forest industry reaching out to textile industry · 2019-03-13 · man-made cellulosic fibers turn...
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Forest industry reaching out to textile industry
Fastmarkets RISI European Conference13.3.2019
Jukka Kantola
Agenda today
• Textile fiber markets• Textile fiber value chains • Dissolving pulp markets• Man-made cellulosic fibers• Arbron will reshape cellulosic textile fiber
value chain• What about environment
Textile fiber markets
• Total annual consumption today 100 Mt , but already 2025 140 Mt - over 40% increase!• Most import textile fibers
Synthetic fibers ≈70 Mt (non-renewable, oil-based) Cotton ≈22 Mt (non-ecological, faces several problems) Cellulosic fibers ≈6 Mt (viscose most important, but CS2 problem) Others ≈1-2 Mt (e.g. silk, wool)
Man-made cellulosic textile fibersare still based on viscose process
• Viscose remains the dominant market leader
• Lyocell is already in commercial use – but struggles with high production costs
• China is by far the largest viscose producer – and a million tons of new capacity coming
Textile fiber value chains
Cellulosic fibers
WoodCarbon
disulphideCS2
SpinningDissolving pulp Textile Industrys
Synthetic fibers
Textile industrySpinningMeltingCracking + PolymerizationOil Drilling
Textile industrySpinningCardingGinningHarvesting
Cotton
Dissolving pulpRapid growth since 2008
• Dissolving pulp refers to the pulp with cellulose content above 90 % (alpha-cellulose content)
• Mainly wood based– although also bamboo is used in Asia• ¾ of the dissolving pulp is used for viscose production. Other applications like
cellophane, wiping, wound dressing, etc • Total market 8 million tons a year – mainly in China, North America, South
Africa, Western Europe and Brazil. Market growth 6-8% each year!
• Major dissolving pulp producers accounts for 60 % of the total
RISI
+6-8%
Man-made cellulosic fibersTurn around took place 2000
• Viscose is a fiber of regenerated cellulose – over 100 years old technology, but still compelling
• Biggest hurdle is CS2 – production moved to developing countries– China alone almost 70% of the output (!), followed by Indonesia
and India. (Europe 9%)• Total capacity 6 million tons a year - doubled since 2000
• Three big ones
• Several Chinese…
Man-made cellulosic fibersIn production
Production chemistry
Main properties Usage Environment,general notes
Viscose CS2, NaOH, H2S, ZnS, Na2SO4
~cotton, silk-look, absorptive, 100y experience
Textiles, wipings, wound dressing, etc
Toxic emissions, bad occupational health.Reference for others
Viscose-Modal Like viscose + special additives
Enchanced viscose Textiles for hard use and regular washing
Worse than viscose
Lyocell NMMO solvent, high pressure process
High strength Similar to viscose modal
99,5% of chemicals recycle, Alpha 99%
Cuprammoniumrayon
[Cu(NH3)4(H2O)2]2+NaOH
Very silk like niche Toxic, no emission
Cellulose acetate CH3COOH, C3H6O Silk like (tobacco) filters Acetic acid unpleasant
Man-made cellulosic fibersUnder development
Production chemistry
Main properties Usage Environment¬es
CCA (also CC), carbamate cellulose
UreaNaOH, H2SO4
Similar to viscose Same as viscose + great potential
Clean tech,many developers: Fraunhofer, VTT, Wuhan univ&other Chinese, etc
Ionic liquid(e.g. IonCell by Aalto Univ)
1,5-diazabicyclo[4.3.0]non-5-enium acetate
~Lyocell strength,High pressure tech
textile Non-toxic chemicals (not commercial), Aalto univ, many others
Entzymatic dissolution
Various entzymes, NaOH, ZnO, H2SO4
Target: viscose Same as viscose Clean tech,VTT
Direct dissolution without derivation or special solvents
Steam explosion, freezing, ultra pure cellulose, MCC, NaOH, H2SO4
Target: viscose ~viscose et al Many R&D groups, no success
Liquid crystal state (anisotropic)
Phosphoric acid Target Ultra high strength
~viscose et al Toxic, difficult process, lab only
Arbron reshapes the value chain of cellulosic fibres
Arbron™ material is more expensive than dissolving pulp, BUT Arbron based textile fibre is competitive against conventional viscose!
CURRENT VALUE CHAIN
Wood Carbondisulphide
CS2
Spinning Textile production
ARBRON™ BASED VALUE CHAIN
Wood SpinningArbron™ textile fiber
Textile productionSoftwood pulp Arbron™material
Dissolving pulp
What is
• Arbron™ is a material used as feedstock for cellulosic textile fiberproduction ADD ON process for a pulp mill
• Arbron™ based textile fiber production can be used in modified viscose plants DROP IN solution for the viscose plants. In a simplified process, which still use existing equipment
• Arbron™ eliminates the need for using the health risk chemical CS2(carton disulfide)
• The Arbron™ method takes advantage of the softwood pulp making process by benefitting energy surplus and wet pulp
• Development program under way
Why ?• The development program takes the entire value chain into consideration
– from standing tree to textile industry Accelerates the required R&D process
• Eliminates the need for carbon disulphide (CS2) at viscose plants Environmentally friendly production process
• Introduction initially in China – later other areas (including EU) Enormous market potential
• Technically efficient production concept Competitive product
What about environment?
Synthetic fibers are based on non-renewable resources• Not sustainable solution• Non-biodegradable • One of the major source for microparticle plastic problem
Need for ecological alternatives is obvious
Cotton is very demanding plant• High water demand (Aral-lake case). Cotton consumes at
least 5 times more water than viscose• One of the biggest pesticide consumer
Viscose currently requires use of highly toxic carbon disulphide. • Still dominating process• Mainly produced in China
To conclude
• Demand for the textile fibers is rapidly growing
• Challenges ahead with synthetic fibers, cotton and current cellulosic fibers
• Man made cellulosic textile fibers are still by large based on 100 years old viscose technology
• Several alternatives for viscose fibers under development
• Arbron™ will be an environmental friendly and safe alternative to produce cellulosic fibers for textiles
Thank you for your interest!
Jukka KantolaCEO – KaiCell Fibers Ltd
+358 40 552 [email protected]
Thank you for your interest!
Jukka KantolaCEO – KaiCell Fibers Ltd
+358 40 552 [email protected]