Vision - Research - Teaching
Presentation to the
Alabama Center for Paper and Bioresource Engineering
Auburn University
June 24, 2015
Dr. John G. Cowie
Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
2
Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
3
Introduction
Doctorate in Materials Science
Vice President of Technology at Agenda 2020
Technology Alliance - American Forest & Paper
Association
Past Chair of TAPPI Biorefinery Committee
Past Leader of the Marketing Team in TAPPI
Nanotechnology Division
President of nanoC - consulting company
4
Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
5
Vision for the Center Alabama Center for Paper and Bioresource
Engineering
This is my first visit to Auburn University
Everything I know about the Center from:
Harry Cullinan
Your Website
6
Vision for the Center Alabama Center for Paper and Bioresource
Engineering
Detailed vision and strategy needs input from inside and
outside the Center
1. Review and evaluation of current research activities
2. Input from industrial leaders (CTOs) and from the
University's staff and directors
3. Perform a SWOT Analysis
4. Benchmark using other Centers like RBI (formerly
IPST) at Georgia Tech
5. Investigate the available funding opportunities
6. Develop a detailed vision and strategy
7
Vision for the Center Petroleum Production Hubbert Peak Oil Plot
In 1956, Geophysicist M. King Hubbert proposed that fossil fuel production would
follow a roughly bell-shaped curve.
8
Vision for the Center U.S. Biobased Products Industry Economic Impact of the Biobased Products
USDA Secretary Tom Vilsack announced last
Wednesday that the U.S. biobased industry is
generating substantial economic activity and U.S. jobs
Economic Impact of the Biobased Product Industry
report
U.S. Biobased Products Industry contributes
$369 billion to the American Economy
4 million new manufacturing jobs
USDA creates the BioPreferred® label program
Innovative wood products
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Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
10
Past Research Value Prior to Pulping
Funded by the DOE and Industrial Consortium Partners
11
Past Research Value Prior to Pulping Purpose
Utilize available enzymes and microorganisms
Develop:
Scientific knowledge
Modeling tools
Process design and
Engineering economic information
Determine if there is:
A compelling business case
If so proceed to commercial scale demonstration
12
Past Research Value Prior to Pulping DOE - Industry Consortium
Two year experimental study
$3 million total
50% funded by DOE
50% funded by Industrial partners
13
Past Research Value Prior to Pulping Participating Pulp & Paper Companies
NewPage
International Paper Company
MWV - MeadWestvaco
Potlatch
SAPPI
Weyerhaeuser
Clearwater Paper
UPM Kymmene
Longview Fibre
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Past Research Value Prior to Pulping Participating Research Institutions
US Forest Service - Forest Products Laboratory
State University of New York – Syracuse - ESF
North Carolina State University
Auburn University
National Renewable Energy Laboratory
IPST at Georgia Institute of Technology
University of Maine
Purdue University
American Process International (API)
Cobalt Technologies
Verenium
15
Past Research Value Prior to Pulping Approach
Technical Feasibility
Pre-extraction & pulping
Extract processing or conditioning
Fermentation and ethanol production
Commercial Feasibility
Innovative process design
Effective plant integration
Capital & operating costs of the best case
process design & integration
16
Past Research Value Prior to Pulping Project Groups
Pre-extraction and pulping
Extraction liquor processing
Fermentation and biofuel production
Modeling and business case development
Economics and commercial feasibility
17
Past Research Value Prior to Pulping Group 1 - Pre-Extraction and Pulping
Goal: Development of a process to extract 40% of the
hemicellulose fraction prior to kraft pulping
Hardwood met extraction yield target but with a
decrease in paper strength
Conditions can be found where a conventional pulp is
produced with softwood - The extract yield is
considerably less than the target
Economics favored acid hydrolysis over enzymatic
hydrolysis
18
Past Research Value Prior to Pulping Group 2 - Extraction Liquor Processing
A process was developed to prepare the extract for
fermentation free of inhibitors as well as recovery a
valuable co-product stream; acetic acid.
