VTT - from Forest Bioeconomy Research towards Sustainable InnovationsPia QvintusMichigan Forest Bioeconomy ConferenceFebruary 12-13, 2019 Midland, MI

19.2.2019 VTT – beyond the obvious 1

Owned by

Ministry of Economic Affairs and

Employment

VTT – beyond the obvious

Established in

1942

258M€Net turnover and other operating income (VTT Group 2017)

2,368Total of personnel

(VTT Group 31.12.2017)

36%from abroad (VTT Group

2017)

27%Doctorates and

Licentiates (VTT Group

2017)

VTT is one of the leading research, development and innovation organizations in Europe. We help our customers and society to grow and renew through applied research. The business sector and the entire society get the best benefit from VTT when we solve challenges that require world-class know-how together and translate them into business opportunities.

Our vision A brighter future is created through science-based innovations.

Our mission Customers and society grow and renew through applied research.

Strategy Impact through scientific and technological excellence.

19.2.2019 VTT – beyond the obvious 2

VTT’s research projects

19.2.2019 VTT – beyond the obvious 3

COMMERCIAL PROJECTS

Impact:• Building competitiveness for VTT’s

customers through world-class research and innovation services

JOINTLY FUNDED PROJECTS

Impact:• More efficient technology transfer• Foundation for new innovations and

political decision-making

SELF-FINANCED PROJECTS

Impact:• Developing VTT’s own competitiveness

and acquiring knowledge and expertise to meet future customer needs

1

2

3

VTT’s business areas

19.2.2019 VTT – beyond the obvious 4

SMART INDUSTRY

AND ENERGY SYSTEMS

SOLUTIONS FOR NATURAL

RESOURCES AND ENVIRONMENT

• Sensing and integration

• Connectivity• Data-driven solutions• National Metrology

Institute VTT MIKES• Micronova

manufacturing services

• Industrial biotechnology and food solutions

• Biomass processing and products

• Sustainable energy and chemical technologies

• Lifecycle solutions• Nuclear safety• Smart energy and transport

solutions• Digital engineering• Business innovation

foresight

KNOWLEDGE INTENSIVE

PRODUCTS AND SERVICES

Biomass processing and productsDevelopment of resource efficient and cost competitive processes and added-value product concepts based on renewable raw materials

BIOMASS PRETREATMENT Mechanical, chemical and enzymatic processing of raw materials

UPGRADING FRACTIONS Lignin up-grading technologies Recovery of high-value components Sustainable dissolution processes

WEB BASED FIBRE PRODUCTS Foam forming of thin and thick webs Moldable web NFC films and membranes Barriers and functional coating

BIO-BASED HYBRID STRUCTURES Biocomposite production technologies, esp. extrusion Man-made fibres and yarns Biopolymer foams, 3D-structures and functional materials

Total125 experts working in

Biomass processing and

products

Why forest bioeconomy?

Finland is #1 forested country in Europe Annual forest growth 110 million m3, only 60% used Long history in pulp and paper industry research Global big players Stora Enso and UPM in Finland Integration of over 100 years old Pulp and Paper Research Institute

(KCL) and VTT in 2009 Identified need of renewal of pulp and paper industry and te long

tradition in pulp and paper research have formed a platform for development of new revolutionary bio products

19.2.2019 VTT – beyond the obvious 6

The value of forest industry production can be doubled and theclimate targets for 2050 can still be obtainedFinnCERES project 2018-2025

19/02/2019 VTT – beyond the obvious 7Source: Arasto, Antti; Koljonen, Tiina; Similä Lassi (eds.). 2018. Wealth from bioeconomy - Integrated bioeconomyand low carbon economy futures for Finland, VTT Technical Research Centre of Finland Ltd.Comparisons are made to year 2016. FinnCERES project by Aalto Universiy and VTT started in 2018

VTT-Aalto BIOECONOMY infrastructure co-operation - the national roadmap of research infrastructures

Building excellence in research, education and enabling technologies

Bioeconomy in Circular Economy

Business models of circular economy

• Product-life extension• Product as a service• Sharing platform• Renewability• Resource efficiency

and recycling

Business Finland launched in the beginning of 2019 Bio and Circular Finland program for innovation funding and development of export activities with budget of 300 million €

VTT Ventures and VTT Launch pad

VTT 2017 10

www.vttventures.fi https://vttlaunchpad.fi/en/

1) Biocomposites2) Biopolymers3) Textiles

19.2.2019 VTT – beyond the obvious 11

There is increasing need in consumer goods, transportation, packaging's and construction for

• materials with low carbon footprint, replacement of oil based materials

• sustainable end of life • natural aesthetic look and haptics• combined with easy processing enabling

diverse shapes

development of strong lightweight composite materials made of (bio)polymers and cellulosic fiberswhich can be composted or recycled

Why Biocomposites ?

