Moving from black to green; Development of biorefinery processes and products in Norway Karin Øyaas, PFI

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Agenda  Norwegian green biomass resources  Current status of the Norwegian Forest based industries  PFI research on Biomass Conversion  About PFI  Green Chemistry and Innovative processes  Examples of R&D activities

 Concluding remarks

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Norwegian Forest based Sector History  Forests represent the major green biomass resource in Norway  Ever since the late 18th century pulp and paper production has been central to onshore value creation, ensuring activities along the whole forest based value chain.  The first Norwegian pulp mill started in 1863, with others following soon after  At the turn of the 18th century the Norwegian pulp and paper industry accounted for up to 60% of Norwegian Industry export value.

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Norwegian Oil Industry Sector History  1969: Oil discovered on the Norwegian continental shelf, and since the early 1970s the expanding oil industry has ensured long-term wealth and welfare to the Norwegian society.  Today the petroleum activities represent Norway's largest industry in terms of value, contributing to over 20% of gross domestic product (GDP). In addition, the petroleum sector's share of total export revenues reached almost 50% in 2012.  However, during recent decades, increasing environmental concern has shifted the focus of research and innovation to strengthen the development of novel, environmentally benign processes and products based on biomass (green and blue).

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Norwegian forest biomass resources  Forests cover almost 37% of land area  Standing woods and annual growth is increasing (> 50% since 1960)  Spruce is the dominant species

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Norwegian Pulp and Paper industry status  Declining demand and prices for key end products (e.g. printing paper)  Strong competition from regions with lower production costs  Leading printing paper producers in a difficult market situation - several closures in recent years  TMP, CTMP and sulphite pulp mills – no remaining kraft pulp mills  Borregaard’s diversified biorefinery goes well! Papir- og fiberinstituttet AS Paper and Fibre Research Institute

SKOG22 National strategy for the forest based sector  Established by the Ministry of Agriculture and Food, autumn 2013  A broad and cohesive strategy for research, development, innovation and knowledge of forestry and wood industries  Focus on recommendations and measures affecting the foundation for the development of a robust and competitive forestry and timber industry  Contributions from the entire value chain: Forestry, Building sector, Fibre/biorefinery, Energy  Completed January 2015 Papir- og fiberinstituttet AS Paper and Fibre Research Institute

SKOG22 Main conclusions  Forestry and wood industries can triple turnover  Several growth areas are foreseen, e.g. as building material, as chemistry, as energy.  Measures:  High degree of processing in Norway  Shift to products with high added value  Better the pulp and paper industries; focus on efficiency, specialization, innovation  Product development in areas where Norway has/may develop competitiveness, e.g. smelting industry, aquaculture, agriculture, oil/gas  Bioenergy to replace a larger share of fossil energy Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Paper and Fibre Research Institute (PFI) Key facts  Established1923  Independent research institute  Member of the INNVENTIA group (S) since 2004 •

Innventia group: world-leading research institute working with innovations based on forest raw materials

 PFI has long experience in R&D related to processing of / products based on lignocellulose • • • •

Fibre, pulp and paper New bio-based materials and chemicals, e.g. biocomposites, nanocellulose, biochemicals Biorefining and bioenergy Raw materials and characterisation

 Co-localised with NTNU* in Trondheim  Several external PhD-students/postdocs *: Norw. Univ. of Science and Technology

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

PFI works along the whole value chain

Printing paper

Packaging

Fiber

Lignocellulose

Biorefinery

New biobased materials

Biofuels Biobased chemicals Papir- og fiberinstituttet AS Paper and Fibre Research Institute

PFI works closely together with the customers - and brings in the required expertise and partners -

Value-chain mindset

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Focus areas at PFI

Biorefining and bioenergy

Biocomposites

Fibre and paper

Nanocellulose and carbohydrate polymers Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Focus area Fibre and Paper Selected research topics  Cost- and energy effective production of fibre and fibre based products  Quality improvements of fibre based products  New fibre based products, e.g.  Construction materials  Fibre based packaging solutions

 Synergy effects - combined production of fibre/ pulp/paper and bioenergy/biochemicals  Innovative and sustainable barrier concepts, e.g. against gas (oxygen), moisture and water  Raw material competence: • • •

