Forest Biomaterials
NC STATE UNIVERSITY
Outline
1. Organization: CNR, FB (PSE & WP)
2. Where we were?
3. Where we are headed?
1
College of Natural Resources - PSE & WP
College of Natural
Resources
Department of Forestry
Dept. of Parks and Recreation
and Tourism Management
Department of Forest Biomaterials
Paper Science and
Engineering (PSE)
Sustainable Materials and
Technology (SMT)
Department Overview
Department of Forest
Biomaterials
Biomass
Properties
Wood
Chemistry
Biomaterials
Paper Science
and Engineering
Chemical
Processing
Mechanical
Processing
Sustainable Materials
and Technology
Extension and Engagement
SMT
Sustainable Materials and Technology
http://natural-resources.ncsu.edu/wps/wp
ü 4 Teaching/Research Faculty
ü 3 Extension Faculty (open position)
ü 1 Research Faculty
ü  Wood Products, Chemistry
ü 45 Undergraduate Students
ü 12 Graduate Students
PSE
Paper Science and Engineering
http://natural-resources.ncsu.edu/wps/pp
ü 12 Faculty- 4 Chem Eng., 4 Chemists, 4 PSE
ü 5 have more than 5 yrs. of industry experience
ü Exec in Residence, Adjunct
ü 20 Research Associates
ü 165 Undergrad Students
Dual Chem Eng degree is unique in the US
Options in Chemistry, Textiles, Environmental Science, Business.
ü 25 Graduate Students
ü 135 Endowed Scholarships
Our Products…
PSE
Paper Science and Engineering
http://natural-resources.ncsu.edu/wps/pp
Total Package
ü ABET Accredited degree
ü Dual degree with Chemical Engineering very important, 9
semesters (different Colleges)
ü Pulp and Paper Foundation
ü  135 endowments, $150k annual contributions
ü  All students above 3.0 on scholarship
ü  Internships/Co-ops
ü Strong emphasis on professional development
ü Tremendous salaries, $65-67k
PSE
Paper Science and Engineering
http://natural-resources.ncsu.edu/wps/pp
Total Package – Slow changes to
successful program
ü New classes in Process Analysis, Life Cycle Analysis,
Green Chemistry
ü Careful integration of specific technology into the
manufacturing system, ‘keep score’ with dollars or
carbon
ü Jobs with the current industry, skills for the future
industry
PSE
Paper Science and Engineering
http://natural-resources.ncsu.edu/wps/pp
Changes in Landscape
ü 12 PPERA programs – all growing, many in Chem. Eng.
Departments, moving faculty positions away from PSE
ü Consolidation of industry, new jobs but no new mills
ü Only 25-33% of new hires are PSE, but PSE graduates
stay longer
ü Value proposition for companies
ü Value proposition for land owners, heat/power,
fuels, paper, wood products, specialty products
SMT
Sustainable Materials and Technology
http://natural-resources.ncsu.edu/wps/wp
ü Significant changes to curriculum and ‘sell’ for
students (WP UG programs at MSU, SUNY, PSU
all closed or merged into other Dept.)
ü Capital for new manufacturing infrastructure is a
challenge
ü Entrepreneurship, innovation, value-added (buy
local)
ü Voluntary branding programs an opportunity, SFI/
FSC, LEED, EDP, Organic Food
FB
Forest Biomaterials
Research Follows Funding
ü USFS, industry funding has declined significantly!
ü New research focus on energy, liquid fuels,
integrated systems, biomaterials
ü Systems integration includes finance, LCA
ü Federal funding dominates, but with industry
connections 40 companies in 5 different consortia,
$3 mil
ü Partnerships with other Universities
ü Eastman partnership, $10mil/5yrs, $12 bil., 15% of
sales in buildings and construction
FB
Forest Biomaterials
FB
Forest Biomaterials
FB
Forest Biomaterials
Research Follows Funding
FB
Forest Biomaterials
ü Who are the Universities’ ‘customers’?
ü Students are our ‘products’; employers and
funders are primary ‘customers’
ü Differences in campus structures and histories
limit replication
ü Models for successful recruiting of students will
vary between Universities, on campus transfer,
HS, community colleges
Forests are a great framework for
sustainability discussion
FB
Thoughts on the Future
ü Need to be candid on economics; current/future,
risks for new ventures
ü Willingness to invest $300-500 mil. on a
subsidized ‘product’
ü Growth rates, ownership patterns and
infrastructure
ü Jobs and economic growth at the local level
ü Ecosystem services is a developing area,
important but who is really willing to pay? (water)
FB
Opportunities for improvement
Summary
ü Good progress and response to changes in
industry
ü Maintain quality of students
ü Continue to grow programs to match ‘demand’
ü Need to expand appeal to mirror the states’
population, women, minorities, first to college
FB
Questions?
