commercial manufacture and application of micro-fibrillated cellulose in paper and paperboard per...
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Commercial Manufacture and Application of Micro-Fibrillated Cellulose in Paper and Paperboard
Per Svending, Imerys Mineral AB, SwedenSeptember 17th 2015
Specialty Papers Conference Milwaukee WI, USA
Publicised images of ”cellulose nanofibrils” show great diversity
A wide range of shapes and sizesmade through different processesby companies, universities, and institutes across the world.
FiberLean™ microfibrillated cellulose (MFC), a recent addition to the papermakers toolbox
Surface micrograph offinepaper containing
FiberLean MFC and filler
The FiberLean™ MFC process
Co-grinding pulp to MFC in the presence of minerals.– The mineral acts as a very fine grinding media
Robust and reliable equipment of relevant industrial scale.
On-site manufacturing, using a minor side stream of mill pulp.
No pre-treatment of fiber required.
The FiberLean product is a MFC/mineral composite.
Co-grinding pulp to MFC in the presence of mineral
1 μm
• Relatively coarse fibrils.
• Fibril length is important for wet end addition
• A wide range of pulps can be used
• Also flexible with regard to the mineral GCC PCC Kaolin Talc TiO2
Commercial scale experience with FiberLean™ MFC
0 50 100 150 200 250 300 350
Basis weight, g/m2
Packaging
Coated Woodfree
Specialty + mechanical
Uncoated Woodfree
Close to 50 full scale trials on 21 paper machines to date• In Europé, North America, South America and Asia.
Trials ranging from a few hours to several days. Extensive experience across segments
• 6 mills in UWF• 6 mills in speciality and mechanical paper• 8 mills in CWF• 2 mills in Packaging
3 commercial contracts for on-site MFC plants.
5 10 15 20 25 30 35 400123456789
10
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Tear
Inde
x (m
N.m
2/g)
5 10 15 20 25 30 35 400
20406080
100120140160180200
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Scot
t Bon
d (J
/m2)
5 10 15 20 25 30 35 400
1
2
3
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Bur
st In
dex
(kN
/g)
Impact of MFC on paper strength
5 10 15 20 25 30 35 4010
15
20
25
30
35
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Tens
ile In
dex
(Nm
/g)
Tensile Burst
Bond Tear
Lab studyMesmer recirculating hand sheets (12 sheets)70% Eucalyptus, 30% NBSK, 550 CSFIntracarb 60 filler
It is possible to increasefiller by 10% or more andsuffer no strength loss.
Impact of MFC on paper tensile
5 10 15 20 25 30 35 4010
15
20
25
30
35
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Tens
ile In
dex
(Nm
/g)
5 10 15 20 25 30 35 400
1
2
3
4
5
6
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Bre
akin
g el
onga
tion
(%)
5 10 15 20 25 30 35 400
200
400
600
800
1000
1200
1400
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Tens
ile E
nerg
y A
bsor
ptio
n (J
/kg)
5 10 15 20 25 30 35 400
0.5
1
1.5
2
2.5
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Youn
gs m
odul
us (G
Pa)
Tensile Elongation
TEA Modulus
Lab studyMesmer recirculating hand sheets (12 sheets)70% Eucalyptus, 30% NBSK, 550 CSFIntracarb 60 filler
Behaviour of MFC in the tensile stress-strain curve
0 0.5 1 1.5 2 2.5 3 3.5 40
2
4
6
8
10
12
14
16
28% filler no MFC28% filler with 1,7% MFC
Displacement (mm)
Forc
e (N
)
Pilot study80% Eucalyptus, 20% NBSK, 500 CSFIntracarb 60 filler
Behaviour of MFC in the tensile stress-strain curve
0 0.5 1 1.5 2 2.5 3 3.5 40
2
4
6
8
10
12
14
16
28% filler no MFC28% filler with 1,7% MFC
Displacement (mm)
Forc
e (N
)
+ 0,6 %-units of stretch+ 21%
+ 24% Tensile
Pilot study80% Eucalyptus, 20% NBSK, 500 CSFIntracarb 60 filler
Impact of MFC on paper tensile
5 10 15 20 25 30 35 4010
15
20
25
30
35
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Tens
ile In
dex
(Nm
/g)
5 10 15 20 25 30 35 400
1
2
3
4
5
6
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Bre
akin
g el
onga
tion
(%)
5 10 15 20 25 30 35 400
200
400
600
800
1000
1200
1400
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Tens
ile E
nerg
y A
bsor
ptio
n (J
/kg)
5 10 15 20 25 30 35 400
0.5
1
1.5
2
2.5
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Youn
gs m
odul
us (G
Pa)
Tensile Elongation
TEA Modulus
Lab studyMesmer recirculating hand sheets (12 sheets)70% Eucalyptus, 30% NBSK, 550 CSFIntracarb 60 filler
Impact of MFC on optical properties
5 10 15 20 25 30 35 4087
88
89
90
91
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Brig
htne
ss (%
at D
65 –
400
nm
)
5 10 15 20 25 30 35 4082
84
86
88
90
92
94
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Opa
city
(%)
5 10 15 20 25 30 35 40500
600
700
800
900
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
S (c
m2/
g))
5 10 15 20 25 30 35 403
3.5
4
4.5
5
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
K (c
m2/
g)
Brightness Opacity
Scattering Absorption
Lab studyMesmer recirculating hand sheets (12 sheets)70% Eucalyptus, 30% NBSK, 550 CSFIntracarb 60 filler
5 10 15 20 25 30 35 400
500
1000
1500
2000
2500
3000
3500
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Poro
sity
, Ben
tsen
(ml/m
in)
Impact of MFC on other properties
5 10 15 20 25 30 35 400123456789
10
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Dra
inag
e tim
e (s
ek)
5 10 15 20 25 30 35 400.5
0.55
0.6
0.65
0.7
No MFCPolynomial (No MFC)3% MFCPolynomial (3% MFC)5% MFCPolynomial (5% MFC)
Paper filler content (%)
Den
sity
(g/c
m3)
Porosity Density
Initial drainage
Lab studyMesmer recirculating hand sheets (12 sheets)70% Eucalyptus, 30% NBSK, 550 CSFIntracarb 60 filler
• The porosity impact can be important for hold-out of ink or coating colour.
