CSF4 Breakthrough technology roadmap · Fourteen of them are described in depth in this document. ... three-level scale is determined based on the potential emission ... low power

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Breakthrough technology roadmap

CSF4 Breakthrough

technology roadmap

Exploring breakthrough technologies for

the papermaking industry

March 2018

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CSF4 Breakthrough technology roadmap

Exploring breakthrough technologies for the papermaking industry

March 2018

The Dutch paper and board sector consists of 18 companies that run a total of 22 mills. More than 70% of our

production is used for packaging purposes, while 25 % is graphical paper (paper for magazines, brochures, leaflets).

The remaining part are hygiene papers. The main raw material used is recycled paper (80 %). Alternative fibres like

tomato stems, grass, miscanthus and beverage cartons are also increasingly popular. The sector employs 4.000 people.

The sector is cooperating closely in a number of innovation paths. In our innovation strategy CSF (creating sustainable

fibre solutions) teams are working on different subjects, like alternative fibres, sustainable energy, multiple use &

recyclability and breakthrough technologies. Professionals from our member companies participate in the teams.

For more information, please contact Annita Westenbroek (innovation manager of the Royal VNP):

[email protected].

mailto:[email protected]

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Preface

The Dutch paper and board industry has achieved major material and energy savings in recent years. Good progress

has been made in the use of sustainable energy, increasing recycling rates and promoting circularity. However the core

of the paper making process has hardly changed over the decades.

During that process, water is added and subsequently removed. This requires a lot of energy. Breakthroughs are needed

to dramatically reduce our energy consumption. Therefore, the Dutch paper industry has started a voyage of discovery

towards technologies that will enable paper to be produced in a completely different way.

without water

or

without having to evaporate water

This is the only route towards a carbon neutral sector in 2050 – a journey that starts today. But which technology will

provide the much-needed breakthrough innovation? Such breakthroughs require inspiration and creativity.

We are challenging scientists, students, technology developers, or basically anyone with bright ideas to elaborate on

solutions, especially young people who realize the necessity and are not yet stuck in fixed patterns and processes.

Findest was asked to make a start with this challenge, scouring cyberspace for potential technologies that might support

future papermaking without water or without water evaporation.

The elaborated technologies in this report are just a selection of a vast list. This selection is meant as a start, it is not

meant to be complete or exclusive, neither as a specific direction.

This report shows that we are serious. We mean business. We are willing to invest in a technology that can revolutionise

the papermaking process.

This is a change that will not come from inside the sector. It should come from you!

Be challenged, be inspired, elaborate your ideas and contact us for any help or support required! The following people

contributed to the content of this report:

• Bert Bodewes (Eska)

• Tjerk Boersma (Sappi)

• Bart Broens (Papierfabriek Doetinchem)

• Arie Hooimeijer (KCPK)

• René Kort (Schut Papier)

• Martin van de Pol (Crown Van Gelder)

• Arnoud Roelandse (Neenah Coldenhove)

• Claire Schreurs (Smurfit Kappa Roermond

Papier)

• August Steinkellner (Mayr-Melnhof)

• Eric van Tulden (DS Smith Paper De Hoop)

• Laurens de Vries (KCPK)

• Jan Wattenberg (Parenco)

• Gerrit Jan Koopman (VNP)

• Rutger van Dijk (VNP)

• Corneel Lambregts (VNP)

• Annita Westenbroek (VNP)

• Arie Hooimeijer (KCPK)

• Laurens de Vries (KCPK)

• Ron van Klaveren (Findest)

• Vincent Franken (Findest)

• Jorick Houtkamp (Findest)

• Roel Boekel (Findest)

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Dear paper innovator,

Findest and CSF4 have worked together on a breakthrough technologies roadmap containing technical concepts that

will recreate the papermaking process. The goal is to decrease the CO2-emissions and energy-usage required for

papermaking substantially! After two engineering design challenges, two hackathons and analysing thousands scientific

papers, the technology scouts and IGORAI found 50 potential technology fields that can impact the future of

papermaking (see appendix I for the full list). Fourteen of them are described in depth in this document.

Over the past months, the team has dived deep into the science behind each case. They found out if, and how, the

technologies could be applied in the papermaking process. In this document, the fourteen cases will be presented on a

roadmap. The roadmap consists of three dimensions:

1. Technology readiness level (TRL). The TRL is narrowed done to five quickly interpretable levels:

2. Emission reduction potential (ERP). The many differences between the technologies and their implications

on the papermaking process, make it impossible to define a percentage of emission reduction. Therefore, a

three-level scale is determined based on the potential emission reduction.

3. Impact on current papermaking process. The technology scouts have looked at papermaking designs from

various viewpoints. Each viewpoint results in different configurations with varying impact on the current process.

A three-level scale is designed to show the impact of a concept on the current papermaking process.