The right raw material for the right product The right processing of the chosen raw material Characterisation Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Wood fibre based construction materials  Construction panels  Wood fibre based interior panels  Wood fibre based facade panels

 Wood fibre based insulation  Compressible insulation mats  Blow-in solutions

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Development of the ATMP process  New mechanical pulping process developed by PFI, Norske Skog and Andritz  The energy consumption in mechanical pulp production can be reduced by 40% - 50%  Implemented at Norske Skog Pisa. → Costs savings ~7 mill $/ year.  Other mills are currently investigating the possibility for investing in the new technology. Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Focus area Nanocellulose and carbohydrate polymers  Production    

Raw materials Pre-treatments (mechanical, enzymatic, chemical) Fibrillation processes (e.g. milling, homogenization) Concentration / drying

 Modifications / conversion  Applications        

Reinforcement - nanocomposites Improved paper qualities (e.g. strength, surface prop.) Viscosifiers Innovative and sustainable barrier concepts Stabilization of emulsions, e.g. in paint Carriers of specific components (e.g. antimicrobial) Membrane and filter applications Health applications, e.g. regenerative medicine, wound healing and biomaterials for medical devices  Applications for the oil field industry Papir- og fiberinstituttet AS Paper and Fibre Research Institute

What is nanocellulose (NFC)? Wood

SEM-pictures: PFI

Fibre

Artwork by Mark Harrington, Univ. Of Canterbury (1996)

Nanocellulose

Nanocellulose (or microfibrillar cellulose) is composed of thin particles, often with a diameter less than 100 nm, produced from biomass Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Biomedical applications based on nanocellulose (NFC)  NFC has many potential biomedical applications, including:  Tissue scaffold  Advanced materials for wound healing  Biosensors  Drug delivery Photo: Gary Chinga Carrasco, PFI

 Results from PFI research has shown e.g.:  Living cells can grow and divide on nanocellulose  Compressible hydrogels produced by crosslinking of NFC and other materials (e.g. marine biopolymers)  pH-responsive NFC hydrogels designed  Selected NFC qualities can function as barriers against bacteria in wounds Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Use of nanocellulose in enhanced oil recovery (EOR) • Development of novel functional chemicals to be used in central technologies related to off-shore activities, e.g.

Photo: Håkon Thingstad

− enhanced oil recovery − drilling fluids − other “green” oilfield chemicals

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Hemicellulose and dissolved sugars – use in Norwegian aquaculture industry and Norwegian feed production

• Dissolved sugars can be used in production of single cell proteins for fish fe • Hemicelluloses can be used as binder in feed pellets • Hemicelluloses can be used as binder and nutrient in animal feed

Photo: Harald Groven

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NORCEL Norwegian Nanocellulose Technology Platform One of five main research projects in the national NANO2021 program (Research Council of Norway). Managed by Paper and Fibre Research Institute (PFI). Three application areas in focus:

• Paper and packaging • Petroleum industry (enhanced oil recovery, EOR) • Tissue engineering

Strong consortium of national and international partners with complementary competences:

NTNU, UoB, UoS, Østfold Research, NORUT, Innventia (S) and CNR-ISTEC (It) Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NORCEL Structure

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NORCEL • Generic competence is built through the research topic activities. • The competence is directed towards applications of increasing complexity.

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Focus area Biocomposites  New wood fiber reinforced composite materials with fossil-based or bio-based matrix materials  Strategies for mixing of fibres and matrix material  Strategies for achieving good compatibility between fibres and matrix material  Characterisation of composite structures  Development of wood fibre granules for further processing  Nanostructured biocomposites  Examples of applications:     

Building and construction materials Decking materials Automotive parts Flexible biocomposites, e.g. for packaging Biomedical applications Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Norwegian biocomposite technology platform  Develop the technology platform for establishing production of next generation biocomposites in Norway, using wood fibres or microfibrillated fibres (MFF) as reinforcement components.  Focus on technical challenges, including: • Fibre/MFF production and modification • Feeding and mixing • Compatibility • Homogeneity • Reduced fibre shortening • Moisture resistance

