VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD

Development of sustainablefibres in Finland

Biotaloudesta viennin veturi – Kuuntele VTT:nnäkökulma, 30.11.2015Professor Ali Harlin, Marjo Määttänen,Sari Asikainen and Pirjo Heikkilä

02/12/2015 2

Constant increase in viscose production since 1990.Current capacity > 3 MtThe markets are dominated by China: > 50 %Secondly by Western Europe, India and IndonesiaNo viscose production in Turkey nor in Finland

Viscose markets are still increasing- Limited capacity in Europe

02/12/2015 3

History of CCA - Cellulose carbamatetechnology

Early patents in USA in 1930’s:Urea derivative of celluloseObjective to replace viscose technology(no CS2 emissions)Neste Cellca from 1970’s to 1990’sZimmer from 1990’s to 2004

Spin-off of “Mechano-Chemical” processing of

natural-based materials: drystate processing technology,

solvent free

Totally revised Cellcatechnology

Environmental andoccupational hygienerequirements

Bio-based product, recyclablematerial, new paper chemical

Viscose replacement as astarting point

CCA at VTT

02/12/2015 4

Cellulose carbamate (CCA) was developed toreplace the old viscose process

Benefits for the industryCCA production is separated from applications

Logistics are similar to other cellulosederivatives and plastics

CCA production is a favourable option for thecurrent cellulose derivative industry or fordissolving pulp mills (new or value addedproducts)

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 forapplications

The concept is tested in industrial scale

02/12/2015 5

CCA technology opening novel opportunitiesOpening a possibility for refining pulp and for giving added value to pulpproduction.Renewing the old viscose processFinal 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 wastransformed into regenerated fibres

02/12/2015 6

The Relooping Fashion Initiativeis about consumers andcompanies working together tomake high-quality clothes thatare 100% reusable and moreenvironmentally friendly.With no harmful chemicalsadded for the durability andsoftness, this new materialmakes you feel good inside out!

Looking good – feeling even better

02/12/2015 7

VTT’s pop-up mill

Test runs in old mill in 2015:

Valkeakoski mill was openedfor test production demos

Sampling for evaluation in

October 2015

02/12/2015 8

VTT’s paper making research environment SUORAThe foam is generated in the pulper or close to theheadboxThe unit includes: Fourdrinier, hybrid and gap formerPressing with shoe press up to 2000 kN/mSpeed up to 2000 m/min

6 mm 12 mm 24 mm

Foam formed tissueand nonwovens inlaboratory scale

Foam formed tissueand nonwovens insemi-pilot scale at

speed of 210 m/min

Pilot-scale foam formingfacilities tissue and

nonwovens

Next generation fibre foamresearch environment forspecial grades and long

fibre usage

Foam forming in pilot scale

02/12/2015 9

Brilliant formation in the case of long fibres, although high forming consistency isappliedMechanical bonding instead of chemical bonding aspect for sustainabilityWidening of raw material combinations process simplifying

After drying

HydroentangledMechanical bonding of foam laid nonwovens(MECBO), VTT internal project, 2014.

Foam-laid nonwovens from cellulosic fibres- Semi pilot-scale - Hydroentanglement

02/12/2015 10

The objective was to develop a cost efficient and sustainable FILAMENTS withhigh performance by using new manufacturing technologies with a

multidisciplinary approach.

The aim was to create simple and inexpensive fibre yarn manufacturingtechniques that retains the original cellulose I structureIntrinsic properties of macro-scale wood fibres

Less processing steps

Background for pulp fibre yarn developmentin DWoC 1.0 (1/3)

CURRENT METHODSNon-wood based• Cotton• Flax• Other long natural fibres

Wood-based, dissolution andregeneration• Viscose• Modal• Lyocell Cellulose II

02/12/2015 11

CNF dryspinning

Choline chloride + urea

Pulpspinning

CNF wetspinning

Dry pulpspinning

YARN FORMING WITH WATER NON-WATER YARN FORMING

DESspinning

Filament forming technologies in DesignDriven World of Cellulose DWoC Project 1.0

02/12/2015 12

Ulilization of cheap and non-toxicchemicals

Chemicals recyclable and reusablein the process

Simple yarn manufacturing process

Aim:Formation of pulp fibre yarns by using a solvent that does not dissolvecellulose but swells effect on interfibre bonding

Fibre yarn spinning using deep eutecticsolvent (DES) (1/4)

02/12/2015 13

MaterialsDeep eutectic solvent

Eutectic mixtures composed of two or three componentswith a lower melting point than each of the individualcomponentsCholine chloride + urea (molar ratio 2:1)Non-toxic, low priceSimilar physicochemical qualities compared to ionic liquidsConsist of hydrogen bond acceptor (HBA, often quartenaryammonium salt) and hydrogen bond donor (HBD)

Bleached softwood pulp (~90 - 95%)

Polyacrylic acid (5 - 10%)Hydrophilic and non-toxic polymerUsed for crosslinking in order to add water stability

Acetone and ethanol

Fibre yarn spinning using deep eutecticsolvent (DES) (2/4)

02/12/2015 14

Fibre yarn spinning using deepeutectic solvent (DES) (3/4)

Pulp washedwith acetoneand dried +Preparation ofChCl/urea DES

Dope preparedwith PAA

Dope extrudedFibre yarn

washed withethanol

Fibre yarncrosslinked at140 oC

Water-stablefibre yarn

Patent pending: FI20155133:

Process for producing shaped articlesbased on cellulose (2015)

02/12/2015 15

Novel fibre yarns:Applications and possibilities

Applications in textiles, technical textiles and compositesDisposables, all-cellulose composites

02/12/2015 16

Conclusions

There is a demand onsustainable and afordabletextile and composite fibresin the markets.

Wood-based cellulose is asignificant option.

New technologies are readyto be launched.

Novel innovations could open doors for totally newapplications.

TECHNOLOGY FOR BUSINESS