WOOD PRODUCTS >>
SUSTAINABLE MATERIALS &
TECHNOLOGY
BACKGROUND
In 2009 changed the name of
the Department of Wood & Paper
Science to Forest Biomaterials
In the Fall of 2013 changed the
name of Wood Products Program
to Sustainable Materials &
Technology
BACKGROUND
In addition to the name change all
course were modified and
additional courses were added to
reflect the new sustainable nature
of the program **
RE-STRUCTURING OF EXISTING
CLASSES
Wood Anatomy and Properties >>
Structural Properties of
Sustainable Materials
RE-STRUCTURING OF EXISTING
CLASSES
Wood Chemistry >> Chemistry of
Sustainable Materials
Wood Processing >> Processing
of Biomaterials
RE-STRUCTURING OF EXISTING
CLASSES
**Sustainable Composites and
Biopolymers
**Significant modifications
NEW COURSES
Sustainable Materials for Green
Housing
Industrial Ecology
Intro to LCA
NEW COURSES
Capstone in Sustainable
Materials & Technology
More Undergraduate Research
RECRUITING EFFORTS
ON CAMPUS
First Year College
**First Year Engineers
Community Colleges
High Schools (lower grades)
RECRUITING EFFORTS
RESULTS in 2013
High School
CC
On Campus
2012 2013
5
0
8
1(2)
2
15
BioChoice™ Lignin: the Launch of a New Bio-­‐
Based Product Pla:orm Rick Mullen
VP, Market Development & Analysis Domtar CorporaGon Michigan Biomaterials Conference Traverse City, MI October 3, 2013 About Domtar
Primarily pulp and paper with growth in
personal care and consumer
products
“The Sustainable Paper Company”;
EarthChoice™ paper brands, 15 years of
FSC certified grades, partnerships with
WWF, Rainforest Alliance, others.
Fortune 500 S&P 400 Mid Cap Russell 1000 Index Index Listing More than 9,000 employees worldwide.
Listed on NYSE and TSX. Greater than $5 Billion annual sales,
approximately $1 Billion EBITDA
Primary manufacturing sites in Canada and the U.S.
Domtar’s Chemical-­‐Pulp Manufacturing System (12 sites) Dryden ON Kamloops BC Espanola ON Rothschild WI Nekoosa WI Hawesville KY Windsor QC Johnsonburg PA Plymouth NC Kingsport TN Ashdown AR Market pulp mill Integrated pulp & paper mill Marlboro SC Domtar’s Fleet of Pulp Mills (or Biorefineries)
Operational supply chain for procurement and conversion of more than 20 million tons per year of woody biomass 8 million tons per year of biomass processed in boilers and co-­‐generation turbine systems Over 500 Megawatt hours of power generation Process over 6 million tons cellulose, 2 million tons lignin, 1.5 million tons hemicellulose and 15,000 tons extracted wood chemicals per year. Over 4.5 million tons of bleached pulp fiber per year in both market pulp and integrated paper facilities (high volume and specialty grades) Innovation is a Core Value at Domtar
Our vision is to be a leader in fiber-based innovation
We will partner with best-in-class collaborators to develop new
fiber-based products and markets.
Seek to capitalize on our existing supply chain, infrastructure,
and the unique capabilities and opportunities they offer.
Create a portfolio of
different products
short-, intermediate-, and long-term initiatives
both tactical and strategic elements.
Several “small” bets; recognizing likelihood of delays and
some failures.
Domtar Bio-Refinery Program:
Three Major Collaborations Announced
Catalytic Fast Pyrolysis
Dryden, Ontario
•  Bio-fuels/bio-chemicals from available,
low value wood streams
•  With support from CRIBE
Three major initiatives announced.
Several others in pipeline.
Numerous smaller, application-type
collaborations also in progress.
Nano-crystalline Cellulose (NCC)
Windsor, Quebec
•  First scale plant for manufacture of NCC
•  Market and applications development.
•  In partnership with FP Innovations, and supported
by NRCAN and Quebec Provincial Government.
LignoBoost™ Technology
Plymouth, North Carolina
De-bottleneck mill, increase production
Start with Lignin as a bio-fuel for internal and external applications
Use as a platform for new product and applications development
Lignin – a new family of material?
With support from USDA-NIFA BRDI program
Introduction: BioChoice™ Lignin
BioChoice™ Lignin is Domtar’s
newest pulp mill by-product offering.
A low ash, kraft lignin isolated from pulp mill black liquor.
First grade is produced in Plymouth, NC mill (Southern Pine)
using Metso’s Lignoboost™ process.
Long term aspiration: multiple grades and mills; different
wood sources; modified or upgraded lignin grades.
The largest, and most advanced of several new bio-based
product development initiatives.
A platform for building a new, bio-based product portfolio.
Why Kraft Lignin, the Lignoboost™ Process,
and the Plymouth, NC Mill?
Kraft Lignin in Black Liquor:
Domtar already produces over 2 million tpy of black liquor, all presently used
for internal fuel. Processes and chemistry part of our core business and
competencies.
25 to 50% of this can (potentially/practically) be isolated and made available
for external sales.
Industry wide, 20x to 30x these volumes are available - practical market
drivers and critical mass exist.
“Relatively” easy access and low capex and opex. Most of the work already
accomplished in pulping.
Most importantly, the present gap between internal fuel value and anticipated
external sales values (less capex/opex) suggest acceptable margins can be
achieved if and when markets are developed.
