractL-CNC, after extraction
• Low cost, hydrophobic component of biomass, lignin, is the coupling agent with polymers
• Solves Grand Challenge of dispersing nanocellulose in plastics: – Cellulose is highly polar and hydrophilic– Most polymers are non-polar and hydrophobic.
• Preserves discrete nanocellulose particle morphology during drying
• Two forms of lignin:– Lignin covalently bonded to cellulose– Physically adsorbed lignin bonded to the permanent
lignin by van der Waals forces
BioPlus Lignin-Coated Nanocellulose
BioPlus Demonstration Line
Screening & Cleaning
Mechanical Treatment
Product Cooling & Storage
Bleach Plant
½ ton per dayStart-up in April 2015
Located at Thomaston Biorefinery
Order samples online at americanprocess.com/bioplus
Traditional Problems
• Expensive
• Limited quantities available for market development
• Hydrophilic – bad dispersion in plastics
• Low thermal stability
BioPlus™ Nanocellulose Solution
• Low cost AVAP novel production
• Pre-commercial demo 100 t/y
• BioPlus-L: oleophilic and hydrophobic
• BioPlus-L has high thermal stability
Inhibitors to Market Development
Polymer Composites
Neat Silicone 1% L-CNC 2% L-CNC
1% CNC in PLA
Agglomerates
1% TEMPO CNF in PLA
Conventional Bleached CNC & CNFVery poor dispersion
Neat PE 1% L-CNC in PE
Neat PHB 1% L-CNC in PHB
BioPlus L-CNCVery uniform dispersion
Neat PS 1% L-CNC in PS0.3% L-CNC in PLA
BioPlus Compostable Bags● Strong ● Renewable ● Compostable ● PLA + BioPlus L-CNC
BioPlus Compostable BagsLab Scale August 2014
Compounding Extrusion Blow Molding
Commercial Scale January 2015
BioPlus Compostable Bags• Dramatic increase observed in modulus of PLA • L-CNC significantly improves extrusion melt blowing of PLA
– Increases melt blown strength which gives a stable bubble column – Acts as a rheology modifier/processing aide/lubricant– Allows displacement of traditional petroleum based additives
20.0 40.0 60.0 80.0 100.0 120.0 140.0temperature (°C)
1.000E6
1.000E7
1.000E8
1.000E9
1.000E10
1.000E11
1.000E12
1.000E13
G' (Pa
)
PLA-0.3% API L-CNC
Neat PLAG’ (Pa)
Temperature °C
PLA- 0.3wt% L-CNC
Neat PLA
Vehicle Light Weighting Project• Objective: Development of a sprayable binder resin
system containing nanocellulose as a reinforcing phase to replace steel in seating assemblies– Opportunity to achieve commercial application on
electric vehicles
• Results: Clark ATL has successfully dispersed L-CNC in the hydrophobic resin system of choice
• Impact: Reducing a vehicle’s weight by just 10 percent can improve fuel economy by 6-8 percent
– U.S. DOE’s target vehicle weight reduction is 50% by 2050.
– According to the DOE the limiting factor in use of lightweight materials in vehicles is availability of sufficient quantities at affordable cost1
ReinforcingMaterial Density (g/cm3)
Calcium carbonate 2.71
Talc 2.69
E-glass fiber 2.5
Carbon fiber 1.8
Nanocellulose 1.5
3D Printing Project• Objective: Reinforce 3D printing feedstock with
high temperature stability, highly dispersableBioPlus-L™ to obtain desired mechanical properties for load-bearing parts
• Impact: Replace high cost, peutroleum–based carbon fiber as reinforcing agent for high temperature polymers like ABS, PLA, Nylon 6,6, and PC with renewable, biobased nanocellulose.
• Phase II Goal: Print a golf cart from nanocellulose reinforced polymer using Oak Ridge’s Big Area Manufacturing (BAAM) facility.
RAW MATERIALS CONVERSION TESTING &
PROTOTYPING PARTNERSHIPS APPLICATIONS
BioPlus Commericalization
RBI: A Valued Partner in the Bioeconomy
StaffingR&D and
Operations Support
Commercialization
Students, PhD (6)
Post Docs (1)Research
Scientists (2)
Students, Undergrad &
MS (2)
Technology Development
Nanostructure Characterization
Applications Development
Chemical Analysis
Fiber quality Analysis
Physical Properties
Testing
Partnerships Formation
API Needs
RBI Expertise & Services
• Don’t skip any steps. The systematic scale-up from lab to pilot to demo to commercial is essential
• Leverage existing “across the fence” infrastructure and co-production
• By nature of these projects.. “scope is never frozen”. Contingency planning is needed.
• Financial Risk of “first of a kind” is very high you have to look everywhere for financing
• It takes a village, a town - the whole world! No company in the space has all the necessary parts
Commercializing in the BioeconomyTop 5 Lessons Learned
P.S. Keep going!
Thank YouPRESENTED BY
Kim Nelson, PhDVP Nanocellulose Technology DevelopmentAmerican Process Inc.
[email protected]/bioplus