The EffNet program focuses on developing a new type of energy- and resource-efficient production technology called foam forming for web products. The program involves partnerships between research institutes, universities, and companies to develop nanocellulose-based concepts and products. Significant resource savings are expected from foam forming, including up to 40% reduction in carbon and water footprints. The program demonstrates foam forming at various scales and explores applications for lightweight materials. It also aims to minimize production costs and environmental impacts through international collaboration and a concept-level approach.

1. Resource efficient fibre web
technologies
Erkki Hellén, VTT
Scientific coordinator
21.11.2013
FIBIC

2. Efficient Networking towards
Novel Products and Processes (EffNet)
• The EffNet program focuses on
– a completely new type of energy- and resource-efficient production
technology for web products and
– designing nanocellulose-based production concepts and new products.
• The target is to develop and demonstrate new types of fibre-based products to
expand the range of products offered by the existing forest cluster companies.
Special efforts will be made to minimise the energy consumption of new products
and processes and develop resource-efficient processes.
EffNet
21.11.201
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Erkki Hellén

3. EffNet - Partners and international networking
EffTech (2a) + EffNet (3a): ~4+15M€
• Partners: 8 Research Institutes and
universities, 8 companies
• International Networking
•
•
•
•
•
EffNet
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Erkki Hellén
Co-operation with 10 countries (Canada,
Denmark, France, Germany, Ireland, Israel,
Sweden, U.K, Uruguay, U.S.A )
The collaboration with research groups
(FPInnovations, KHT, Sweden).
Long term research visits (Imperial College,
UK, Trinity College Dublin, Ireland and the
University of Texas at Austin, USA)
Co-operation with Yttkemiska Institutet
(YKI), Sweden, on foam chemistry
Joint M. Sc. Theses (University of Uruguay)

4. Concept level approach
• Efficiency through area-based measurement criteria
• Energy MWh/(km)²
• Water m³/(km)²
• Total costs (fixed+variable) €/(km)²
•
•
•
•
New production technologies: foam and ultra high consistency forming
Raw material efficiency through biominerals and binding fillers
Reduction of total cost of ownership over the entire value chain
Scientific excellence of nanocelluloses: characterization -> rheology ->
dewatering -> safety -> environmental sustainability
• Lean concepts by optimized design of production line wide performance
• Multi-objective design methodology for production systems
EffNet
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Erkki Hellén

5. FOAM FORMING – LEAP IN RESOURCE EFFICIENCY
• Significant resource savings
are expected for foam
forming technology
– The biggest advantage
through fiber savings
– Less drying energy due to
decreased basis weight
– Chemical costs are lower
due to reduced basis
weight and improved
retention
• Sustainability
– Even 40% reduction in
carbon and water
footprints
EffNet
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Erkki Hellén

6. FOAM FORMING – ENABLING RENEWAL
Lightweight structures from novel raw material combinations
Foam +
Nanomaterials
Natural fibres
Ultra lightweight
materials
Regenerated
fibres
Synthetic fibres
EffNet
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Erkki Hellén
Functional
chemicals

7. 21/11/2013
7
FOAM FORMING AT VTT’S SUORA ENVIRONMENT

8. MAIN BENEFITS OF FOAM FORMING
EXCELLENT FORMATION
HIGH BULK
ADVANCED RAW MATERIAL COMBINATIONS
EffNet
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Erkki Hellén

9. HIGH BULK -> LIGHTWEIGHT STRUCTURES
Operating window for current
technology and raw materials
150
Modified Scott Bond [j/m 2 ]
130
110
Not
possible
with
water
forming
Pilot data
water
Foam
Foam+10%NFC
90
foam+20%NFC
70
50
30
Foam forming
10
-10
0
2
4
6
8
10
12
Bulk [cm 3 /g]
• new raw material combinations
• raw material savings
• usage of materials impossible in water or dry
laid technologies
EffNet
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Erkki Hellén

10. SUPERIOR FORMATION INDEPENDENT OF FIBER LENGTH
• Strength at low grammages
• Utilization of long fibers
Tensile Index [Nm/g]
30
3
Specific Beta formation [√g/m]
- 69 %
20
+ 41%
2.5
+ 30%
2
25
- 49 %
+ 47%
1.5
- 16 %
15
10
Water
0
Foam
15
30
45
60
75
Water
Foam
0
Spruce-CTMP
EffNet
21.11.201
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Pine 2
Birch 1
Erkki Hellén
105
Grammage [g/m2]
1
0.5
90
120
13

11. GLOBALLY UNIQUE RESEACH INFRA FROM LAB TO
PILOT SCALE
Handsheet formers
Web speed
Amount of
fibers
Layered
products
Forming
geometry
EffNet
SUORA research
environment
A4 & 500*500 mm.
Laboratory pressing &
drying
>Few grams
Web width 120 mm.
Laboratory pressing &
drying
300 m/min (foam)
300 m/min (water)
> 5 kg
Web width 250 mm. Reeled
sample & offline cylinder
drying
~1000 m/min (foam)
2000 m/min (water)
> 300 kg
1-sided dewatering
Sample size
Small circulation device
‘ KISU’
3-layers (foam)
Single layer (water)
1-sided dewatering
Single layer (foam)
3 layers (water)
Fourdrinier / hybrid / gap
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Erkki Hellén