Foaming of biocompositescombines advantages of

Thermoplastic foams Natural fibers

• Light weight• Low material usage• Energy and cost savings• Certain properties improved

• High strength• High stiffness• Non-abrasiveness• Easy availability• Sustainable

New business opportunities Application areas e.g. packaging,

construction, transportation1319.2.2019 VTT – beyond the obvious

Sustainable light-weight products with cellular structure

Thermoforming of biocomposite films

19/02/2019 VTT – beyond the obvious 14

New business opportunities Application areas e.g. packaging,

construction, furniture, transportation

combine the properties of both plastic and cardboard. It can be moulded as plastic having at the same time high natural fibre content

19.2.2019 VTT – beyond the obvious 15

Potential use of paper industry side streams in compositesProject : EU- Reffibre

Significant amounts of valuable components such as fibres and mineral fillers are lost in the form of side streams.

Global demand for sustainable products is steadily increasing and new environmental concerns and waste disposal laws are pushing the industry to find new and alternative uses for waste residues.

improved composite properties decreased waste generation improved resource efficiency reduced environmental footprint add value of the side streams

RealisedSide streams from

paper industry successfully

demonstrated as raw material in injection

moulded and extruded products

The research leading to these results has received funding from the European Community's Seventh Framework Programme

under grant agreement n° 604187 http://www.reffibre.eu/

Side stream

Side streams from the paper production

Melt compounding+

Additives

Injection mouldingor extrusion

Thermoplasticpolymer

Granulates

Pretreatmentse.g. grinding, drying

Products

19.2.2019 VTT – beyond the obvious 16

Totally biobasedinjection moulded chair

Lisa Wikström, VTT

Material development was performed by VTT as a part of ACel program in the Clic Innovations Ltd (TEKES).

Biobased injection mouldable thermoplastic composite material with the focus on high cellulose fibre content, good visual look, improved material performance and competitive price.

No petroleum based raw materials New additives improves the material properties

enabling to meet the material performance targets Material demonstrated in injection moulded end

products

100%Biobased

30% cellulose

VTT developed totally biobased composite material which were demonstrated in injection moulded chair together with KO-HO Industrial design and Plastec Finland Oy.

Paptic – fibre composite material to replaceplastic

19.2.2019 VTT – beyond the obvious 17

A bioplastic composite paper combining the benefits of paper, plastics and textiles• Certified pulp as raw material• Recyclable in cardboard recycling system

BiopolymersLigninCellulose

19.2.2019 VTT – beyond the obvious 18

Lignin

19.2.2019 VTT – beyond the obvious 19

Higher Value from LigninVTT research activities

LIGNIN• Kraft• Soda• Organosolv• Hydrolysis residue

Phenolic resins for wood products

Rubber and plastic products

Carbonised materials

Thermoplastic materials

• CatLignin technology for highly reactive lignin

• Solvent fractionation• Biotechnical activation

Surface active agents• LigniOx technology for versatile dispersants• Concrete and gypsum plasticizers• Dispersant for inorganic fillers/pigments

• Reinforcement fillers• Antioxidants• Fire retardants

• Thermoplastic matrix polymer for composites• Tackifier for hot melt adhesives• Coatings

• Carbon black by HTC• Activated carbon: water

purification, energy storage, catalysis

Fuels & chemicals

• HTL• Pyrolysis• Solvolysis

High performance concrete plasticizers Higher performance compared to lignosulfonate

admixtures and most of the synthetic plasticizers

LigniOx technology based on alkali-O2 oxidationfor versatile lignin dispersants

Dispersant of various pigments for paints, inks and coatings TiO2, CaCO3 and kaolin dispersion close to commercial synthetic

dispersant Carbon black dispersion better than commercial synthetic

dispersant

Gypsum plasticizer & set-retardant Comparable to commercial

plasticizers

Superplasticizer, 0.2%

LigniOx lignin, 0.4%Lignosulfonate, 0.4%

No plasticizer

VTT Patent Applications: US9676667, WO2015/049424, WO2017/077198

19/02/2019

Main activities : Oxidation concepts for various technical lignins Scale-up and construction of mobile pilot unit Integration to biorefineries Product formulation & prototype for concrete

plasticizers Demonstration of process and product

performance at industrial conditions Techno-economic and environmental

assessments Regulatory issues for market uptake

LigniOx BBI Innovation Action (05/2017 – 04/2021, 5.6 M€)

