Inorganic-organic Nanocomposites & Nanoscale Surface

Modification

Energy Consumption & Reduced Capital CostsTed WegnerTed Wegner

USDA Forest Service USDA Forest Service Forest Products LaboratoryForest Products Laboratory

June 15, 2007June 15, 2007

NanocompositesNanocomposites

Global Wood-based Panels Production, 1970-2005

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Global Paper and Paperboard Production, 1970-2005

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Oceania

Latin America

Europe

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North America

Technical Challenges

Understand & control surface chemical reactivity

Characterization of structures at nanoscale

Measurement of physical properties at nanoscale

Multiple material compatibility

Directed self assembly of nano-components

Focus Area 4: Inorganic-organicnanocomposites nanoscale surfacemodification

Target: Produce nano-compositematerials from forest materials

Strength of Materials: building blocks and interfaces

nacre

dentinbone

enamel

Gecko Feet

Source :K Autumn, PNAS 2006

Source :Gao, Fratzl et al, PNAS 2004

Perceived Issues with Perceived Issues with Wood-based CompositesWood-based Composites

Low strength and stiffness with eventual rheological/creep problems

Poor durability and water-related problems

Limited service life Limited or poor fire performance Requirement for enhanced

performance, durability, fire resistance, and service life in non-residential construction

Nanotechnology Advanced Nanotechnology Advanced Wood-based CompositesWood-based Composites

Natural composite componentsNatural composite components Combined wood and natural biofiber Combined wood and natural biofiber

composites possessing synergistic performance composites possessing synergistic performance and service life using bio-based resins and service life using bio-based resins

Totally bio-based, sustainable composites Totally bio-based, sustainable composites High-performance bio-based composites using High-performance bio-based composites using

inorganic binders or natural bio-based binders inorganic binders or natural bio-based binders such as ligninsuch as lignin

Biomimetic compositesBiomimetic composites Self-healing systems that include resins or Self-healing systems that include resins or

sub-systems that reactivate when they sense sub-systems that reactivate when they sense degeneration of bond properties or mechanical degeneration of bond properties or mechanical displacementdisplacement

Recycled materialsRecycled materials Systems that promote use of recycled materials Systems that promote use of recycled materials Systems that enhance its later recyclabilitySystems that enhance its later recyclability

Nanotechnology Advanced Nanotechnology Advanced Wood-based CompositesWood-based Composites

Smart compositesSmart composites Systems that sense and warn users of mechanical Systems that sense and warn users of mechanical

overloadoverload Systems that sense moisture and warn users of its Systems that sense moisture and warn users of its

presencepresence Systems that sense fungal or enzymatic activity and Systems that sense fungal or enzymatic activity and

react to suppress itreact to suppress it Systems that sense fire and react to suppress and Systems that sense fire and react to suppress and

extinguish itextinguish it Additives (such as wax, preservative chemicals, fire Additives (such as wax, preservative chemicals, fire

retardants)retardants) Systems that enhance bonding by acting as coupling Systems that enhance bonding by acting as coupling

agentsagents Systems that result in water-resistant—even water-Systems that result in water-resistant—even water-

proof—constituent materialsproof—constituent materials BindersBinders

New bio- or synthetic-based binders with enhanced New bio- or synthetic-based binders with enhanced performance performance

Environmentally responsible and sustainable binder Environmentally responsible and sustainable binder systems systems

New Markets Needed !!

Nanotechnology for Reduced Energy Consumption & Reduced Capital Costs

ObjectivesObjectives

Apply nanotechnology and employ Apply nanotechnology and employ nanomaterials in forest products nanomaterials in forest products processing in order to reduce processing in order to reduce manufacturing costs by manufacturing costs by both both reducing the amount of energy reducing the amount of energy consumed during processing and consumed during processing and capital equipment requiredcapital equipment required. .

