USFS-Forest Products Laboratory's Priority Research Areas for Cellulose Nanomaterials and Biocomposites

RBI-Executive Conference @GaTech

10-11 March, 2015

Robert J Moon Materials Research Engineer Forest Products Lab

Adjunct Prof., School of Materials Science & Engineering Member of Renewable Bioproducts Institute Adjunct Prof., School of Materials Engineering, Member of Birck Nanotechnology Center

robertmoon@fs.fed.us

USFS-Forest Products Laboratory's Priority Research Areas for Cellulose Nanomaterials and Biocomposites

RBI-Executive Conference @GaTech

10-11 March, 2015

U Agarwal, Z Cai, C. Clemons, B Illman, RJ Moon, W Nieh, A Rudie, R Sabo, G Schueneman, M Tshabalala, T Wegner, JY Zhu USDA Forest Service Forest Products Laboratory One Gifford Pinchot Drive Madison, WI 53726-2398 p: 608-231-9200

www.fpl.fs.fed.us

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Why Cellulose Nanomaterials?

• Light/Stiff/Strong • Optical • Surface Chemistry

What can CNs do that no other nanoparticle can do?

• Few EHS Concerns • Renewable • Sustainable • Biodegradable

• High Production Potential • Low Cost Potential • US Source Local Jobs

Societal Needs Industry Healthy Forests

It is not one specific property that sets Nanocellulose apart

from the rest, rather the unique combination of

relevant characteristics that gives these materials utility

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Why Cellulose Nanomaterials?

• Light/Stiff/Strong • Optical • Surface Chemistry

What can CNs do that no other nanoparticle can do?

• Few EHS Concerns • Renewable • Sustainable • Biodegradable

• High Production Potential • Low Cost Potential • US Source Local Jobs

Societal Needs Industry Healthy Forests

It is not one specific property that sets Nanocellulose apart

from the rest, rather the unique combination of

relevant characteristics that gives these materials utility

Helps USFS Fulfil its Mission: • “Caring for the Land and Serving People” • Goal: …to achieve quality land management under the sustainable multiple-use management concept to meet the diverse needs of people.

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USFS-FPL -CN R&D

USFS

FPL

individual projects

• Broad Program Areas

• Broad R&D Platform Areas

• Scientist- ID specific Projects

• Partners- ID “Needs”

S S S S S S

P P

P P P P

P P P P

P

FPL Scientists - flexibility to pursue research within

the context of overarching USFS Priorities and Goals

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Outline

• USFS • Snapshot • Summary

• FPL • Snapshot • Cellulose Nanomaterials R&D

• Drivers, Approach, Focus Areas • Research Areas

• Summary & Impact

• FPL Scientist Snapshots

Cellulose Nanomaterials (CNs)

CNFs

CNCs Rod-like

Fibril-like

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USFS- Snapshot Forests Essential • Climate control, CO2

• Clean water • Habitat • Products • Jobs

Program Areas • Fire • Forest Health • Invasive Species • Resource Mgmt/Use • Water/Air/Soil • Inventory & Monitoring…

USDA-FS • National Forest System • State & Private Forests • R&D

Forest Land in US • 751 million acers • >50% Private

Fire Hazard

Opportunity: • Remove dead wood • Make CNs from • Reduce fuel loading

R&D Focus Areas • Climate Change Adapt • Biomass & Bioenergy • Nanotechnology • Water Management • Urban Natural Resources

R&D Structure • 77 research units • 67 locations • 83 Exp. Forests • 370 Research Natural Areas • 500 Scientists • 3000 employees…

Guiding Principle: •Create Nat'l Wealth •Create Jobs • Solve Critical Forest

mgmt. Problems

•Healthy Forests

•Healthy Forest Products Industry

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USFS -CNs R&D- Summary

• Drivers: • Wood utilization & products Jobs • Fire Reduction save lives, forests & $