The raw extract is concentrated by ultrafiltration to
produce a concentrate of up to 23% sugar solids
The acetic acid which is recovered
19
Past Research Value Prior to Pulping Group 3 - Fermentation and Biofuel Production
Goal: Development of a fermentation process to
convert 80% of the extracted sugars to biofuels
Technical proof of concept study evaluating five
different fermentation microorganisms
Zymomonas mobilis - NREL
Pichia stipitis - US Forest Service Forest Products
Laboratory and the University of Wisconsin
Saccharomyces cerevisiae - Purdue University
E. coli - Verenium
Proprietary bacterial strain - Cobalt Technologies
All microorganisms tested met the target
20
Value Prior to Pulping Group 4 - Modeling and Business Case
Development
Four different models were used
HYSYS, WinGEMS, Excel and ApiMax
ApiMAX models existed for conventional mills and
were modified for VPP cases
The Excel model used with the ApiMax correlated best
with the experimental data
21
Past Research Value Prior to Pulping FPL Excel Model
22
Past Research Value Prior to Pulping ApiMax Simulation
23
Value Prior to Pulping Modeling and Business Case Development
Basic Assumptions in Economic Analysis
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Value Prior to Pulping Modeling and Business Case Development
Captal Cost vs. Sugar Concentration
Capital Cost Estimates for Hemicellulose Extraction Process as a
Function of Sugar Concentration Following Evaportaion
25
Value Prior to Pulping Modeling and Business Case Development
Operating Cost Estimates
Annual Operating Cost ($/year) as a function of Sugar
Concntration Following Evaporation
26
Value Prior to Pulping Modeling and Business Case Development
Ethanol Production Cost Estimates
Estimated Production Cost for Ethanol as a Function of
Sugar Concetration
27
Value Prior to Pulping Modeling and Business Case Development
Acetic Acid Production Cost Estimates
Estimated Production Cost for Acetic Acid as a Function of
Sugar Concetration
28
Past Research Value Prior to Pulping Economic Model Output: Ethanol
Case
Base maple
Pine cases range
Maple cases range
"Best" Maple Ethanol Case
IRR %
0
- 18 to - 4
- 7 to 15
15
Note: "Best" Case assumes the following: 18% more wood
available at same price, 7% more pulp can be sold at the same
price, Full heat integration, Use of existing equipment for the
chipping, Excess steam available at $10 /MT rather than $22/MT
29
Past Research Value Prior to Pulping Economic Model Output: Butanol
Case
Base maple
Pine cases range
Maple cases range
"Best" Maple Butanol Case
IRR %
0
19 to 21
6 to 39
39
30
Past Research Value Prior to Pulping Technical Conclusions
Hemicellulose can be extracted from wood chips prior
to pulping and converted at high yield to biofuels
Acetic acid can be recovered from the hemicellulosic
extract providing a clean sugar stream for fermentation
Pulp yield, quality and value are dependent upon the
degree of hemicellulose extraction
Low extraction conditions (10% mass removal)
maintain similar quality metrics of conventional pulp
Higher mass removals (up to 23%) alter the
characteristics of the VPP pulp vs conventional pulp
Based upon ROI, a 15% extraction level is preferred
31
Past Research Public-Private-Partnership (PPP) Advancing Development of Nanomaterials
Funded by The US Forest Service
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Past Research Public-Private-Partnership (PPP) Advancing Development of Nanomaterials
The US Forest Service
Nanotechnology research involving universities
Grow the research programs in the area of
cellulosic nanotechnology
Create a legal framework for a Public-PrivatePartnership (PPP)
33
Past Research A Research Joint Ventures (RJV) Model Advancing Development of Nanomaterials
Pioneered by the Semiconductor Research
Corporation (SRC), research joint ventures (RJVs)
represent a public/private partnership through which
firms collaborate to acquire technical knowledge
The forest products industry needs to create a RJV
similar in framework to the SRC through a membership
based consortium
34
Past Research A Research Joint Ventures (RJV) Model Legal Arrangements of a RJV
All collaborative R&D projects require some form of
legally binding agreement between partners
The consortium agreement sets out the internal
management guidelines – during and after project
Legal agreement written and signed
35
Past Research A Research Joint Ventures (RJV) Model Benefits
Reduced research costs due to a reduction in
duplicative research
Faster commercialization since the research stage is
shortened
Develop an industry-wide competitive vision
Greater R&D productivity and greater patenting activity
Access to key university personnel
36
Past Research A Research Joint Ventures (RJV) Model Outcome Full implementation of the RJV Model
Establishment of P3Nano in the U.S. Endowment for
Forestry & Communities, Inc.