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Focus area Biorefining and bioenergy  Pretreatment and separation of lignocellulose based materials for production of biofuels and chemicals  Utilization of process flows (e.g. side streams) for production of biobased chemicals  Conversion of lignocellulose to chemicals and biofuels; thermochemical and biochemical conversion routes  Production of bio-oils by pyrolysis  Upgrading of bio-oil, for further refining into fuels (e.g. for ship transport) and biobased chemicals  Torrefaction  Torrefied pellets  Intermediate product in gasification processes Papir- og fiberinstituttet AS Paper and Fibre Research Institute

R&D Example Renewable wood-based biofuels for shipping  Need for low-sulphur alternatives to conventional shipping fuels due to new EU regulations in Sulphur Emission Control Areas (SECAs) since Jan 2015 and coming limits in other sea areas from Jan. 2020.  Need for low- sulphur alternatives to conventional bunker oils  Project objective: Develop alternative low-sulphur bio-based transportation fuels based on upgraded fast pyrolysis oils  Project partners, R&D: PFI (project owner/ coordinator), Aston University (UK), NTNU  Industry partners along the whole value chain (forest - fuels – shipping – engine production)  Partly financed by the Research Council of Norway Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NorBioLab The Norwegian Biorefinery Laboratory National research infrastructure funded by the Research Council of Norway (37,5 mNOK; ~4 m€) 2014 - 2021 Managed and coordinated by PFI. Collaborating partners: SINTEF, NTNU and NMBU The laboratory is investing in new, advanced research infrastructure – tools for: • •

Developing new processes and products based on biomass Verifying new technological processes before further implementation Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Sigurd Rolland Pettersen ([email protected]), 8th NTNU NanoLab Symposium, November 12th 2013

NorBioLab Structure

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NorBioLab C6 and C6/C5 sugar platform: • Autoclave reactor lab with acid proof autoclave units and EX-protection. • Rapid heating displacement reaktor. • Unit for enzyme production and enzymatic hydrolysis • Reactor for high dry matter and high viscosity fermentation with in-situ product separation system • Multiple autoclave system for catalyzed reactions in liquid phase

Biogas platform: • Dolly reactors and anaerobic cabinet to complete previous investments at the biogas laboratory

Syngas platform: • Entrained Flow (EF) reaktor (gasification)

Pyrolysis oil platform: • Fast pyrolysis pilot plant for pyrolysis oil production • Reactor for production of hybrid bio-fossil fuels through coprocessing in Fluidized Catalytic Cracking (FCC) Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NorBioLab Collaboration a central success criterion

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NorBioLab Catalytic Fast Pyrolysis (CFP) Unit  Continuous, flexible bubbling bed reactor with in situ and ex situ catalytic upgrading  Suited for production of liquid fuels and biochemicals from different biomass feedstocks Unique characteristics: • Catalyst can be exchanged during trial →avoid rapid catalyst deactivation • Upgrading conditions can be adjusted separately • Ex situ CFP: Char separated (cyclones) prior to vapor feeding to upgrading unit → Improved control of vapor phase reactions; Generally challenging in lab scale

• No similar system exists in Europe Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NorBioLab Catalytic Fast Pyrolysis (CFP) Unit  Unit for Catalytic Fast Pyrolysis Process Development at PFI  Scheduled to be in operation by autumn 2016

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

NorBioLab High Pressure Rapid Heating Displacement Reactor

 Unique tool for developing new biomass conversion processes (e.g. pretreatment, separation).  Suitable for organic solvent based extraction of wood polymers at high temperature / short retention time.  Will be in operation at PFI during 2016. Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Characterisation of biomass and products Central tools supporting all aspects of our research  Chemical  Physical  Thermic  Morphological

Papir- og fiberinstituttet AS Paper and Fibre Research Institute

Concluding remarks  Innovative process development and green chemistry development are receiving increasing attention in Norway  Forests represent the dominating green biomass resource  PFI is a central R&D stakeholder devoted to conversion of green biomass resources/biorefining, including:    

Pulping, paper and packaging Biocomposites Nanocellulose and carbohydrate polymers Biorefining and bioenergy production

and coordinates central national R&D and infrastructure projects in the biorefinery area Papir- og fiberinstituttet AS Paper and Fibre Research Institute

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Papir- og fiberinstituttet AS Paper and Fibre Research Institute