Nanotechnology applications can take the Nanotechnology applications can take the forms of: forms of: nano-catalysts to reduce the temperatures and nano-catalysts to reduce the temperatures and

time needed to delignify wood in pulping; time needed to delignify wood in pulping; low corrosion nano-coatings and nano-materials low corrosion nano-coatings and nano-materials

to prolong the life of capital equipment; to prolong the life of capital equipment; nano-dimensional tags/markers for fiber nano-dimensional tags/markers for fiber

separations; separations; nano-inspired products that help with water nano-inspired products that help with water

removal on paper machines (drainage wires, removal on paper machines (drainage wires, vacuum boxes, wet presses, and dryers), kilns, vacuum boxes, wet presses, and dryers), kilns, and hot presses; and hot presses;

robust nano-dimensional sensors (temperature, robust nano-dimensional sensors (temperature, pressure, tensile/compressive forces, etc.) that pressure, tensile/compressive forces, etc.) that can be used to monitor and optimize processing can be used to monitor and optimize processing conditions as well as reduce/eliminate off conditions as well as reduce/eliminate off specification product productions; etc. specification product productions; etc.

Pulping and Paper/Paperboard Pulping and Paper/Paperboard Production TargetsProduction Targets

Reduce pulping process energy Reduce pulping process energy consumption by at least 33% and produce consumption by at least 33% and produce the same or better quality fiber at 5-10% the same or better quality fiber at 5-10% higher yieldhigher yield

Reduce energy consumed in the process Reduce energy consumed in the process of increasing black liquor solids (kraft of increasing black liquor solids (kraft pulping) by at least 50%pulping) by at least 50%

Develop lower-cost technology to replace Develop lower-cost technology to replace the current (energy and capital intensive) the current (energy and capital intensive) causticizing processcausticizing process

Reduce energy and produce same or Reduce energy and produce same or better-quality paper products by using: better-quality paper products by using: (a) nano-coating pigments and (b) three (a) nano-coating pigments and (b) three times the non-fiber filler contenttimes the non-fiber filler content

Reduce the energy consumed in paper Reduce the energy consumed in paper dewatering, pressing, and drying by at dewatering, pressing, and drying by at least 50%least 50%

Waste Streams/WastewaterWaste Streams/Wastewater develop cost-effective methods to develop cost-effective methods to

reduce or eliminate odorous kraft reduce or eliminate odorous kraft emissions beyond the mill propertyemissions beyond the mill property

Develop alternative methods for Develop alternative methods for wastewater treatment that are less wastewater treatment that are less energy- and capital-intensive than energy- and capital-intensive than current biological effluent current biological effluent treatment systems.treatment systems.

Develop low corrosion nano-Develop low corrosion nano-coatings and nano-materials to coatings and nano-materials to prolong the life of capital prolong the life of capital equipmentequipment

Fiber Recovery and RecyclingFiber Recovery and Recycling Develop functional nanomaterials to enable Develop functional nanomaterials to enable

paper and fiber taggingpaper and fiber tagging Use nanomaterials to facilitate ink removal Use nanomaterials to facilitate ink removal

(i.e. de-inking) and contaminant removal(i.e. de-inking) and contaminant removal Develop low corrosion nano-coatings and Develop low corrosion nano-coatings and

nano-materials to prolong the life of capital nano-materials to prolong the life of capital equipmentequipment

Develop nanomaterials to improve Develop nanomaterials to improve recyclability of paper and paperboard recyclability of paper and paperboard productsproducts

Wood ProductsWood Products Reduce VOC and HAP emissions from Reduce VOC and HAP emissions from

manufacturing wood-based products by manufacturing wood-based products by 90%90%

Use nanoscale materials and technology to Use nanoscale materials and technology to improve conversion efficiencies of wood improve conversion efficiencies of wood productsproducts

Use nano-coatings and nano-catalysis to Use nano-coatings and nano-catalysis to decrease emissions to indoor air from decrease emissions to indoor air from wood-based products by 50%wood-based products by 50%

Investigate ways to use nanotechnology Investigate ways to use nanotechnology and nanomaterials to enhance and and nanomaterials to enhance and increase the efficiency of drying wood and increase the efficiency of drying wood and wood-based materials in kilns and presseswood-based materials in kilns and presses

Increase marketable chemical byproducts Increase marketable chemical byproducts of wood by 10%of wood by 10%

Employ robust nano-dimensional sensors Employ robust nano-dimensional sensors (temperature, pressure, (temperature, pressure, tensile/compressive forces, etc.) to tensile/compressive forces, etc.) to monitor and optimize processing monitor and optimize processing conditions and improve conversion yields conditions and improve conversion yields as well as reduce/eliminate off as well as reduce/eliminate off specification product productions; etc.specification product productions; etc.

Questions