LigniOx commercialisation

CatLignin – Highly reactivelignin by thermal treatmentTaylor-made kraft lignin properties by thermal treatment of black liquor at pulp mill • Lignin with high number of phenolic functionalities & adjusted Mw• Increased reactivity for resins • Improved antioxidative properties e.g. for composites• Improved adhesion in HMAs

Proven in lab and small pilot scale for industrial SW & HW black liquors

VTT Patent Applications: WO2016207493, WO2018115592

Reactive sites for PF resins

Birch plywood strength50% phenol substitution

Lignin for thermoplastic materialsLignin use potential in several thermoplastic end-products as such or after chemical modification Plastic composites Coatings Hot melt adhesives (HMA)

Lignin can provide in thermoplastic materials cost savings with additional functionality, e.g. Reinforcement Antioxidativity UV-protection Fire retardancy Adhesion

VTT Patent Application: FI20175001

Tannin polyphenols Tannins are currently produced from the bark and wood of

certain southern tree species Acacia (wattle, mimosa, bondtite), Schinopsis (quebracho), chestnut, 200 000 t/a production

• Tannin polyphenols + starch derivative as glues for laminates and vaneer based products1

Estimated 1 Mt/a (d.m.) spruce and 2 Mt/a (d.m.) pine bark produced in wood working industry in Finland

• Condensed tannins are the main components of softwood bark extractives (Mw = 2000 – 3000 Da)

• High reactivity towards aldehydes

• Hot water extraction demonstrated in pilot scale (raw tannin extracts in multi kilo scale)

• Pine tannin PF resin (30% substitution) displays similar results to commercial reference PF resin

• Tannin containing insulation foams display promising properties, yet not commercial quality

19.2.2019 VTT – beyond the obvious 25

Condensed tannin

1 WO 11/073531 Adhesive agent, a manufacturing method and the use of said agent

Tannin PF resin / shear strenght

Cellulose

19.2.2019 VTT – beyond the obvious 26

VTT’s Thermocell

100% BIOBASED MATERIALS

CelluloseMolarmass

adjustment

Function-alization Pelletization Applications

27

WO2016193542A1 and FI20175114

19.2.2019 VTT – beyond the obvious

Global bioplastics demand by type (metric tons)

28

Source: Global Markets and Technologies for Bioplastics, BCC Research, Jun. 2016, #PLS0550D

PBS – polybutylene succinatePE – polyethylenePHA – polyhydroxyalkanoatePLA – polylactic acidPP – polypropylenePTT – polytrimethylene terephthalatePVC – polyvinyl chloride

VTT’s Thermocell

Circular Materials Challenge 2018 Award, Ellen MacArthur Foundation

Ecopack Challenge 2018 Award, Packaging Innovations in assoc. with Marks&Spencer&

Finalist for Sustainability Awards 2018, Packaging Europe&

2919.2.2019 VTT – beyond the obvious

Textiles

19.2.2019 VTT – beyond the obvious 30

The global situation of textile fibresIntroduction

January 16, 2019 Hanna Hörhammer 31

4

5

6

7

8

0

20

40

60

80

100

120

1980 1990 2000 2010 2020 2030

Wor

ld p

opul

atio

n, b

illio

ns

Wor

ld fi

bre

cons

umpt

ion,

mill

ion

tonn

es

Year

TotalSyntheticNaturalCellulosic

62%31%

6%

World fibre market 2017

Figures illustrated based on data from The Fiber Year 2018 and www.worldometers.info.

(polyester, nylon, acrylics)(cotton, wool , silk)

(regenerated)

19.2.2019 VTT – beyond the obvious 32

Wood Cellulosepulp

Regeneratedfibres

No dissolution

Cellulose derivatives

Viscose

Cellulose Carbamate, spinned off to IFC

Ioncell-F (Aalto University, Helsinki University)

BioCelSol (TUT, VTT)

Paper, carton board

Paper yarn, spinned off to Spinnova

DES-yarn (VTT)

Textile fibre research at VTT

Biocelsol technology for regenerated fibres

Value proposition: Regeneration of cellulosic fibres in a sustainable way -using abundant cellulose raw material and applying environmentally sound technologies.

Competitive edge: The sustainable Biocelsol technology produces staple fibres with excellent physical and chemical characteristics. VTT has long experience and outstanding knowledge in the field of cellulose valorization.