• R&D Priority Areas: • Biomass & Bioenergy • Nanotechnology

• Activities: • In NNI since 2005 • Organizing workshops/roadmaps • Research Funding ~$4.5M/yr • Pilot Scale CN processing ~$3.2M • Public-Private Partnerships-

• FY2016 Budget Proposal: • $80M President’s budget • 2 Nat'l Network for Manufacturing Innovation (NNMI) institutes

• Cellulose Nanomaterials • Biomanufacturing and Bio-Based Products

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Outline

• USFS • Snapshot • Summary

• FPL • Snapshot • Cellulose Nanomaterials R&D

• Drivers, Approach, Focus Areas • Research Areas

• Summary & Impact

• FPL Scientist Snapshots

Cellulose Nanomaterials (CNs)

CNFs

CNCs Rod-like

Fibril-like

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Forest Products Lab- Snapshot The Lab: • Established in 1910, - Madison, Wisconsin

• Largest Federal Forestry Research Lab • 45 Scientists, 155 total employees • $20M/yr budget, ~$4.5M/yr on Nano • ~10 Scientists on Nano

R&D Focus Areas: • Healthy & Sustainable Forests • Nanotechnology/Nano-materials • Advanced Structures/Green Building • Bioenergy/Biorefinery • Advanced Composites • Defense/Homeland Security Use of Wood-based Materials

(use of forest biomass from forest restoration,

fuels reduction, insect killed, invasive species,

etc.)

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FPL -CNs R&D- The Drivers Healthy & Sustainable Forests: • Find use of low-value forest biomass • Develop Value-added Products • Large Volume Uses • In-Wood Processing • Support Local Businesses • Create Jobs in Rural America

FPL R&D must satisfy

USFS – Mission!

Industry Healthy Forests

FPI-Gov-Uni Research: Efficient Use of Renewable Resources

PULP WOOD HARVEST RESIDUE SAW LOGS

LUMBER

POWER

VA

LUE

MILL RESIDUE

PARTICLEBOARD

MDF

OSB

PARALAM

CONSTRUCTION PLYWOOD

HARDWOOD PLYWOOD

LVL

I-JOIST

GLULAM

CHEMICALS

COMPOSITE LUMBER

LIQUID FUEL

CELLULOSE NANOMATERIALS

FUEL PELLET

WOOD COST

PACKAGING

SCRIMBER

PRINTING PAPER

TISSUE

VENEER LOGS

USFS – CNs Perspective • Use lower cost wood

• Increase Value

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FPL -CNs R&D- Approach Commercialization: • Develop Underlying Science & Technology (Platform Technologies) • Develop CN Supply (pilot plant facilities)

• Develop Partnerships (PPP) • Develop New Applications • Develop Road Maps to Advance Technologies

• Industry Consortium, Industry Associations, NNI, etc.

• Risk Reduction • Environment-Health-Safety • Develop Codes & Standards (for materials and new applications)

• Develop Market Studies for New Applications • Develop Generic Business Case Development

• Technology Readiness levels 1-3

• Generic Cellulose Nanomaterial

Platform Technologies

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FPL -CNs R&D- Focus Areas Research/Development/Deployment: • Production of CNs for Research and Scale-up • Characterization • Surface Functionalization • CN-Composites • Organic/Inorganic Composites • Multi-Length Scale Modeling • Manipulation of Tree Cell Wall Architecture

• Broad areas of CN R&D…

• FPL Scientists - flexibility to pursue research within the context of

overarching USFS Priorities and Goals

Input:

FPL nanotech: http://www.fpl.fs.fed.us/research/research_emphasis_areas/introduction.php?rea_id=4

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Production Characterization Functionalization

Flexible Electronics Manufacturing

Composites Template Structures Separators/Barrier

FPL -CN R&D- Summary

• Particles & Comps

• Properties

•Distribution

• Interfaces

•Methods

• Sources

• Yields

•Drying

• …

• Dispersion

• Interface

• Durability

• New systems

• Structures

Predictive Modeling

Dri et al.