12. VALUE CHAIN CO-OPERATION: development of binding fillers
Biomineral
development
Kemira, VTT,
Aalto
Printing
KCL, VTT
Laboratory
sheets
VTT, Aalto
Pilot
calendering
Metso
Semi-pilot
testing
VTT, Stora
Enso
Pilot scale
trials
VTT, UPM
Concept demonstrated by increasing the filler
content of paper from 30% to 40%
EffNet
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Erkki Hellén

13. EFFICIENT NETWORKING
Environmental management and
sustainable use of nanocellulose
• National co-operation between two Finnish Strategic
Centres for Science, Technology and Innovation (SHOKs)
• The Forest Cluster/EffNet program and
• The Cluster for Energy and Environment/MMEA
Program
• Outcome: Finnish perspective on
– the most critical product safety, environmental
efficiency and regulation challenges of NFC
production and the usage of it in intermediate and
end-products
Report available at:
http://www.syke.fi/download/noname/%7B6EB71A59-55F6-4529-AB91-A2D8AB8C3025%7D/29791
EffNet
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Erkki Hellén

14. FROM NETWORKING TO COMMERCIALIZATION
Metso IQ Surface Measurement
• Combining the best forces to common goal
–
–
–
–
–
–
–
–
Tampere University of Technology, Department of Automation Science and Engineering
Lappeenranta University of Technology, Information technology
Metso Automation
University of Eastern Finland, Optics
University of Helsinki, Department of Mathematics
University of Jyväskylä, Department of Physics (P), Department of Information Technology (IT)
University of Oulu, Control (C), Optoelectronics (O)
UPM-Kymmene
• Unique image-analysis based formation measurement
• Predicts printability already in paper mill by online and enables the reduction of customer
complaints.
• Accurate and stable profile measurement for precise control of sheet surface properties in
machine and cross directions.
For more information see
http://www.metso.com/Automation/pp_prod.nsf/WebWID/WTB-120904-2256F-C465D?OpenDocument
and for a video http://www.youtube.com/watch?v=xA-RgxPr8Is
EffNet
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Erkki Hellén

15. SCIENTIFIC EXCELLENCE: nanocelluloses
Distribution and retention
Pumping and mixing
Classification
Bacterial cellulose
Centrifugal
pump
Size/Dimensions/Branching
Scale bar: 20 μm
Chain or rod-like
structure
Nanofibres
Nanocrystals
All dimensions in nanoscale
Nanofibrillated
6
Microfibrillated
Ribbon-like
structure
Overall dimensions in
macroscale, fine structure
in nanoscale
Optimized pipe
dimensioning
5
4
New pump
type
20
3
2
Branched
structure
15
1
Overall dimensions in
macroscale, fine structure
in nanoscale
10
0
Image area 2x2 μm
Image area 1x1 μm
Screw
pump
5
0
Image area 2x2 μm
Image area 2x2 μm
Charge/Chemistry
Colloidal dispersion
Effect of REACH
TEM
Polyelectrolyte-like
Woodfibre like
AFM
Decreasing surface charge
Amount of nanomaterial
Basic characterization
Visual appearance
OM
Transmittance
SEM
Swelling
Rheology
EffNet
21.11.2013
Viscosity
Strength properties
Erkki Hellén
Preservability
Specific surface area Dewatering

16. FUTURE: TOWARDS FOAM TECHNOLOGY PLATFORM
EffTech &
EffNet 20072013 (FIBIC)
• Potential of
foam
Technology
• Demo
products
• Laboratory
and semipilot scale
Naseva I & II,
2008-2013
• Stabile foams
• Nanocellulose
foams
• Filters and
insulation
Jyväskylä
Innovation
2011-2012
• Thermoset
composites
• Decorative
products
VTT 20112012
• Mouldable
and
transparent
webs
• Nonwoven
products
1cm
EffNet
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Erkki Hellén
KOTVA 20122013 (ERDF)
• SUORA
scale-up
• Foam
process
development
TESTAA
2012-2013
(ERDF)
• Added value
products
• Research
infra for
SMEs
FiFo 20132014
(Academy)
• Fibrous
foams
• Foam
rheology

17. Impacts
• Competence
– To the date 40 peer reviewed articles from the program
– Over 100 international conference presentations
– 13 MSc thesis finished
– 4 PhD thesis finished & 10 PhD thesis ongoing
– 4 patent applications
– Value of networking: broad insight and expertise within and after the program
• Industrial
– Unique, national research infra
– Foam forming: radical leap in resource-efficiency for packaging board and a new
platform for fiber-based products (non-wovens, construction, composites…)
– Great potential with micro fibrillated celluloses
– New knowledge and novel tools to improve production efficiency
– New services, product ideas and technology concepts utilized in company driven
product development projects
The results provide a solid basis for further development towards efficient industrial
solutions, generating value and new business opportunities for the industry.
EffNet
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Erkki Hellén