37
Past Research Market Projections for Nanocellulose - Enabled
Products
Funded by the US Forest Service
38
Past Research Market Projections for Nanocellulose - Enabled
Products
Objectives
Discuss Market Drivers for Nanocellulose
Summarize the results of a study on potential markets
for nanocellulose
Categories of applications
Methodology
Volume estimates
Recommend some future research directions
39
Past Research Market Projections for Nanocellulose - Enabled
Products
Environmental Market Drivers
Consumer/Retailer demand
Regulatory
Light‐weighting to improve fuel
efficiency
Café standards
Energy Efficiency
Building codes
Bio‐based materials
Greener Consumer Products
Shopping bag/water bottle
bans/additive red‐listing
EU Directive – vehicle recycling
Carbon Dioxide targets
Renewable/compostable
Landfill bans/ recycling
targets
40
Past Research Market Projections for Nanocellulose - Enabled
Products
Assumptions
Recent research reports/expert network to identify
target applications
Current market size is maintained (no growth)
Commercialization within the next 6‐11 years
Cost competitive with current alternatives
Technical issues addressed
No barrier to adoption
41
Past Research Market Projections for Nanocellulose - Enabled
Products - Targeted Applications
HIGH VOLUME
LOW VOLUME
NOVEL and Emerging APPLICATIONS
Cement
Wallboard Facing
Sensors - Medical & Environmental
Automotive Body
Insulation
Reinforcement fiber ‐ construction
Automotive Interior
Paint‐Architectural
Water filtration
Packaging Coatings
Paint‐Special Purpose
Air Filtration
Paper Coatings
Paint ‐OEM Applications
Viscosity modifiers
Paper Filler
Aerospace Structure
Purification
Packaging Filler
Aerospace Interiors
Cosmetics
Replacement ‐Plastic Packaging
Aerogels for the Oil Industry
Excipients
Plastic Film Replacement
Organic LED
Hygiene and Absorbent Products
Flexible and Recyclable Electronics
Textiles for Clothing
Photovoltaics
3D printing
Photonic Films
42
Past Research Market Projections for Nanocellulose - Enabled
Products
Market Estimates
Vol = M *NC content * MP
M = recent market size
NC Content = % nanocellulose
MP = market penetration rate
43
Past Research Market Projections for Nanocellulose - Enabled
Products
Example: Automotive Body
Cars
Light Trucks
~1.57 T
~2.08 T
WT (AVG) * Vol (15.8e6) * 1/3 of vehicle weight steel * 50% replacement * 1/2
the steel replaced * 65% CNF in resin * Market Penetration Rate
(1.57 tonnes + 2.08 tonnes)/2 x 1/3 x 1/2 x 1/2 x 0.65 x 15,800,000 vehicles =
1.56 million tonnes
44
Past Research Market Projections for Nanocellulose - Enabled
Products
Estimated Market Penetration Rates
High Volume Applications
45
Past Research Market Projections for Nanocellulose - Enabled
Products
High Volume Cellulose Nanomaterials
U.S. Market Penetration Estimates
46
Past Research Market Projections for Nanocellulose - Enabled
Products
Annual Tonnage Estimate by Forest Products Subsector
47
Past Research Market Projections for Nanocellulose - Enabled
Products
High Volume Cellulose Nanomaterials Potential
Applications‐ World
48
Past Research Market Projections for Nanocellulose - Enabled
Products
Low Volume Cellulose Nanomaterials ‐
Potential Applications
49
Past Research Market Projections for Nanocellulose - Enabled
Products
Comparison to RISI Market Study
Jack Miller, Principal Consultant, Market-Intell LLC
Associate Consultant, RISI
23.5 million tonne potential
1.2 million tonne at 5% market penetration
50
Past Research Market Projections for Nanocellulose - Enabled
Products
BCC Research Report - June 2015
The global market for nanocellulose totaled $46.8
million in 2014 and is projected to approach $277.7
million by 2019. CAGR of 42.8% through 2019.