• 3-D Printing

•Roll-to-Roll

• Fibers

• Foams

• …

•Uniform coverage

•New Chemistries

•Oxygen

•Moisture

•Chemical

• …

• Printing

• Transfer

• …

Padalkar et al.

• Sacrificial

•Hybrid

•Hierarchical

•Mechanical

• Thermal

• Interface

• …

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CNC-CNF Pilot Plants Scientists at Uni P3Nano

Road Mapping Partnerships

TAPPI Nano Publications Market Analysis

FPL -CN R&D- Impact

Workshops •USFS-NNI - 2014 • Industry, Academia, Fed

• 60+ peer review

• 1 book

• 50+ Conference

• 7+ patent apps

• Conference: 2007 – present

• Nanodivision

• Public-private Partnership

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USFS Funded CN Pilot Plants CNC & CNF Pilot Plant

•2012, Forest Products Laboratory

•$1.7 Million

•CNC ~30kg/wk, batch process

•CNF ~ 5kg/wk, batch process

CNF Pilot Plant •2012, University Maine

•$1.5 Million

•Upgrade CNF Facilities

•1 ton/day, batch process

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USFS Funded CN Pilot Plants CNC & CNF Pilot Plant

•2012, Forest Products Laboratory

•$1.7 Million

•CNC ~30kg/wk, batch process

•CNF ~ 5kg/wk, batch process

CNF Pilot Plant •2012, University Maine

•$1.5 Million

•Upgrade CNF Facilities

•1 ton/day, batch process

CN Distributed: April 2013 - Jan 2015

• 190+ private companies

• 90+ public research/academic institutions

• In 33 different countries

• CNF: > 5,500 lbs.

• CNC: > 350 lbs.

October 2007 Access to Purdue Facilities & Resources Member: Birck Nanotechnology Center Initiate Efforts in CN: 7 Faculty, 9 Students

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Partnerships in Nanotechnology

October 2013 Access to GaTech Facilities & Resources Member: Renewable Bioproducts Institute Coordinate efforts Industry Cooperation

December 2013 P3Nano

•Public-Private Partnership • Strategic Planning •Risk Reduction •Pooling Resources

P3Nano a Public-Private Partnership -- Industry/Government/Academia

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FPL -CN R&D- Summary

• Drivers: • Wood utilization & products Jobs • Value-added Products

• R&D Priority Areas: • Biomass & Bioenergy • Nanotechnology • Advanced Composites

• Activities: • Pilot Scale CN processing • Organizing workshops/roadmaps • Partnerships • Research • Organizing Conferences • FPL Scientists at Universities

• New FPL Sci. at:

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Outline

• USFS • Snapshot • Summary

• FPL • Snapshot • Cellulose Nanomaterials R&D

• Drivers, Approach, Focus Areas • Research Areas

• Summary & Impact

• FPL Scientist Snapshots

Cellulose Nanomaterials (CNs)

CNFs

CNCs Rod-like

Fibril-like

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FPL Scientists doing CN R&D • Umesh Agarwal

• http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=147

• Zhiyong Cai • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=137

• Craig Clemons • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=138

• Barbara Illman • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=161

• Robert J Moon • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=185

• Alan Rudie • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=145

• Ron Sabo • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=141

• Greg Schueneman • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=221

• Mandla Tshabalala • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=189

• JunYong Zhu • http://www.fpl.fs.fed.us/people/bios/employee_level_bio.php?employee_id=160

(partial list)

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Ramie Ramie

Thank you for your Attention To learn more about Cellulose Nanomaterials “State of the Art”

Review Papers: Contact Me:

robertmoon@fs.fed.us

R J Moon, Chemical Society Reviews.(2011). DOI:10.1039/C0CS00108B

http://www.fpl.fs.fed.us/

Websites:

http://www.tappinano.org/