Vision - Research - Teaching
Presentation to the
Alabama Center for Paper and Bioresource Engineering
Auburn University
June 24, 2015
Dr. John G. Cowie
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Introduction
Doctorate in Materials ScienceVice President of Technology at Agenda 2020 Technology Alliance - American Forest & Paper Association
Past Chair of TAPPI Biorefinery CommitteePast Leader of the Marketing Team in TAPPI Nanotechnology Division
President of nanoC - consulting company
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Vision for the Center -Alabama Center for Paper and Bioresource Engineering
This is my first visit to Auburn UniversityEverything I know about the Center from:
Harry CullinanYour Website
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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 activities2. Input from industrial leaders (CTOs) and from the University's staff and directors
3. Perform a SWOT Analysis4. Benchmark using other Centers like RBI (formerly IPST) at Georgia Tech
5. Investigate the available funding opportunities6. Develop a detailed vision and strategy
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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.
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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. jobsEconomic Impact of the Biobased Product Industry reportU.S. Biobased Products Industry contributes
$369 billion to the American Economy4 million new manufacturing jobs
USDA creates the BioPreferred® label programInnovative wood products
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Past Research -Value Prior to Pulping
Funded by the DOE and Industrial Consortium Partners
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Past Research -Value Prior to Pulping -Purpose
Utilize available enzymes and microorganismsDevelop:
Scientific knowledgeModeling toolsProcess design and Engineering economic information
Determine if there is:A compelling business case If so proceed to commercial scale demonstration
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Past Research -Value Prior to Pulping -DOE - Industry Consortium
Two year experimental study$3 million total
50% funded by DOE50% funded by Industrial partners
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Past Research -Value Prior to Pulping -Participating Pulp & Paper Companies
NewPageInternational Paper CompanyMWV - MeadWestvacoPotlatchSAPPIWeyerhaeuserClearwater PaperUPM KymmeneLongview Fibre
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Past Research -Value Prior to Pulping -Participating Research Institutions
US Forest Service - Forest Products LaboratoryState University of New York – Syracuse - ESFNorth Carolina State UniversityAuburn UniversityNational Renewable Energy LaboratoryIPST at Georgia Institute of TechnologyUniversity of MainePurdue UniversityAmerican Process International (API)Cobalt TechnologiesVerenium
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Past Research -Value Prior to Pulping -Approach
Technical FeasibilityPre-extraction & pulpingExtract processing or conditioningFermentation and ethanol production
Commercial FeasibilityInnovative process designEffective plant integrationCapital & operating costs of the best case process design & integration
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Past Research -Value Prior to Pulping -Project Groups
Pre-extraction and pulpingExtraction liquor processingFermentation and biofuel productionModeling and business case developmentEconomics and commercial feasibility
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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 pulpingHardwood met extraction yield target but with a decrease in paper strengthConditions can be found where a conventional pulp is produced with softwood - The extract yield is considerably less than the targetEconomics favored acid hydrolysis over enzymatic hydrolysis
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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 solidsThe acetic acid which is recovered
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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 biofuelsTechnical proof of concept study evaluating five different fermentation microorganisms
Zymomonas mobilis - NRELPichia stipitis - US Forest Service Forest Products Laboratory and the University of WisconsinSaccharomyces cerevisiae - Purdue UniversityE. coli - VereniumProprietary bacterial strain - Cobalt Technologies
All microorganisms tested met the target
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Value Prior to Pulping -Group 4 - Modeling and Business Case Development
Four different models were used HYSYS, WinGEMS, Excel and ApiMaxApiMAX models existed for conventional mills and were modified for VPP casesThe Excel model used with the ApiMax correlated best with the experimental data
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Past Research -Value Prior to Pulping -FPL Excel Model
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Past Research -Value Prior to Pulping -ApiMax Simulation
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Value Prior to Pulping -Modeling and Business Case DevelopmentBasic Assumptions in Economic Analysis
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Value Prior to Pulping -Modeling and Business Case DevelopmentCaptal Cost vs. Sugar Concentration
Capital Cost Estimates for Hemicellulose Extraction Process as a Function of Sugar Concentration Following Evaportaion
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Value Prior to Pulping -Modeling and Business Case DevelopmentOperating Cost Estimates
Annual Operating Cost ($/year) as a function of Sugar Concntration Following Evaporation
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Value Prior to Pulping -Modeling and Business Case DevelopmentEthanol Production Cost Estimates
Estimated Production Cost for Ethanol as a Function of Sugar Concetration
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Value Prior to Pulping -Modeling and Business Case DevelopmentAcetic Acid Production Cost Estimates
Estimated Production Cost for Acetic Acid as a Function of Sugar Concetration
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Past Research -Value Prior to Pulping -Economic Model Output: Ethanol
Case IRR %Base maple 0Pine cases range - 18 to - 4Maple cases range - 7 to 15"Best" Maple Ethanol Case 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
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Past Research -Value Prior to Pulping -Economic Model Output: Butanol
Case IRR %Base maple 0Pine cases range 19 to 21Maple cases range 6 to 39"Best" Maple Butanol Case 39
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Past Research -Value Prior to Pulping -Technical Conclusions
Hemicellulose can be extracted from wood chips prior to pulping and converted at high yield to biofuelsAcetic acid can be recovered from the hemicellulosic extract providing a clean sugar stream for fermentationPulp yield, quality and value are dependent upon the degree of hemicellulose extractionLow extraction conditions (10% mass removal) maintain similar quality metrics of conventional pulpHigher mass removals (up to 23%) alter the characteristics of the VPP pulp vs conventional pulpBased upon ROI, a 15% extraction level is preferred
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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-Private-Partnership (PPP)
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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 knowledgeThe forest products industry needs to create a RJV similar in framework to the SRC through a membership based consortium
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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 partnersThe consortium agreement sets out the internal management guidelines – during and after projectLegal agreement written and signed
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Past Research -A Research Joint Ventures (RJV) Model -Benefits
Reduced research costs due to a reduction in duplicative researchFaster commercialization since the research stage is shortenedDevelop an industry-wide competitive visionGreater R&D productivity and greater patenting activityAccess to key university personnel
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Past Research -A Research Joint Ventures (RJV) Model -Outcome -
Full implementation of the RJV ModelEstablishment of P3Nano in the U.S. Endowment for Forestry & Communities, Inc.
