GRI's Fibrous Filler Technology - P2 InfoHouse · 2018-06-13 · 1 GRI’s Fibrous Filler...

1

GRI’s Fibrous Filler Technology

G.R. International

April 5th, 2006

Presented by: Dr. Vijay Mathur, GR International

32918 6th Avenue SW, Federal Way, WA 98023 Ph: 253-924-6070

[email protected]

A Paper Technology Vision Company©

2

AGENDA April 5th, 2006

1. Background and Acknowledgements 2. Statement of Problem 3. GRI Technology Solutions and Innovation 4. Project Objective and Schedule 5. Status of Milestones / Key Issues 6. Project Output / Key Accomplishments 7. Commercialization Barriers / Economics 8. Commercialization Plan and Strategy 9. Energy Efficiency

G.R. International

10. Current Status


3

Background and Acknowledgements

� Project Title: Fibrous Fillers to Manufacture

� Project Number: DE-FC07-0131D14439

� Principal Investigator:

� Industrial Partners:

G.R. International

Ultra-High Ash / Performance Paper

Dr. Vijay K. Mathur

– Weyerhaeuser Company – Grays Harbor Paper Company – Lawrence Livermore National

Laboratories – Pennsylvania State University – University of Washington


4

Statement of Problem

G.R. International A Paper Technology Vision Company©

5

Statement of Problem

� The Paper Industry currently uses fillers to reduce manufacturing cost and energy consumption

� The problem is that the current fillers causes a Loss in Paper Strength

•This is due to their size, shape, and aspect ratio

� This strength loss limits the amount of filler added into paper to ~15% to 18%


6

GRI Technology Solutions and Innovations


7

I.

• pigment

• pigment

•

(intrinsic stiffness)

II.

III. Chemical Pretreatment for Fillers (Licensed from Weyerhaeuser)

GRI Technology SolutionsG.R. International

“Fibrous Fillers:” Patented Calcium Silicate Products

Silicate nano-fibers (SNF / Tech-8) - ultra-high opaque

Silicate macro-particle (SMP / Tech-4) - ultra-high bulk

Silicate macro-particle low-drying demand (SMF-LDD / Tech-6) – lower drying demand and ultra-high stiffness

“Super” PCC / Tech-2: Patented High Pressure Process


8

Products Tech-8 SEMs

G.R. International

10 µm 1 µm

10 µm

Silicate Nano-Fibers (SNF)

Confidential Proprietary


9

Products Tech-4 SEMs

G.R. International

)

10 µm 1 µm

10 µmConfidential Proprietary


Silicate Macro-Particle (SMP

10

Scalenohedral

GRI’s Technology“Fibrous Fillers”

Nano-Clustered PCC

“Super” PCC for Fillers

11Calendared

G.R. International

i

86

87

88

89

90

91

92

93

94

0% 10% 40%

Fi (%)

( )

li(

80

82

84

86

88

90

92

94

96

0% 20%

(%)

( )

GRI Technology SolutionsA Paper Technology Vision Company©

Br ghtness

20% 30% 50%

ller

IS O

PCC HO SNF SMP

Norma zed Opacity to 74 gsm)

10% 30% 40% 50%

Filler

IS O

PCC HO SNF SMP

12Calendared

G.R. International

Bulk

1.5

1.7

1.9

2.1

2.3

2.5

0% 20% 40%

(%)

m 3 / g

)

lt-Side)

50

75

100

125

150

175

200

225

250

275

0%

Fill (%)

f i i

( )


10% 30% 50%

Filler

PCC (HO SNF SMP

Smoothness (Fe

10% 20% 30% 40% 50%

er

S h ef

el d

U n

t s

PCC HO SNF SMP


Tensile Index

25

30

35

Stiffness (Gurley)

145

170

195

GRI Technology Solutions/ g 120 U

n it s

20

N* m

95

Gu r

l e y

5

10

15

20

45

70

0% 10% 20% 30% 40% 50% 0% 10% 20% 30% 40% 50%

Filler (%) Filler (%)

