Nanotechnology in the Forest Products Industry

Sean Ireland

Verso Paper Tel: 207-469-4253 [email protected]

Phil Jones

Tel: 770 331 0325 Imerys [email protected]

Ted Wegner

Tel: 608 231 9434 US Forest Products Lab [email protected]

John G. Cowie

American Forest & Paper Association Tel: 202 463 2749 [email protected]

Agenda 2020 Technology Alliance

Nanocrystalline Cellulose Source: NIST & FPL NSF Nanoscale Science& Engineering Grantees Conference

Nanotechnology in the Forest Products Industry Presentation at the National Science Foundation Grantees Meeting John G. Cowie Ph.D.

American Forest & Paper Association Agenda 2020 Technology Alliance December 8 th , 2009

Emerging Markets for Nano-Enabled Biomaterials Presentation Outline

 Agenda 2020 & Forest Products Industry  Nanotechnology in FPI  Nano focus areas  Industry priorities:  2009 Roadmap  Most recent priorities  Nano research needs

Reinventing the forest products industry through innovation

Agenda 2020 Technology Alliance

 Member alliance - transformational R&D  Special Project of AF&PA  Industry-led partnership with government and academia  Reinvent the forest products industry through innovation  Collaborative, pre-competitive RD&D

Reinventing the forest products industry through innovation

4

Moving Nanotechnology Forward in the Forest Products Sector

      2005 FPI Nanotechnology Roadmap 2006 Agenda 2020 FPI Technology Roadmap 2006 Priorities Workshop 2007 NNI Forest Products Industry CBAN Consultative Board for Advancing Nanotechnology 2008 Focus Workshop 2009 Technology Roadmap

Reinventing the forest products industry through innovation

Agenda 2020 Innovation in the Forest Products Industry

 The Forest Products Industry developed:  strong public-private partnership  common and agreed upon agenda for advancing nanotechnology  Agenda 2020 signed CBAN with the NSET subcommittee through NNCO  Conversion of industry goals to fundamental science needs  Link with other industry sectors to explore commonalities

Reinventing the forest products industry through innovation

6

Priority Forest Products Industry: Focus Areas for Product Features Based on Technology Roadmap

1.

Develop biomass-based packaging 2.

Increase the performance-to-weight ratio of paper by 20-50% 3.

Modify existing and/or create new paper characteristics to increase capabilities 4.

Deconstruct biomass into fundamental components without disrupting nano-properties 5.

Develop bio-based composites leveraging the unique properties of biomass

Reinventing the forest products industry through innovation

20 to 50% Improvement in the Strength / Weight Performance Objective:

Increase the performance-to-weight ratio of paper by 20-50% less fiber Significantly increasing strength of the fiber substrate, enables:  Reduction in basis weight  Use of significantly more recycled fiber and inferior quality fibers  Use of inexpensive fillers Photos from: Marielle Henriksson, Lars A. Berglund, Per Isaksson,Tom Lindstro ¨ m, and Takashi Nishino|, KTH, Stockholm Sweden

Reinventing the forest products industry through innovation

20 to 50% Improvement in the Strength / Weight Performance Enabling technologies – pre-competitive research:

 Increase strength of fiber to fiber bonds  Use nanotechnologies to permit significant concentration of inexpensive non-fibrous fillers  Employ nanomaterials to increase opacity of fibrous webs  Develop coatings and surface treatments to increase strength and stiffness of paper Photos from: Marielle Henriksson, Lars A. Berglund, Per Isaksson,Tom Lindstro ¨ m, and Takashi Nishino|, KTH, Stockholm Sweden

Reinventing the forest products industry through innovation

Cellulose Nano-Crystals are Remarkably Uniform The ubiquitous nature of cellulose:

 Cellulose nanocrystals dispersed  Cellulose nanocrystals are uniform Photos from: Michael T. Postek, Andras Vladar, John Dagata, Natalia Farkas, Bin Ming Ronald Sabo, Theodore H. Wegner and James BeecherNIST, Gaithersburg, MD

Nanocellulose uniform Forms photonic structures From Derek Gray

Reinventing the forest products industry through innovation

Modify or Create New Paper Characteristics to Increase Capabilities: Optical Objective:

Develop new fiber-based products that take advantage of the uniform nature of the nano-material to develop photonic structures.

