Nano Crystalline Cellulose: A Canadian Adventure

Transcription

1 The Domtar-FPInnovations Joint Venture for Nano Crystalline Cellulose Nano Crystalline Cellulose: A Canadian Adventure September 2012 Rene Goguen, Vice-President Manufacturing

2 CelluForce Background information The Demonstration plant and team The process The product Applications development strategy September 2012

3 CelluForce Background information The Demonstration plant and team The process The product Applications development strategy September 2012

4 Background info Incorporated in August 2010 Head Office in Montréal QC 40 employees entirely dedicated to nanotechnology The result of a Joint-Venture agreement between 2 major players in the Forest Industry September 2012

5 Our Shareholders FP Innovations Leadership through innovation. A strengthening of the Canadian forest sector sglobal competitivenessthroughresearch, knowledge transfer and implementation 300 scientists, 550 employees through $95 million budget Domtar The largest integrated manufacturer and marketer of uncoated freesheet paperin NorthAmericaand the second largest in the world basedon production capacity Revenues of $5.9 billion CAD, 9000 employees 5

6 The Journey Build the world s first Demonstration plant for the precommercial production of NCC, $46 M investment in order to: Introduce a new wood-based nanomaterial Master the manufacturing process Develop business partners in several applications and sectors Create a significant new market Build / Licence commercial plants

7 Our Partners Federal( NRCan) -Via TT (PSDO): -Via PPGTP: Provincial (MRNF) $ 23,2 M $ 11,2 M $ 12,0 M $ 10,2 M 7

8 CelluForce Background information The Demonstration plant and team The process The product Applications development strategy September 2012

9 CelluForce - The team The Start-up team 9

10 The CelluForce demonstration plant Production capacity: kg/day Processscaled-up fromfpinnovationspilot lab Construction managed by Domtar engineering Fast-track project due to funding requirements: 14 months from groundbreaking to completed process

11 Demonstration plant exterior 11

12 Sept :Relocation of underground services

13 Jan 2011: Foundations complete just before winter!

14 May : Assembly of building structure

15 May : Wood use in process area roof

16 May / June 2011: Cover picture Pulp and Paper Canada Magazine

17 September 30th, 2011: Ready for commissioning

18 Finished Building Interior 18

19 Finished Building Interior 19

20 Demonstration plant specifics 35,000 ft² building Separateareas for: Dry processing High acidconcentration 11 unit operations, 10 suppliers Highlyinstrumented Full DCS control, in-house programming Effluent spillcollection / neutralizationsystem Biogasgenerationsystem

21 CelluForce Background information The Demonstration plant and team The process The product Applications development strategy September 2012

22 CelluForce NCC process Dried pulp from Domtar Pulp preparation Reaction Filtration Drying& Packaging Dry NCC to customer Makeup acid Acid preparation Acid concentration Dilute Acid Recovery Biogas system Effluent treatment

23 Process specifics ProcessInputs: Bleached kraft pulp Mill services: Process Water Acid(93% H2SO4) Caustic Steam Electricity, air Processoutputs: Process effluent to mill treatment system Finished product 200/500 kg bags

24 CelluForce Background information The Demonstration plant and team The process The product Applications development strategy September 2012

25 A Canadian Development 1960s : Université de Montréal Dr R.Marchessault Discovery of NCC properties 1990s: McGill University Dr. Derek Gray and team Laboratory evaluations 2000s: FPInnovations-Dr. Richard Berry and team Continued laboratory evaluations Developed pilot lab process Scaled up process to Demo plant 2010: FPInnovations-Domtar Joint Venture = CelluForce

26 Origin of forest sector nanotechnology crystalline region microfibril : amorphous region acid hydrolysis H 2 SO 4 date Cliquez et modifiez le texte TEM image of cotton nanocrystals 26

27 By SEM Ajouter un titre

28 New products and process improvement with nanocrystalline cellulose Rheology Strength Magnetism Path Optical Properties Self Assembly High Surface Area 28

29 High reinforcement potential Density (g/cm 3 ) Tensile strength (MPa) Young s modulus (GPa) Elongation at break (%) NCC , SWCNT , MWCNT , Carbon 1.7 4, Kevlar , Aramid 1.4 3,000-3, E-glass 2.5 2,000-3, S-glass 2.5 4, Stainless steel , Kraft softwood ~1.5 ~700 ~20 ~2-4 Cotton ~7-8 Jute Flax ,

30 Our Product NCC Crystalline typical dimensions: 100 nm long, 5 nm wide 30

31 Toxicitytesting Rat Acute Oral Toxicity Test No effects on survival or pathology Ajouter un titre LD50 > 2000 mg NCC/kg Rabbit Acute Dermal Irritation Test No signs of irritation Primary irritation index: 0 Rat Acute Inhalation Toxicity LD50 was observed to be > 0.25 mg NCC/L Skin Irritation Skin Sensitization 28-dRat Feeding Study Invitro test for Gene Mutations Invitro test for Chromosomal damage Invivo test for chromosomal damage

32 CelluForce Background information The Demonstration plant and team The process The product Applications development strategy September 2012

33 General Applications 33

34 Further examples of general applications Water soluble cellulosic polymers Cosmetics Paints and coatings Construction materials Detergents Oilfield industry Polymerization Engineering Paper making Textile industry Foodstuffs 34

35 Target Attributes Strength enhancement; weight reduction Increased productivity Improved barrier performance (e.g., gas barrier in liquid packaging) Rheology enhancement and control Improved reactivity

36 Our Mission We harness the power of nature s basic elements to transform your product performance 36

37 Segmentation: Mapping our Clients Orientation Externally Driven Self reliant Relationship Collaborative L/M H/L H/L Strategic alliance Opportunistic M/H H/M H/L Internally Driven L/M L/M L/L 37

38 Current Sector Focus Coatings and paints Composites Films and Barrier Textiles Adhesives Nonwovens Rheology Modifier (e.g., oil muds, concrete) Rubber CelluForceInc.

39 Intellectual Property(IP) Shareholders strength Licence (FPI) IP development Collaboration: Customers, suppliers, FPI, Universities, ArboraNano, NanoQuébec Building a strong IP base 39

40 Strategic Vision Market-driven product development Sustainable applications based on NCC for: Enhanced performance Lower overall material costs To deliver short-and medium-term advantages to the market place CelluForce Inc. CONFIDENTIAL

41 Driving our future Together 41

42 CelluForce - The team The Management team Jean Moreau, President and CEO Richard Berry, VP and CTO René Goguen, VP Manufacturing Maryse Morin, Accounting and Administrative Manager Alain Richard, Demo plant manager Daniel Morisset, Demo plant coordinator Wadood Hamad, Principal scientist Jack Miller, Business development Greg Maloney, Business development Rod Badcock, Business development Raman Nayar, Business development 42