Offering: Purification and regeneration of cellulosic based material (both virgin and recycled fibres) and production of functionalized textile staple fibres in scales from bench to pilot.

Outcome: Concept and input to R&D. Production and testing of textile staple fibres. Process optimization and concept evaluation.

Process:

Photo

(ensure we have rights to publish)

Pretreatment Wet spinning Textile staple fibresDissolution

January 16, 2019 Hanna Hörhammer 33

Cellulose purification

Fibre regeneration/manufacturing technologies

January 16, 2019 Hanna Hörhammer

Technology Dissolution Regeneration Status Comment

Viscose Pretreatment: NaOHDerivatisation: CS2 -> Cell. xanthate Dissolution: NaOH, 8-12 C

Wet spinning(H2SO2, Na2SO4, ZnSO4)

Dominantcommercial

Toxic compounds (CS2)!

Lyocell Diss.: Direct, NMMO, 80-100 C Dry-jet wet spinning(NMMO, H20)

Commercial NMMO instable. NMMO recovery critical.

Carbamate Pretr.: NaOHDeriv.: Urea -> CCADiss.: NaOH, Zn < 0 C?

Wet spinning(H2SO4, Na2SO4, Al2(SO4)3)

Start-upPilot

Demonstrator dress 2017. Fashion Show 2018

Spinnova No dissolution Orientation of fibres in multiphase flow

Start-upPilot

First demonstrator garments produced 2016

Biocelsol Pretr.: Enzymes, mechanicalDiss.: Direct, NaOH, Zn < 0 C

Wet spinning(H2SO4, Na2SO4)

Research Zn recovery challenge

Ioncell Diss.: Direct, ionic liquid IL([DBHN][OAc]), 80 C

Dry-jet wet spinning(H20)

Research IL recovery critical.Deontrator dress 2018Metsä Spring building the pilot

Cold alkaline Pretr.: NaoHDiss.: Direct, NaOH, Zn < 0 C

Wet spinning(H2SO4, Na2SO4, Na2CO3)

Research Similar to Biocelsol.

Other: Nitrocellulose, Alceru, Cocel, Cupro, DMAc/LiCl…

Introduction

VTT

34

S

IFC

European developers of cellulose based fibres

January 16, 2019 Hanna Hörhammer

Actors Technology Scale of equipment

Lenzing Viscose, NMMO Viscose: 780 000 t/yearNMMO: 220 000 t/year

IFC Carbamate Pilot (Bioruukki), 25-30 tons/a

MetsäSpring Ioncell Demo plant under construction (Äänekoski), capacity 500 tons/a

Spinnova Spinnova Demo plant sarted production in 12/18, up to 300 tons/a

VTT Biocelsol Bench: -> 1 kg/d (Bioruukki)Pilot: -> 60 kg/d (Bioruukki) Rebuild and automised industry pilot

SciTech Viscose Bench (Bioruukki)

Aalto Ioncell Bench: ~100 g/d (Otaniemi)

RISE (incl. Swerea) Cold alkaline Lab (Stockholm)Bench: 500-5000 mL dope/h = 330 g/h (Mölndal)Pilot: 150 kg dope/h = par. 10kg/h (Mölndal)

Fraunhofer Viscose, NMMO, carbamate

Adjustable wet spinning lines; 40-3000 filaments (Potsdam)

Other: MoRe, TITK, IBWCh, Sniace…

35Lab > Bench > Pilot > Demo > Commercial

Spinnova – textiles from wood pulp

19.2.2019 VTT – beyond the obvious 36

• Certified pulp as raw material• Controlled rheology of multiphase flow of

fibers in water to extrusion• No harmful chemicals• Minimal water usage

Infinited Fiber Company – regenerated fibresfrom textile wastes or dissolving pulp

19.2.2019 VTT – beyond the obvious 37

• Post consumer textile waste or dissolving pulp as raw material• Non-toxic cellulose carbamate process

19.2.2019 VTT – beyond the obvious 38

1942 20181984

76 years of innovations Read more: www.vttresearch.com

19.2.2019 VTT – beyond the obvious 38

World Circular Economy Forum 2019

19.2.2019 VTT – beyond the obvious 39https://www.sitra.fi/en/projects/world-circular-economy-forum-2019/#

World Circular Economy Forum 2019

19.2.2019 VTT – beyond the obvious 40

Venue: Finlandia Hall, Helsinki

Wellcome!

#VTTbeyondtheobvious