Target market opportunities:

 Lightweight printing papers with high opacity  Paperboard with high light barrier for packaging light-sensitive contents without use of metal foil  Papers and folding cartons with new security and anti counterfeiting features  White-surfaced paper and paperboard with high content of recycled and/or unbleached fiber

Reinventing the forest products industry through innovation

Modify or Create New Paper Characteristics to Increase Capabilities: Optical Optically transparent nanofiber paper

Masaya Nogi,* Shinichiro Iwamoto, Antonio Norio Nakagaito, and Hiroyuki Yano Kyoto University, Kyoto, Japan  Paper Airplane: Nanofiber paper folds like traditional paper  Comparison of traditional paper (right) scatters more light than unpolished nanofiber paper (left)

Reinventing the forest products industry through innovation

Modify or Create New Paper Characteristics to Increase Capabilities: Electronic Electro-active paper for a durable biomimetic actuator

Sung-Ryul Yun, Gyu Young Yun, Jung Hwan Kim, Yi Chen and Jaehwan Kim1 Center for EAPap Actuator, Department of Mechanical Engineering, Inha University, 7-49 Songdo-Dong, Yeonsu-Ku, Incheon 402-751, Korea •Cellulose based electro-active paper, a smart material •Electric field is applied across thickness produces large bending deformation •Piezoelectric effect better than quartz

Reinventing the forest products industry through innovation

Develop Materials of the Future Objective:

Create new revenue streams with new products based on novel forest-derived nanomaterials

Target market opportunities:

 High-performance  composites High-strength wood composites   High-strength paper Chemicals, pigments, additives

Reinventing the forest products industry through innovation

Develop Materials of the Future Enabling technologies – Pre-competitive research:

 Liberation and fractionation of cellulose nanocrystals  Functionalization and chemical modification of surfaces of cellulosic nanomaterials  Processes for utilizing wood-based nanomaterials in composites  Biomimicry – using nanomaterials for ultra high strength and particular effects by imitating natural structures

Reinventing the forest products industry through innovation

Abalone shell White Beetle

Thank you!

Please contact me for more information:

John Cowie, Technology Director Tel: 1-202-463-2749 (USA) Email: [email protected]

American Forest & Paper Association Agenda 2020 Technology Alliance 1111 19 th Street NW, Suite 800 Washington, DC 20036 USA

Reinventing the forest products industry through innovation

16

The Forest Products Industry & Cellulose Nanotechnology

Sean Ireland New Product Development Manager Verso Paper Co.

NSF Nanoscale Science and Engineering Grantees Conference 2009

•

U.S. Forest Products Industry

to produce products • Accounts for over 6.2% of US GDP • Ninth Largest Manufacturing Sector in US • Forest Products Industry is the top 10 manufacturing employer in

43

states

450

1.5 Trillion tons of cellulose grown annually worldwide S.B. Lang 1996

400

Millions of Cubic Metres

350 300

US Growth/Harvest = 2:1

Non-Tropical Tropical Source : FAO, SOFO 97, LEK analysis 250 100 90 80 70 60 200 50 40 150 100

Percent of Total World industrial Production

30 20 50 10 0 0

US Forest Products Industry

• Wood Processing Systems and Infrastructure – Huge physical scale – High capital costs – High technical sophistication along entire supply chain • Enormous economic pressures over the past decade due to Global competition & changing demographics – Numerous mergers, consolidations and shut downs of higher cost production capacity – Reduction in R&D investments – Individual companies focus on core competencies and core commodity products • Need for new products & markets

Times Are Changing The first attempts at self assembly with cellulose nano-materials. Now…

Times Are Changing 1979

What are Cellulose Nano Components

Cellulose Disordered

1 nm

Cellulose Nanocrystal Properties

Cellulose Nanocrystals 3 – 5nm diameter

http://woodscience.oregonstate.edu/faculty/simonsen. • High-aspect crystallites from wood. (3-5nm x 100+nm) • High Strength / Mechanical Properties • Piezoelectric (Equivalent to quartz) • Commercial Potential • Relatively inexpensive • Renewable and Biodegradable • Safe

Allows control of transmittance and color.