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Past Research -Market Projections for Nanocellulose - Enabled Products
Funded by the US Forest Service
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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 applicationsMethodologyVolume estimates
Recommend some future research directions
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Past Research -Market Projections for Nanocellulose - Enabled Products
Environmental Market Drivers
Consumer/Retailer demand RegulatoryLight weighting to improve fuel‐ efficiency Café standards
Energy Efficiency Building codes
Bio based materials‐Shopping bag/water bottlebans/additive red listing‐
Greener Consumer Products EU Directive – vehicle recycling
Carbon Dioxide targets
Renewable/compostableLandfill bans/ recyclingtargets
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Past Research -Market Projections for Nanocellulose - Enabled Products
Assumptions
Recent research reports/expert network to identify target applicationsCurrent market size is maintained (no growth)Commercialization within the next 6‐11 yearsCost competitive with current alternativesTechnical issues addressedNo barrier to adoption
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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
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Past Research -Market Projections for Nanocellulose - Enabled Products
Market Estimates
Vol = M *NC content * MPM = recent market sizeNC Content = % nanocelluloseMP = market penetration rate
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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
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Past Research -Market Projections for Nanocellulose - Enabled Products
Estimated Market Penetration Rates High Volume Applications
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Past Research -Market Projections for Nanocellulose - Enabled Products
High Volume Cellulose NanomaterialsU.S. Market Penetration Estimates
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Past Research -Market Projections for Nanocellulose - Enabled Products
Annual Tonnage Estimate by Forest Products Subsector
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Past Research -Market Projections for Nanocellulose - Enabled Products
High Volume Cellulose Nanomaterials Potential Applications‐ World
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Past Research -Market Projections for Nanocellulose - Enabled Products
Low Volume Cellulose Nanomaterials ‐Potential Applications
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Past Research -Market Projections for Nanocellulose - Enabled Products
Comparison to RISI Market Study
Jack Miller, Principal Consultant, Market-Intell LLCAssociate Consultant, RISI23.5 million tonne potential1.2 million tonne at 5% market penetration
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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 2019Cellulose nanocrystals as a segment reached $18.0 million in 2014 - $116.6 million by 2019
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Past Research -Market Projections for Nanocellulose - Enabled Products
Next StepsEstimate Novel Application VolumesRefine Estimates
Competitive advantageCost sensitivityAdoption ratesSurvey for applicationsTechnical issuesTime to market
Jobs estimates
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Past Research -Open Vetted Engineering/Economic Model of Cellulose Nano-Crystal Production
Funded by P3Nano, U.S. Endowment for Forestry & Communities, Inc.
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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?