Cellulose nanofibrils as a segment totaled $28.2 million
in 2014 - $158.3 million by 2019
Cellulose nanocrystals as a segment reached $18.0
million in 2014 - $116.6 million by 2019
51
Past Research Market Projections for Nanocellulose - Enabled
Products
Next Steps
Estimate Novel Application Volumes
Refine Estimates
Competitive advantage
Cost sensitivity
Adoption rates
Survey for applications
Technical issues
Time to market
Jobs estimates
52
Past Research Open Vetted Engineering/Economic Model of
Cellulose Nano-Crystal Production
Funded by P3Nano, U.S. Endowment for Forestry &
Communities, Inc.
53
Past Research Open Vetted Engineering/Economic Model of
Cellulose Nano-Crystal Production
Questions to be answered
What are the economic drivers of CNC production?
What process choices can be made to manage sulfuric
acid?
Are there advantages to co-locating on a mill site?
Will intellectual property issues hinder the proposed
design?
54
Past Research Open Vetted Engineering/Economic Model of
Cellulose Nano-Crystal Production
Pulp
Hydrolyze
Base
Water
Quench
and
Separate
Neutralize
and
Separate
Concentrate
CNC
Concentrate
Acid
Glucose
And
Sodium Sulfate
Water
CNC
Acid
Water and Glucose
55
Block diagram of a commercial CNC production process
Past Research Open Vetted Engineering/Economic Model of
Cellulose Nano-Crystal Production
Approach
1. Process design
2. Capital cost estimates
3. Cost model validation
4. Cash flow analysis
5. Intellectual property
(US Forest Service - FPL)
(American Process Inc.)
(nanoC)
(US Forest Service - FPL)
(nanoC)
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Past Research Private Consulting Proprietary Research
Client List
USDA Forest Service
US Endowment for Forestry & Communities, P3Nano
Sappi North America
NewPage - Verso Paper
Fibria Cellulose
American Process Inc.
Mohawk Fine Papers
Termomecanica
57
Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
58
Future Research New Products
BioFuels
BioChemicals
BioMaterials
59
Future Research BioFuels
Low Return on Investment (ROI)
High feedstock prices
High capital costs for biorefinery
Low fuel prices
Narrow spead between total cost and fuel prices
60
Future Research Path Forward
Integration into pulp mills to lower operating costs
Low cost waste woody biomass
Move toward high value added products
Chemicals, not fuels
Lignin to higher value added products, not
burned
Nanocellulose production integrated into pulp
mills
Partnerships and joint ventures are central to mutual
success
61
Future Research Path Forward - Potential Partnerships
Lignin
Metso LignoB
DOE ORNL for carbon fiber
Hemicellulose (sugar)
Renmatix
Biofine
Pure Vision
Fiberight
Nanocellulose
American Process Inc.
US Forest Service - FPL
62
Future Research Cellulose Nanomaterials Market Opportunities
High-Volume Markets
Automotive, paper & packaging coatings and
fillers, substitution for plastic packaging and film
Low-Volume Markets
Wallboard/Insulation, aerospace, paints
Novel and Emerging Applications
Sensors, filtration, electronics & photovoltaics,
3-D printing
63
Future Research Cellulose Nanomaterials Opportunities & Challenges
Examples
Composites; automotive
body parts
Aerogels/Foams
Opportunities
• Light-weight
• Drying method
• High-strength
• Interface chemistry
• Lower cost
• Surface treatment -compatibility with resins
• Light-weight, high strength
“sandwich” structures
•
Cost-effective drying
•
Interface chemistry
•
Dispersion
•
Strength properties
• Thermal insulation
• Acoustic insulation
Paints & Coatings
Challenges
• Scratch-free floor coatings
Higher-strength, more • Spackle
robust coating; scuff
• Clear Films and protective
resistance
panels
Develop functional base
materials together with
Interface chemistries
64
Future Research Cellulose Nanomaterials Opportunities & Challenges
Examples
Medical
Filtration/Separation
Opportunities
• Wound healing
• EHS considerations
• Tissue scaffolding
• Clinical trials
• Hemmorrhage control
• Interactions with human
tissue
• Evaluate filtration options
especially with other media
• Water purification
• Oil from water cleanup
• Separation of oil from water
using foam as a sponge using