PCC (HO) SNF SMP PCC (HO) SNF SMP

13Calendared

14Calendared

G.R. International

Cali

Bulk

i

Sti

il

i

i

i i

Fill i i

PCC


Multifunctionality of SNF

0.0%

25.0%

50.0%

75.0%

100.0% per

Poros ty

ffness

Tens e Index

ISO Br ghtness

ISO Opac ty

Sheet Scatter ng Coeffic ent

er Scatter ng Coeffic ent

Sheffield Smoothness

15Calendared

G.R. International

Cali

Bulk

i

Sti

il

i

i

i i

Fill i i

iO2



0.0%

25.0%

50.0%

75.0%

100.0% per

Poros ty

ffness

Tens e Index

ISO Br ghtness

ISO Opac ty




PCC PCC + 7% T

16Calendared

G.R. International

Cali

Bulk

i

Sti

il

i

i

i i

Fill i i

PCC i



0.0%

25.0%

50.0%

75.0%

100.0% per

Poros ty

ffness

Tens e Index

ISO Br ghtness

ISO Opac ty




PCC + 7% T O2 SNF

17

GRI Technology SolutionsG.R. International

i i i

$0

$10

$20

$30

$40

$50

$60

i (lb/ )

)

/ /


Basis We ght Reduct on Econom cs

18.0 18.5 19.0 19.5 20.0

Basis We ght 3300ft2

Fille

r Sa

ving

s Pe

r To

n (O

D

12% PCC 0% SMP 7% PCC 13% SMP

18

GRI Technology SolutionsG.R. International A Paper Technology Vision Company©

19

The Key Innovations are: �

and Silica) • US Patent #: 6,726,807B1

� Multifunctional Performance of “Fibrous Fillers” • Improves Sheet Bulk, Porosity, Smoothness, Optical, and Strength Properties Simultaneously

�

Rates • US Patent #: 6,251,356

�

Calcium Carbonates, From a Common Reactor • US Patent Allowed, Serial # 09/797,173

InnovationG.R. International

Fiberous Crystals from Inorganic Materials (Calcium Oxide

Pressure Carbonation System to Produce Super Precipitated Calcium Carbonate at 400% to 600% Higher Reaction

Producing Multiple Pigments, “Fibrous Fillers” and


20

Project Objectives and Schedule


21

Project Objectives and Schedule

� Objectives: •Techno-Economic Viability of Manufacturing

•Low Cost Super Precipitated Calcium Carbonates (SPCC) or Tech-2

•Technology

� Schedule •Initiation Date: •Original Expected Completion Date: •Revised Expected Completion Date:

G.R. International

“Fiberous Filler”

Protoytpe Plant for Scale-Up of Fiberous Filler

4/14/03 9/30/06 4/13/06


22

Status of Milestones / Key Issues


23

Status of Milestones / Key Issues

The Key Issues are: � Could Not Complete the Work on Interfacial

Interaction, Paper Structure, and Paper Properties • Task I: University of Washington

� Partially Completed the Mechanism of Formation of

• Task II: Lawrence Livermore National Laboratories

�

in Surface Treatment Formulations • Task V: Western Michigan University

G.R. International

“Fiberous Fillers”

Partial Completion of Application of “Fiberous Filler”


24

Projects Output / Key Accomplishments


25

Project Output / Key Accomplishments

�

• •

–Silicate Nano-Fibers (SNF) or Tech-8 –Silicate Micro-Fibers (SMF-LDD) or Tech-6 –Silicate Micro-Particles (SMP) or Tech-4

� Objective II Accomplishments: •

� Objective III Accomplishments: • Designed, Engineered, and Erected the Prototype Plant to Produce Multiple Pigments

–Tech-6, Tech-4, and Tech-2

G.R. International

Objective I Accomplisments: Development and Validation of Techno-Economic Viaility Techno-Economic Viability Manufacturing Demonstration of:

Development and Validation of S-PCC or Tech-2


26

Commercialization Barriers / Economics


27

Commercialization Barriers / Economics

Barriers to Commercialization � Market Resistance to New Silicate Technology � 1st Commercial Validation of Technology

G.R. International

Economics of a Typical Multiple Pigment Plant Capital (millions): ~7.0 Revenue (millions): ROI(%): ~31.0


~13.5

28

Commercialization Plan and Strategy


29

Commercialization PlanG.R. International

1997 2000 2001 2002 2003 2005 2006 2007 2011

Concept

Lab

Pilot

Commercial Scale-up

DOE Funding

Plant

First Commercial Plant

R&D Stage Commercialization


Commercialization

Bench Reactor

Reactor

Prototype Commercialization

30

Financing StrategyG.R. International

GRI

Strategic Partners/ Customers

Pigment/Chemical Manufacturers

Debt/Equity Partners

Debt Equity

Licensing


31

Energy Efficiency


32

Energy EfficiencyG.R. International

55%

()

ional

/


Caliper

3.8

4.0

4.2

4.4

4.6

4.8

5.0

5.2

5.4

35% 40% 45% 50% 60% 65%

Press Solids

Cal

iper

mils

ConventPCC GRI's Micro PCC SMP

33

Energy Efficiency G.R. International A Paper Technology Vision Company©

1.5

2.0

2.5

3.0

3.5

4.0

4.5

30 35 40 45 50 55

Press Solids (%)