Cellulose Nanotechnology Applications

materials from renewable resources • • • • • • • • • • • • • Batteries Super-Capacitors Bio Plastics Nano Coatings Reinforced Polymers Smart Sensors High Efficiency Filters Photonic Devices Nano Membranes Wood Construction Packaging Chemical Industry Light Weight Nano Composites Biomedical Tissue E-Ink Nano-Adhesives Wood Composites Printing Energy Aerospace Industry Forest Products Industry Information Technology Academia Automotive Industry Automation Machinery Services Consulting

Cellulose NanoCrystals – Safe?

products yet there is little or no knowledge of their life cycles or fate in the environment.

Novel Materials in the Environment: The case of Nanotechnology, Royal Commission on Environmental Pollution, Report 27 • The issue is the nanoparticles, not the nanotechnology • IH Studies on

basic materials

still needed • Environmental samplers for nanomaterial sensing • Preliminary Data Suggest that

Cellulose

Nanomaterials are SAFE with Minimal Health and Safety Issues.

Cellulose NanoCrystals – Safe?

Understand the EXPOSURE and RISK We cannot afford to just leave the EHS door wide open…

Nano Cellulose Size Distribution

Source: Isogai et al, Department of Biomaterial Sciences, The University of Tokyo

Coefficient of Thermal

0.025

Expansion

2.7 ppm/K

0.020

0.015

0.010

0.005

0.000

40 60 Temperature (C) 80 100

The extremely low CTE of TOCN fims is available for electronic and flexible display devices. The CTE of glass is ca. 8ppm/K.

Fukuzumi et al., Biomacromolecules, 2008 Source: Isogai et al, Department of Biomaterial Sciences, The University of Tokyo

AFM CNC Characterizations

Source: Robert Moon, USFS at Purdue University, US Forest Service, 2008

NFC as a Coating

Ink-Jet Printing done by a LEXMARK 9300 with black pigment ink

X 100k 200 nm

Uncoated paper Uncoated PVA sheet PVA sheet coated with nanofibrillated cellulose (3 g/m 2 ) Source: Douglas Bousfield et al, University of Maine Paper Surface Science Program, 2009

Potential Nano-Cellulose Market Impacts

• Chemical (13.8% GDP) – Cellulosic polymers • Automotive (6.3% GDP) – Utilizing clear composites for safety improvements.

• Forest Products (6.2% GDP) – Smart Packaging, Step Improvements in Current Products, – Understand that their Forests are a Strategic Resource • Plastics (4.5% GDP) – Developing and Improving upon bio-plastics • Defense Industry – New clear composites for use on tanks, missiles and personnel protection.

– Solar Power coatings on vehicles and personnel • • Cellulose Nanotechnology has “Near-term” manufacturability.

These market sectors are > 30% of our GDP ($4.3T US Dollars)

R&D Issues (Industry Perspective)

expensive. (Truly novel research and development) • Universities and Government Labs have some of the needed equipment.

– Majority of funding is directed at non-biological nano-materials • Not enough science publicly available (U.S.) for business leadership to make economic decisions.

– Research drives business models and economy • Crossing the “Valley of Death” • Raw Materials not sufficiently available for good research • Generally Incompatible with existing manufacturing techniques

•

R&D Critical Path

Raw Material Production

for R&D Utilization •

Characterization

of Cellulose Nanomaterials • Cellulose Nanomaterial

Dispersion

Techniques • • • CNC

Composite

techniques,

Characterization

and Multi-Scale

Modeling

of such.

Coupling Photonic

Methods of Nanoparticles to Matrix effects of nanomaterials •

Energy Efficient Liberation

and Fractionation of Cellulose Nanocrystals (CNC) from wood • Processes to

Prepare

,

Stabilize

and

Manufacture

nanomaterial composites

Current Global Cellulose R&D

• Developed nations with significant shares of the world’s forests are investing heavily in cellulose nanotechnology • Foreign governments to include trading blocs such as the EU are investing resources into nanocellulose R&D • Goals appears to be developing the IP necessary to gain advantage – R&D investments are 1300% – 3900% higher than the US – This could potentially give them an upper hand in the market place • Particularly alarming in countries where there is no “Valley of Death”

Cellulose Nanotechnology Investment

– Worldwide approximately $750M invested in cellulose nanotechnology • US Invests $4.7B

– – – –

~$10M $231M $261M $45M

in cellulose nanotechnology R&D • Canada invests $551M in cellulose nanotechnology R&D » Special interest in commercialization of those products » Does not include multiple high dollar entry grants for government sponsored programs. ($85M NINT, $46M FPInnovations) • Japan invests $18.7B

in cellulose nanotechnology R&D » $33M in full conversion to nano-fiber packaging.