Potential volumes/revenues from isolated lignin could make a significant
contribution to core business. Potential for even greater contribution
exists through modified or upgraded lignin.
Kraft Lignin:
The Market Development Dilemma
Supply Assurance Requirements: The development of suitable
applications and markets requires a sufficiently large/reliable/
consistent supply of quality product.
+
Take-Away Assurance Requirements: In order to produce such a
supply, major capital investment and risk required. Furthermore, an
economic disposition for this supply is needed during the interim
market development period.
+
Unfavorable Risk/Reward and Market Conditions: Historical spread
between lignin internal fuel value and external nets did not warrant
capital investment/risk. Nor did market receptiveness.
=
Limited Supply and/or Market Development (especially for Kraft
lignin).
Kraft Lignin:
The Market Development Dilemma (cont.)
Recent Developments Have Changed the Dynamic: 1.  AnGcipated spread between internal fuel value and anGcipated external sales value (net of capex/opex) has improved → acceptable returns. 2.  Lignin as a renewable alternaGve to fossil fuel derived feedstock -­‐ sustainability now more than a Ge-­‐breaker, a potenGal market-­‐pull? 3.  Unique synergies specific to the Plymouth NC mill resulted in capital risk and cost miGgaGon, and an assured interim takeaway. Rationale for Metso Lignoboost™
Why
Lignoboost™
?
Reliable technology
supplier; an
established
vendor and
project partner.
Advanced process
and machinery
design with
acceptable
references.
Courtesy of Metso Power, used with permission
Dewatering
H2SO4
CO2 Precipitation
Conditioning
Black liquor OUT
Dewatering & washing
Cooking chemicals and
organic substances
Recovery Boiler
Evaporation
Lime kiln
Digester
Rationale for Plymouth NC Mill
A Good Starting Point: Lignin Removal as a Stand Alone Project
1.  Historical shift in grade structure led to Recovery Boiler bottleneck of
5%. All other unit operations/permits are good for an additional 75 tpd
of pulp. Lignin removal from black liquor enables incremental
production increase.
2.  Market/business demand for additional pulp production.
3.  Ability to shift lignin fuel load to existing (oversized) biomass boilers.
As a result, lignin removal at Plymouth was a stand alone capital project
based on marginal production, reduced unit costs, and improved mill
efficiencies.
A Platform for Development of New Bio-Based Product Portfolio
1.  Ability to eventually displace lignin in biomass boilers with low cost
regional biomass (hog fuel). Lignin available for external use as
required.
2.  Low cost and low risk demonstration of reliable/consistent supply.
3.  Low cost and low risk platform for development of new, value added
products.
Lignin Product Applications Development
1. Solid fuel for internal and external applicaGons (NCSU, customers, others) 2. Lignin/Thermoplas8c compounds (NCSU, NRC, customers) 3. Emulsifiers for different applicaGons (NCSU, customers, others) 4. Fuel addi8ves (NCSU) 5. Polymer precursors (NCSU) 6. High performance adhesives and resins (FPL, customers) 7. Polyurethanes (Georgia Tech, customers, others) 8. Carbonaceous applicaGons including fiber (NCSU, ORNL, FPL) “Integrated Bio-Refinery” at Plymouth
§
Domtar leveraged our stand alone, self funded lignin removal project to
win support for the broader, far reaching “Integrated Bio-Refinery”
demonstration at Plymouth.
§
A major USDA-NIFA award that has resulted in five additional
collaborative partnerships with nine additional development projects
starts to date. "
Project Status as of September 2013
Lignoboost™ at Plymouth commissioned in early February,
2013. Culmination of a 2 ½ yr, major capital project.
Commercial quantities being produced on a 24/7 basis.
Product used both as internal fuel and for external sales.
Goal is to use all product for external sales and replace fuel
value with low cost biomass.
Production ramp-up (target of 30,000 tpy) proceeding as
planned.
Market development and sales proceeding as planned.
Summary The first production scale installation of Metso’s Lignoboost™ process is
successfully underway at Domtar’s Plymouth, NC pulp mill.
The product, Domtar’s BioChoice™ Lignin is presently being used for
internal fuel and external sales. Production and sales ramp-up both
proceeding well.
Successful commercial launch of a new, bio-based product line.
Short- to intermediate-term:
–  a high quality bio-fuel for internal and external use.
–  sold to intermediate and end users for different applications.
–  used to create a platform for (collaborative ) development of new applications and
bio-based product lines for Domtar.
Intermediate- to long-term:
–  higher value applications as bio-chemicals and bio-materials.
–  development of other grades of BioChoice™ Lignin at other Domtar mills.
–  potential development of (modified) lignin product lines.
Acknowledgements
For their contributions, thanks to: Bruno Marcoccia, Director of R&D, Domtar. W. Dale Mitchell, Director of Bio-­‐Materials Business Development, Domtar. Domtar Plymouth Project Team: Brian Spear, Marty Barfield, Dianne Hardison. Our collaborators on the Plymouth Lignin Project: Domtar also wishes to acknowledge the USDA-­‐NIFA’s Biomass Research Development Initiative for its financial support of this project.