cellulose nanomaterial
Concrete
Challenges
• Plasticizer effects to improve
fluidity
• Develop broader separation
technologies
• Understand reaction
mechanisms
• Enhanced hydration
• Self-healing, bendable
concrete
65
Future Research Cellulose Nanomaterials Opportunities & Challenges
Examples
Viscosity control
Opportunities
• Oilfield applications
• Paint thixotrope
Electronics / Optical
Paper
Challenges
• Understand rheological effects
and component interactions
• Develop formulations
• Photonic colors
• Manipulation
• Batteries
• Required paper smoothness
• Supercapacitors
• Strength; aligned assembly
• Recyclable electronics
• Recyclable components to
match lignocellulosics
• Overcome drainage issues
• Higher-strength grades
• Lighter weight
• Overcome reduced light
scatter, brightness, opacity
• Higher filler
• Cost-benefit; capital and
operating costs
66
Future Research Cellulose Nanomaterials Opportunities & Challenges
Examples
Surface Treatments/
Opportunities
Challenges
• Coating hold-out for reduction
in coat-weights
• Develop excellent dispersion of
CNF’s to avoid buildup behind
blades of coater
• Replacement of conventional
binders
• Barrier Coatings Films
• Achieve uniform fibril size
• Lighter-weight paperboard
• Develop good dispersion of
cellulose nanomaterial
Paper Coating
Packaging
• Achieve moisture stability
• Reinforced extrusions on board • Develop interface chemistries
67
Future Research Cellulose Nanomaterials Specific Research Needs
Char. &
Testing
Manufacturing
Drying
Appli-
Cations
• Measure/characterize particle morphology and size:
manufacturing - market - research purposes
• Measurement methods - manufacturing control
• Liberate nanofibrils with resin
• Economic redispersion - Overcome agglomeration
• Surface functionalization methods -- compatibility with enduse composites
• Conventional polymers and/or biodegradable polymers
68
Future Research Cellulose Nanofilaments Kruger FiloCellTM
Cellulose filaments on the left are peeled from kraft pulp fibers. The filaments have a
high aspect ratio, up 1,000 - Kruger's FiloCell™ produced in Trois-Rivières, Québec.
69
Future Research Cellulose Nanofilaments Kruger FiloCellTM
FiloCell™ reinforcing agent now being produced at a Kruger demonstration plant in
Trois-Rivières, Québec.
CF trials in printing paper show a good potential for making
lighter sheets at the same strength.
70
Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
71
Teaching Plans, Experiences and Desires
Experience teaching
Graduate level materials science courses at the
University of New Mexico
Materials science laboratory classes at Worcester
Polytechnic Institute
Scanning electron microscopy laboratory at
Massachusetts Insitute of Technology
72
Teaching Plans, Experiences and Desires
Qualified to teach:
Material and Energy Balances
Thermodynamics
Kinetics
Transport phenomena
Heat and Mass transfer
73
Teaching Plans, Experiences and Desires
Desire to teach:
Nanotechnology - Nanomaterials
Biorenewable Resources
Advanced Topics in Biomaterial Manufacturing
74
Presentation Outline
Introduction
Vision for the Center
Past research
Future research
Teaching plans, experiences
and desires
Concluding Remarks
75
Concluding Remarks Pulp and Paper State of the Industry
Paper and Paperboard
1999: 105.3 MT decrease of 26% to 2014
Industry sectors:
Corregated Containers
1999: 20.5 MT - no change for 2014
Newspaper
2002: 17.5 MT, decrease of 65%
Printing and Writing Paper
2000: 33.1 MT, decrease of 39.4%
Tissue
Increasing on a per capita basis
Data from the American Forest & Paper Association (AF&PA) 2014
76
Concluding Remarks Pulp and Paper Product Life Cycles Curve
Pulp and Paper Industry needs new products/revenue
streams
77
Concluding Remarks Pulp and Paper DuPont's Major Product Cycles
DuPont has moved through three major product cycles
in its 200-year history. The third cycle is just beginning.
78
Concluding Remarks Pulp and Paper New Products and Revenue Streams
BioFuels
BioChemicals
BioMaterials
Nanocellulose
3D Printing
Lignin to carbon
fiber (ORNL)
79
Thank You Any Questions?
80
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