• Density can be regained by trading the positive impact on smoothness and bond strength with less intense calendering and/or use of coarser fiber, such as CTMP.
• While initial drainage slows down there is a positive impact on couch and press solids.
FiberLeanTM performance summary
Tensile Index
Tear Index
Scott Bond
TEAOpacity
Porosity
Density
-100%
0%
100%
20% filler, No MFC 30% filler, 3% MFC
Date Title of the presentation14
Full scale results from adding FiberLean to increase filler level in a woodfree paper
0 5 10 15 20 250
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Addition of FiberLean with 20% MFC content (%)
Tens
ile s
tren
gth
MD Tensile
CD Tensile
2% MFC+8% filler
4% MFC+16% filler
The strength of the paperis maintained at increasinglevels of filler and MFC.
Beyond the primary target application of filler increase in P&W papers there are new product development opportunities to pursue
Based on porosity reduction• Improved hold-out of coatings
Based on strength and opacity• De-materialisation
Reduction in coat weight to reach a given gloss level
Adding FiberLean™ MFC to specialty paper at constant filler loadingall chemical pulp at 250 CSF and 20% filler
Tensile Energy
AbsorptionTear Index Scott Bond
Bendtsen Porosity
Opacity
J/kg mN m 2 /g J/m 2 ml/min %
Reference 792 5,7 209 258 87,8
1% MFC 924 5,7 288 180 88,2
2% MFC 859 5,8 291 114 88,3
4% MFC 1224 6,5 377 104 88,8
To facilitate applications like this FiberLean can be supplied at up to 50% MFC contentwith the balance being almost any type of mineral filler.
Selecting correct filler loading to reach a given opacity and strength at minimum basis weight
Target strength and opacity
Filler content (%)
Basis
wei
ght (
g/m
2 )
No filler - minimum sheet weight for required strength
No filler - minimum sheet weight for required opacity
No filler - minimum sheet weight for required opacity
Selecting correct filler loading and sheet weight with FiberLean™ Pilot paper machine data
0% 5% 10% 15% 20% 25% 30%30
40
50
60
70
80
90
84% Opacity no mfc 84% Opacity 2% mfc 84% Opacity 3% mfc 84% Opacity 4% mfc
Total Filler Loading
g/m
2 fo
r ta
rge
t
Selecting correct filler loading and sheet weight with FiberLean™ Pilot paper machine data
0% 5% 10% 15% 20% 25% 30%30
40
50
60
70
80
90
84% Opacity no mfc 84% Opacity 2% mfc 84% Opacity 3% mfc 84% Opacity 4% mfc
Total Filler Loading
g/m
2 fo
r ta
rge
t
Constant opacity
Selecting correct filler loading and sheet weight with FiberLean™ Pilot paper machine data
0% 5% 10% 15% 20% 25% 30%30
40
50
60
70
80
90
84% Opacity no mfc 84% Opacity 2% mfc 84% Opacity 3% mfc
84% Opacity 4% mfc 1,5 kN/m tensile strength no mfc Power (1,5 kN/m tensile strength no mfc)
1,5 kN/m tensile strength 2% mfc Power (1,5 kN/m tensile strength 2% mfc) 1,5 kN/m tensile strength 3% mfc
Power (1,5 kN/m tensile strength 3% mfc) 1,5 kN/m tensile strength 4% mfc Power (1,5 kN/m tensile strength 4% mfc)
Total Filler Loading
g/m
2 fo
r ta
rge
t
Constant opacity
Constant strength
Selecting correct filler loading and sheet weight with FiberLean™ Pilot paper machine data
0% 5% 10% 15% 20% 25% 30%30
40
50
60
70
80
90
84% Opacity no mfc 84% Opacity 2% mfc 84% Opacity 3% mfc
84% Opacity 4% mfc 1,5 kN/m tensile strength no mfc Power (1,5 kN/m tensile strength no mfc)
1,5 kN/m tensile strength 2% mfc Power (1,5 kN/m tensile strength 2% mfc) 1,5 kN/m tensile strength 3% mfc
Power (1,5 kN/m tensile strength 3% mfc) 1,5 kN/m tensile strength 4% mfc Power (1,5 kN/m tensile strength 4% mfc)
Total Filler Loading
g/m
2 fo
r ta
rge
t
Paper with no MFC63 g/m2
8% filler84% opacity1,5 kN/m tensile
Paper with 2% MFC53 g/m2
17% filler84% opacity1,5 kN/m tensile
Paper with 4% MFC48 g/m2
21% filler84% opacity1,5 kN/m tensile
58 g/m2
Fiber
44 g/m2
Fiber 38 g/m2
Fiber
Summary and conclusions
MFC is now available for commercial use in papermaking Filler increase in P&W paper is a key application Several product development projects for packaging and specialty
papers are ongoing Using MFC and filler to tailor a paper grade to required opacity and
strength targets with minimum material use offers one of the most exciting opportunities.
Acknowledgements
To my colleagues at Imerys FiberLean R&D in Par Moor Centre in the UK who have done most of the test work, and especially to Dr Jon Phipps, who designed and ran the constant opacity/strength experiments.
Source: Peter Callesen, www.petercallesen.com
Thank you!