BTU

/Ton

Pap

er (1

06 )

1500

2000

2500

3000

3500

4000

4500

lb D

ryer

Ste

am/T

on P

aper

ionPapermachine Dryer Steam Consumption As A FunctOf Press Solids

*Steam Temperature 230 - 266 °F

Range for 230 - 266 °F (steam 21- 39 psia)

34

Energy EfficiencyG.R. International

Energy Savings (Trillions BTU/yr)

Pulp Mill* 31.5

Paper Mill** 11.5

Total 43.0

*: 1000 ton pulp mill vs. 600 ton pulp mill and 400 ton

**: Press Solids increased from 45% to 55%


“Fiberous Filler” mill

35

Potential Savings To U.S. IndustryG.R. International

Attainable Industry Total Attainable Product SNF $900 90,000 $81 million (Ti02 Reduction) SMP $15 20,000,000 $300 million (Bulk, Stiffness, Basis Weight Reduction) Energy Savings $12 20,000,000 $240 million

Incremental Pulp Profits $200 1,000,000 $200 million (10% Filler Increase) PCC $20 1,000,000 $20 million (Lower Cost) Total $841 million / Year


Savings $/ton Usage (tons) Savings (per year)

(Paper Mill)

36

Current Status

• Building The Prototype / Commercial Plant


37

“Fibrous Fillers”

Lime Slaking

CO2 Boiler

•Power

Paper

Mill

Precipitated Calcium Carbonate

Pigment Mill Pulp Mill Paper Mill

SNF SMP

SPCCCa(OH)

Ca(OH)

SiO2

Ca(OH)2 + CO2 CaCO3 + H2O

Ca(OH)2 + SiO2 CaSiO3 .H2O

Multiple Pigments From a Single Plant

Fibrous Fillers

• Recovery (Lime Kiln)

38


39

G.R. International 50# GH Offset HiBright SM PM#1

ial

)

l

Trial


Grays Harbor Paper - March 28th, 2006

91.45

91.50

91.55

91.60

91.65

91.70

91.75

91.80

91.85

Pretr Trial

Brig

htne

ss (I

SO

Pre-Tria

40

G.R. International

Pretrial

(

ial

Trial

A Paper Technology Vision Company© 50# GH Offset HiBright SM PM#1

Grays Harbor Paper Trial - March 28th, 2006

111

112

113

114

115

116

117

118

119

120

Trial

Smoo

thne

ss F

elt S

ide

Shef

field

)

Pre-Tr

41

G.R. International

50# GH Offset HiBright SM PM#1

ial

Trial



100.00

110.00

120.00

130.00

140.00

150.00

160.00

Pretr Trial

HST

Pre-Trial

42

G.R. International

29

29.5

30

30.5

31

31.5

32

32.5

33

33.5

34

Pretrial

Trial

A Paper Technology Vision Company© 50# GH Offset HiBright SM PM#1


Trial

Stea

m P

ress

ure

(Mai

n D

ryer

Sec

tion)

Pre-Trial

43

Apri

i

ll ii th

i i (i i ) i

ines ( l i i ). i l

i i l ine tuniFurther tri i l

i i l i i

rd

98550Date: l 4, 2006

From: Bob Brennand

To: Operations

Subject: Prelim nary GRI S-PCC Trial Results

Summary Though we have not trialed the S-PCC on a wide variety of products yet, the fo ow ng properties improved on both mach nes during the second (March 28 ) trial: Steam Usage, Brightness, HST, and Sheff eld Smoothness. Several other propert es CD Stretch, CD & MD Tensile Energy Absorpt on, Burst, and Poros ty improved on one of the two mach nes, and some properties deteriorated on one of the two mach Caliper/Bu k, Poros ty, and MD & CD St ffnessConsidering the short t me the GRI reactor has been operating, the resu ts to date are very encourag ng, and I th nk there is room eft for f ng the S-PCC manufacturing process.

als n the future shou d be performed on a wider variety of paper products, but the data so far ind cates the S-PCC s very c ose to be ng “qualif ed” at GHP.

801 23 Street Hoquiam, WAPhone: 360-538-5742 Cell: 360-310-0747 [email protected]

44

Path Forward GRI and our industry partners are requesting an

extension of the project by one year, so that we can:

G.R. International

1. run extended trials 2. continue research on energy savings 3. continue research on cost reduction 4. meet original program objectives


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GRI's Fibrous Filler Technology - P2 InfoHouse · 2018-06-13 · 1 GRI’s Fibrous Filler...

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