Development of sustainable fibres in Finland

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1 VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Development of sustainable fibres in Finland Biotaloudesta viennin veturi Kuuntele VTT:n näkökulma, Professor Ali Harlin, Marjo Määttänen, Sari Asikainen and Pirjo Heikkilä

2 Viscose markets are still increasing - Limited capacity in Europe Constant increase in viscose production since Current capacity > 3 Mt The markets are dominated by China: > 50 % Secondly by Western Europe, India and Indonesia No viscose production in Turkey nor in Finland 02/12/2015 2

3 History of CCA - Cellulose carbamate technology Early patents in USA in 1930 s: Urea derivative of cellulose Objective to replace viscose technology (no CS2 emissions) Neste Cellca from 1970 s to 1990 s Zimmer from 1990 s to 2004 Viscose replacement as a starting point Bio-based product, recyclable material, new paper chemical CCA at VTT Spin-off of Mechano- Chemical processing of natural-based materials: dry state processing technology, solvent free Environmental and occupational hygiene requirements Totally revised Cellca technology 02/12/2015 3

4 Cellulose carbamate (CCA) was developed to replace the old viscose process Benefits for the industry CCA production is separated from applications Logistics are similar to other cellulose derivatives and plastics CCA production is a favourable option for the current cellulose derivative industry or for dissolving pulp mills (new or value added products) Only minor investments are needed for current viscose industry: major savings can be attained in operating costs R&D work has been done with industrial partners for CCA production as well as for applications The concept is tested in industrial scale 02/12/2015 4

5 CCA technology opening novel opportunities Opening a possibility for refining pulp and for giving added value to pulp production. Renewing the old viscose process Final products can be developed together with VTT. Enabling the use of a wide variety of rawmaterials from dissolving pulp to natural fibres to be applied for regenerated fibres Recent pilot at VTT: Recycled post-consumer cotton was transformed into regenerated fibres 02/12/2015 5

6 Looking good feeling even better The Relooping Fashion Initiative is about consumers and companies working together to make high-quality clothes that are 100% reusable and more environmentally friendly. With no harmful chemicals added for the durability and softness, this new material makes you feel good inside out! 02/12/2015 6

7 VTT s pop-up mill Test runs in old mill in 2015: Valkeakoski mill was opened for test production demos Sampling for evaluation in October /12/2015 7

8 Foam forming in pilot scale VTT s paper making research environment SUORA The foam is generated in the pulper or close to the headbox The unit includes: Fourdrinier, hybrid and gap former Pressing with shoe press up to 2000 kn/m Speed up to 2000 m/min Foam formed tissue and nonwovens in laboratory scale Foam formed tissue and nonwovens in semi-pilot scale at speed of 210 m/min Pilot-scale foam forming facilities tissue and nonwovens Next generation fibre foam research environment for special grades and long fibre usage 6 mm 12 mm 24 mm 02/12/2015 8

9 Foam-laid nonwovens from cellulosic fibres - Semi pilot-scale - Hydroentanglement Brilliant formation in the case of long fibres, although high forming consistency is applied Mechanical bonding instead of chemical bonding aspect for sustainability Widening of raw material combinations process simplifying After drying Mechanical bonding of foam laid nonwovens (MECBO), VTT internal project, Hydroentangled 02/12/2015 9

10 Background for pulp fibre yarn development in DWoC 1.0 (1/3) Non-wood based Cotton Flax Other long natural fibres CURRENT METHODS Wood-based, dissolution and regeneration Viscose Modal Lyocell Cellulose II The objective was to develop a cost efficient and sustainable FILAMENTS with high performance by using new manufacturing technologies with a multidisciplinary approach. The aim was to create simple and inexpensive fibre yarn manufacturing techniques that retains the original cellulose I structure Intrinsic properties of macro-scale wood fibres Less processing steps 02/12/

11 Filament forming technologies in Design Driven World of Cellulose DWoC Project 1.0 DES spinning YARN FORMING WITH WATER Pulp spinning CNF wet spinning NON-WATER YARN FORMING Dry pulp spinning CNF dry spinning Choline chloride + urea 02/12/

12 Fibre yarn spinning using deep eutectic solvent (DES) (1/4) Aim: Formation of pulp fibre yarns by using a solvent that does not dissolve cellulose but swells effect on interfibre bonding Ulilization of cheap and non-toxic chemicals Chemicals recyclable and reusable in the process Simple yarn manufacturing process 02/12/

13 Fibre yarn spinning using deep eutectic solvent (DES) (2/4) Materials Deep eutectic solvent Eutectic mixtures composed of two or three components with a lower melting point than each of the individual components Choline chloride + urea (molar ratio 2:1) Non-toxic, low price Similar physicochemical qualities compared to ionic liquids Consist of hydrogen bond acceptor (HBA, often quartenary ammonium salt) and hydrogen bond donor (HBD) Bleached softwood pulp (~90-95%) Polyacrylic acid (5-10%) Hydrophilic and non-toxic polymer Used for crosslinking in order to add water stability Acetone and ethanol 02/12/

14 Fibre yarn spinning using deep eutectic solvent (DES) (3/4) Pulp washed with acetone and dried + Preparation of ChCl/urea DES Dope prepared with PAA Dope extruded Fibre yarn washed with ethanol Fibre yarn crosslinked at 140 o C Water-stable fibre yarn Patent pending: FI : Process for producing shaped articles based on cellulose (2015) 02/12/

15 Novel fibre yarns: Applications and possibilities Applications in textiles, technical textiles and composites Disposables, all-cellulose composites 02/12/

16 Conclusions There is a demand on sustainable and afordable textile and composite fibres in the markets. Wood-based cellulose is a significant option. New technologies are ready to be launched. Novel innovations could open doors for totally new applications. 02/12/

17 TECHNOLOGY FOR BUSINESS