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Forest Biomaterials in Canada:
FPInnovations’ Scientific and
Technical Expertise Jimmy Jong, PhD.
Research Manager for Cellulosic Biomaterials
FPInnovations, Canada
For Oct. 11, 2017, Uruguay (Symposium Forest Biomaterials)
Outline
Introduction of FPInnovations in Canada
Creating Opportunities for Forest Sector
Current Focus: Cellulosic Biomaterials
CNC
CF
CelGel
Conclusions
2
FPInnovations Offices and
Laboratories
3
FPInnovations offices
and laboratories
Industry, Universities,
Provincial and Federal
Governments
Canadian Wood Fibre
Centre
FPInnovations:
Forest Operations,
Wood Products
and Pulp, Paper &
Bioproducts
(Vancouver, BC)
Fire Operations
Group (Hinton, AB)
Bio-Economy Technology
Centre (Thunder Bay, ON)
FPInnovations
Head Office and
Forest Operations
and Pulp, Paper &
Bioproducts
(Pointe-Claire, QC)
FPInnovations:
Wood Products,
Forest Operations
and Pulp, Paper &
Bioproducts
(Québec,QC)
FPInnovations (Previously known as Paprican) 95 years of Research Expertise
World’s largest not-for-profit Forest Research Organization
– 470 employees
– 220 Member companies
– Liaison with 27 Universities (120 professors,
government labs and industrial R&D)
Innovation programs
– Genetics and Genomics of trees
– Fibre Assessment
– Advanced Building Systems
– Pulp and paper, Packaging, Consumer Products & Nonwovens
– Bio-based Chemicals & Biomaterials
– Biorefinery & Sustainability
Québec (QC)
Vancouver (BC)
Pointe Claire (QC, Canada)
Vancouver (BC)
4
The Future Forest Product Industry?
Pro
du
cts
Develo
pm
en
t
Wood products Pulp
Some
Chemicals NCC Lignin CNF Sugars Energy
Processes Development
Disassemble wood into components
Cre
ate
Pro
ducts
New
Markets
Penetration
5
6
World’s First Cellulose Filament Plant Strategic Alliance with Kruger ($43M)
• 5 ton/day
• Applications: Paper, tissue/towel, thermoplastics, nonwovens…
Pre-Commercial Stage
Trois-Rivières QC - 2014
World’s First Cellulose NanoCrystals Plant Joint Venture (CelluForce) with Domtar ($45M) • 1 ton/day
• Applications: rheology, strength reinforcement, optical…
First commercial application in 2013
Windsor QC - 2012
Canada’s First Lignin Separation plant Licensing to West Fraser (>$16M)
• 35-50 tons per day
• Applications: adhesives, surfactants, composites , packaging…
Pre-Commercial Stage
Hinton AB - 2014
Major FPInnovations’ Contributions to Innovation
(Demo plant)
Current Focus:
Development of
Cellulosic Biomaterials
7
General Approach
• Extract/modify building
blocks from wood fibres: CNC (Cellulose NanoCrystals)
CF (Cellulose Filaments)
CelGel (Chemically Modified
Pulp)
• Evaluate their value Pulp & Paper
Composites
Adhesives
Textiles & hygiene
Coatings…
Examples of FPI’s Biomaterials
CNC CF
CelGel
8
Single fibre Microfibril
OCH2OH
H H
OHH
H
HO
H
H
O
HH
CH2OH
OH
O
OHO
H
OCH2OHCH2OH
H H
OHH
H
HO
H
H
O
HH
CH2OHCH2OH
OH
O
OHO
H
Cellulose
CF
Nanofibril
New Biomaterials from Wood
Fibres Wood
Nano Crystals (CNC)
Softwood Kraft
Hardwood Kraft
Length Differences Between Fibres, CNC and CF
Basis: One NBSK fibre is 2.5 mm long
CNC :
Size of an ant
CF
10
CNC (Cellulose NanoCrystal)
11
From Tree to CNC
Yield: 20 % >60%
CNC
~100 nm length &
5 nm diameter
12
CNC as a New Canadian Substance
CNC obtained regulatory approval under Canada’s New
Substances Notification Regulations (NSNR) for
unrestricted use in Canada
CNC is the first nanomaterial that Canada will be adding
to the Domestic Substance List
13
CNC Industrial Applications
CNC
14
CNC Demo Plant
Cellulose Nano Crystalline
World largest CNC production line
Joint Venture
Québec
CelluForce the world leader in the commercial development of Cellulose Nano Crystalline
• R&D 21,4M$
• Plant 45M$
From few grams per week to 1 ton per day
First commercial application in 2013
Windsor Québec - 2012
CF (Cellulose Filament)
16
From Single Fiber to Thousands of Filaments
CNF
Patented CF Production Process
• A purely mechanical process of wood pulps,
robust and reliable
• 20-40% solids, option of fully dried CF
• Never-dried CF can be shipped to users in bags
CF Substantially Improves Wet-web Strength
0
100
200
300
10 20 30 40 50 60
Web Solids Content (%)
Wet-
Web
TEA
(m
J/
g)
10% Lab CF
Control
70% heavily refined NBSK
Web contains 30% PCC +800%
19
CF Demo Plant
Cellulose Filaments
World largest production line
Strategic Research Alliance
Québec
FPInnovations and Kruger join forces to build
the first Cellulose Filament Plant in the world
• R&D 25M$
• Plant 43M$
From 100s kg per day to 5t/d (8 hr shift)
Trois-Rivières Québec - 2014
CelGel
(Chemically Modified Fibres
Still in Development)
22
What is CelGel?
• CelGel is a Pulp produced through Chemical Modification
process
• Work in collaboration with McGill University
23
Dry Pulp Chemically
Modified Pulp Cellulosic Gel
CelGel: Key Attributes
High absorbency
• Nonwoven hygiene
• Towel
Non-toxic process
Biodegradability
24
• Installed a new Pilot Wet-Spinning line
Capabilities to Produce Continuous
Spun Fibres at FPInnovations
Wet Spun Fibers
Shower Water Bath Acid Bath Dryer Winder
Patent Application US 2016/0213804
Dope
Spun
Fibers
Spinneret plate
(3,000 holes; 70 m diameter)
26
Absorbency of Spun Fibres
Potential applications:
Absorbent hygiene, medical applications, wipes
Rayon Spun fibres
27
Cellulose Hydrogels
Chemical crosslinked cellulose with large liquid absorbency
and storage capacity
(Potentially replacing SAP-Super Absorbent Polymer)
Morphology of swollen,
freeze-dried CelGel-HG
Hydrogel
DRY SWOLLEN
CelGel-HG Large voids for liquid
absorption and storage
> 300 times mass gain
Process reversible
28
Conclusions
• Despite challenges, current Forest and
Pulp & Paper Industry has a bright future
Think outside box
Need to invest in new innovations
Cellulosic biomaterials
• Several cellulosic biomaterials (CNC, CF,
CelGel, etc) show great promise to
positively transform the Forest Industry
www.fpinnovations.ca
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Thank You! For more information, contact:
Dr. Jimmy Jong
Research Manager, Cellulosic Biomaterials Program
514-782-4497
514-816-4027 (cell)