• Sweden invests $15B to $61M in cellulose nanotechnology • European Union invests

$5.5B in nanotechnology

–

~$150M

in cellulose nanotechnology R&D – EU pledged to triple nano investment to $50.6B Euros(3% GDP) » Increase to $450M in cellulose nanotechnology R&D

– Led by the USDA Forest Service – Member of National Nanotechnology Initiative (NNI) – Additional work through grants from NSF – Supported by industry – Formal Industry Liaison to NNI • Industry and USDA Forest Service are working to form an Industry-Government-Academia Cellulose Nanotechnology Research Team

• Academic Establishments • • Current Land Grant Universities – Over $2.5B in R&D facilities – Over 300 Scientists and Students – Experience working with cellulose – Experience working at nano scales Research – US Patents: • 20,105 with nanotechnology • 2419 with nano referencing cellulose – US Publications • 110,000 (out of 406,000) in nanotechnology • 301 in cellulose nanotechnology



FPI-USDA Nanotechnology Initiative

within academia, government and industry to accelerate U.S. R&D  Roles & Responsibilities  USDA/USFS  Federal Program Leader, Manager and Administrator, Policies  Prototype Research   Support for bridging “Valley of Death” Funding through appropriation process  Industry  Provide direction and bridge between Science and Application      Program Support and Stewardship Scale-up Prototype Design and Development Partner Global industry knowledge and awareness CNTC support, business leadership and manufacturing know-how Support quest for adequate funding  Academia  Initial Cadre using current USFS Nanotechnology Centers.

 Provide the Basic and Applied Research and Development  Work with Industry to bridge “Valley of Death”

Cellulose Nanotechnology

• Annual Recurring Budget Need: $95M for 10 years • Initial Research – Two Government Labs – 7 Universities – 7 Private Labs – 2 Independent Labs • Funding – Equipment – Research – Materials – Centers of Excellence

Center

• • • • • Pay-Offs

US is Dominant in Key 21 st Century World Markets Resurgence of U.S. Manufacturing Sector Reinvented Forest Products Industry Cross the “Valley of Death” & achieve speed to market New High Tech Products

Develop the Science & Technology for High Performance, Multifunctional Materials & Products • • • • •

Increased Manufacturing Jobs Creates Rural Wealth US Forests are a Strategic Resource Increased Federal Revenues US leader in Cellulose Nanotechnology

Program Delivery

• Seek to Establish Adequate R&D Funding • Launch Core Program – USDA/US Forest Service – Cellulose Nanotechnology Center(s) • Launch Annual RFPs/FOAs – USDA – USDA/NSF – USDA/DOE • Carry out Program Evaluation & Direction Setting – USDA Forest Service – Agenda 2020 (Industry) – Other Federal Agencies

Raw Material Supply • Currently developing at two sources to maintain quality and standards

– USDAFS Forest Products Lab • Cellulose Nanocrystals (CNC) • Contact Ted Wegner, 608-231-9434 – [email protected]

– University of Maine • Nano-Fibrillated Cellulose (NFC) • Contact Mike Bilodeau, 207-581-2281 – [email protected]

Thank You

Sean Ireland E-Mail: [email protected]

Telephone: 207-469-4253 Verso Paper Corp.

2 River Road Bucksport, ME 04416

Raw Material Supply • Currently developing at two sources to maintain quality and standards

– USDAFS Forest Products Lab • Cellulose Nanocrystals (CNC) • Contact Ted Wegner, 608-231-9434 – [email protected]

– University of Maine • Nano-Fibrillated Cellulose (NFC) • Contact Mike Bilodeau, 207-581-2281 – [email protected]