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Past Research -Open Vetted Engineering/Economic Model of Cellulose Nano-Crystal Production
Hydrolyze Quenchand
Separate
Neutralizeand
Separate
ConcentrateCNC
ConcentrateAcid
WaterPulp
Acid
Water and Glucose
WaterGlucoseAnd
Sodium Sulfate
CNC
Base
Block diagram of a commercial CNC production process
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Past Research -Open Vetted Engineering/Economic Model of Cellulose Nano-Crystal Production
Approach
1. Process design (US Forest Service - FPL)
2. Capital cost estimates (American Process Inc.)3. Cost model validation (nanoC)4. Cash flow analysis (US Forest Service - FPL)5. Intellectual property (nanoC)
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Past Research -Private Consulting -Proprietary Research
Client List
USDA Forest ServiceUS Endowment for Forestry & Communities, P3NanoSappi North AmericaNewPage - Verso PaperFibria Cellulose American Process Inc.Mohawk Fine PapersTermomecanica
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Future Research -New Products
BioFuelsBioChemicalsBioMaterials
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Future Research -BioFuels
Low Return on Investment (ROI)High feedstock pricesHigh capital costs for biorefineryLow fuel pricesNarrow spead between total cost and fuel prices
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Future Research -Path Forward
Integration into pulp mills to lower operating costsLow cost waste woody biomassMove toward high value added products
Chemicals, not fuelsLignin to higher value added products, not burnedNanocellulose production integrated into pulp mills
Partnerships and joint ventures are central to mutual success
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Future Research -Path Forward - Potential Partnerships
LigninMetso LignoBDOE ORNL for carbon fiber
Hemicellulose (sugar)RenmatixBiofinePure VisionFiberight
NanocelluloseAmerican Process Inc.US Forest Service - FPL
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Future Research -Cellulose Nanomaterials -Market Opportunities
High-Volume MarketsAutomotive, paper & packaging coatings and fillers, substitution for plastic packaging and film
Low-Volume MarketsWallboard/Insulation, aerospace, paints
Novel and Emerging ApplicationsSensors, filtration, electronics & photovoltaics,
3-D printing
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Future Research -Cellulose Nanomaterials -Opportunities & Challenges
Examples Opportunities ChallengesComposites; automotive body parts
•Light-weight•High-strength•Lower cost
•Drying method• Interface chemistry•Surface treatment --
compatibility with resins
Aerogels/Foams •Light-weight, high strength “sandwich” structures
•Thermal insulation•Acoustic insulation
• Cost-effective drying• Interface chemistry• Dispersion• Strength properties
Paints & CoatingsHigher-strength, more robust coating; scuff resistance
•Scratch-free floor coatings•Spackle•Clear Films and protective
panels
Develop functional base materials together with Interface chemistries
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Future Research -Cellulose Nanomaterials -Opportunities & Challenges
Examples Opportunities ChallengesMedical •Wound healing
•Tissue scaffolding•Hemmorrhage control
•EHS considerations•Clinical trials• Interactions with human
tissue
Filtration/Separation •Water purification
•Oil from water cleanup•Separation of oil from water
using foam as a sponge using cellulose nanomaterial
•Evaluate filtration options especially with other media
•Develop broader separation technologies
Concrete •Plasticizer effects to improve fluidity
•Enhanced hydration•Self-healing, bendable
concrete
•Understand reaction mechanisms
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Future Research -Cellulose Nanomaterials -Opportunities & Challenges
Examples Opportunities ChallengesViscosity control •Oilfield applications
•Paint thixotrope
•Understand rheological effects and component interactions
•Develop formulations
Electronics / Optical •Photonic colors•Batteries •Supercapacitors•Recyclable electronics
•Manipulation•Required paper smoothness•Strength; aligned assembly•Recyclable components to
match lignocellulosics
Paper •Higher-strength grades•Lighter weight
•Higher filler
•Overcome drainage issues•Overcome reduced light
scatter, brightness, opacity•Cost-benefit; capital and
operating costs
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Future Research -Cellulose Nanomaterials -Opportunities & Challenges
Examples Opportunities ChallengesSurface Treatments/ Paper Coating
•Coating hold-out for reduction in coat-weights
•Replacement of conventional binders
•Develop excellent dispersion of CNF’s to avoid buildup behind blades of coater
•Achieve uniform fibril size
Packaging •Barrier Coatings Films•Lighter-weight paperboard
•Reinforced extrusions on board
•Achieve moisture stability•Develop good dispersion of
cellulose nanomaterial•Develop interface chemistries
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Future Research -Cellulose Nanomaterials -Specific Research Needs
• Measure/characterize particle morphology and size: manufacturing - market - research purposes
• Measurement methods - manufacturing control
Char. & Testing
• Liberate nanofibrils with resin Manu-
facturing
• Economic redispersion - Overcome agglomeration Drying
• Surface functionalization methods -- compatibility with end-use composites
• Conventional polymers and/or biodegradable polymers
Appli-
Cations
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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.
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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.
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Teaching Plans, Experiences and Desires
Experience teaching Graduate level materials science courses at the University of New MexicoMaterials science laboratory classes at Worcester Polytechnic InstituteScanning electron microscopy laboratory at Massachusetts Insitute of Technology
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Teaching Plans, Experiences and Desires
Qualified to teach: Material and Energy BalancesThermodynamicsKineticsTransport phenomenaHeat and Mass transfer
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Teaching Plans, Experiences and Desires
Desire to teach: Nanotechnology - NanomaterialsBiorenewable ResourcesAdvanced Topics in Biomaterial Manufacturing
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Presentation Outline
IntroductionVision for the CenterPast researchFuture researchTeaching plans, experiences
and desiresConcluding Remarks
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Concluding Remarks -Pulp and Paper -State of the Industry
Paper and Paperboard1999: 105.3 MT decrease of 26% to 2014
Industry sectors:Corregated Containers
1999: 20.5 MT - no change for 2014Newspaper
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
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Concluding Remarks -Pulp and Paper -Product Life Cycles Curve
Pulp and Paper Industry needs new products/revenue streams
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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.
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Concluding Remarks -Pulp and Paper -New Products and Revenue Streams
BioFuelsBioChemicalsBioMaterials
Nanocellulose
Lignin to carbon fiber (ORNL)
3D Printing
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Thank You - Any Questions?