Commercially available

Large scale pilot

Small scale pilot

Experimental stage

Theoretical stage

Low emission reduction potential

Moderate emission reduction potential

High emission reduction potential

Completely different process

Substantial changes to current process

Minor changes to current process

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Index

CSF-4 BREAKTHROUGH TECHNOLOGY ROADMAP 6

Case 1 Dry Formation 7

Case 2A Solution Spinning 9

Case 2b Cellulose Solution 11

Case 3 Cross-linking 13

Case 4 Alcohol as a Carrier 15

Case 5 Supercritical Solution 17

Case 6 Supercritical Drying 19

Case 7 Electro Dewatering 21

Case 8 Ultrasonic Dewatering 23

Case 9 Osmotic Dewatering 25

Case 10 Microwave Drying 27

Case 11 Hygroscopic Drying 29

Case 12 Superheated Steam 31

Case 13 Foam Forming 33

Appendix I: Complete technology list 35

Bibliography 39

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Case 1 Dry formation

Introduction

The most challenging aim for energy reduction in papermaking is the complete mitigation of water in the process. This

case encompasses the scouting for techniques that can form a paper-like-web in a dry environment. The use of dry

formation techniques is already broadly applied in the field of nonwoven textile production. Techniques like carding and

needle punching have the aim to align and physically entangle the textile fibres mechanically. Two categories have been

identified: Mechanical web formation and air-based web formation.

Application to papermaking

Air-based web-formation is a technology that is already applied

in papermaking industry on a large scale for the creation of soft

paper products (air laying). The papermaking technique is not yet

able to produce paper with similar strength and properties to wet-

laid papers [1]. The biggest advantages are energy reduction up to

50%, elimination of wastewater treatment, 30-50% reduction in

investment costs, low power and operation costs [2]. Disadvantages

are its increase in electricity use, less uniform paper thickness, lower

sheet strength and reduced smoothness [2]. In 2004 a research

from Aalto University had shown that it is possible to use Air

Dynamic Forming (ADF) as an alternative to conventional papermaking [3]. This technology might be able to overcome

the limitation of traditional air-laying technique.

Mechanical web formation. In literature, there is no evidence for using mechanical nonwoven production techniques

(carding, needle punching) to produce pulp-based nonwovens. The fibre length of a few mm’s can be the underlying

reason which is ten-fold smaller than textile fibres (10-25 mm) while having similar diameters. Further experimental

research is required to develop a mechanical technique to form a paper web.

Potential partners

• Dan-Web

• Anpap

• Rando

• Aalto University: founder of air dynamic forming

Figure 1 Air laid technology © Textile innovation knowledge platform

Energy reduction potential Technology Readiness Level

http://www.dan-web.com/Dan-web

http://www.anpap.fi/

http://www.randomachine.com/ourhistory.html

8


Requirements table

Concept Commercial viability Energy

reduction Paper

strength Water usage recyclability Continuous TRL

Air-laid technology (including ADF)

Yes, Air laid technology is applied on commercial

scale up to 50% Low

None when not accounting for a strength binder

Similar to normal paper

Yes 5-6

Mechanical nonwoven

Biggest challenge will be formation of the short fibre length (1-2mm)

High energy reduction potential

Assumed low

May be required for crosslinking

Expected similar to

normal paper N/A 1-2

Sources [4]–[8]

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Case 2A Solution spinning

Introduction

The main constituent of papermaking pulp is cellulose a natural polymer that, with the proper solvent, can be dissolved.

Dissolved cellulose can be solidified to fibres by using an anti-solvent or by removing the solvent. Fibers can, therefore,

be generated with a tailored length and diameter. It is valuable to explore the properties of such fibres and what

techniques are available to spin such fibres.


The technique aims to efficiently remove the solvent from the dissolved cellulose ensuring the aggregation and

solidification of the cellulose. Based on the type of spinning technique a thread or a nonwoven mat can be produced.

The process is applied to create nano-cellulose fibres (crystalline or micro-fibrillated) [9]. The main challenges are to

seek a high-throughput spinneret and use a cheap, scalable, non-volatile and non-toxic solvent [10], [11] (See case

2B). Other challenges are scalability of the technique and paper-like material

spinning [12]. The scouted techniques to create a cellulose web are

electrospinning and solution spinning.

• Electrospinning: Is a technique that uses electricity to extract the

solvent from the cellulose solute. The solution is pressed through a

nozzle into a charged field (kV). In this charged field the solution

evaporates allowing the cellulose to solidify in small fibres (nano- &

microfibers).

• Solution blowing: is based on a liquid (solute) that is pressed through a

nozzle. Solidification occurs using heat to evaporate the solvent and by using an anti-solvent (e.g. water).

Therefore, a rinse and drying step is still required.

Potential partners

• Neenah Gessner

• Lenzing

• Ri.se

• Elmarco

• Areka

Figure 3 Solution blowing

Figure 2 Electrospinning © Textile learner


http://www.neenah-gessner.de/en/home.html

https://www.lenzing.com/home.html

https://www.ri.se/

http://www.elmarco.com/

http://www.arekagroup.com/

10


Requirements table

Concept CO2 emission

reduction

Paper-like

material

Homogeneous application

Bond other fibres

Recyclable Paper web formation

TRL

Electrospinning

Substantial electricity use:

Applied voltage 2-12 kV/cm, flow rate 5-20 µl/min

Yes, Similar to air-laid paper

(nonwoven napkin)

Yes, with electrospinning

it can be tailored

Yes, but fibre strength is not

known

Solvent evaporates

Yes, for example, a nonwoven

napkin is made (Young's modulus

between 5 - 30 Mpa)

5-6

Melt/solution

blowing technique

Hot air pressure is used (140 degrees C), the solution is heated up to 140

degrees C. Coagulation occurs

in water, also washed in water. CO2 drying could

be applied

Nonwoven type of fabric, a

thin or thick web

can be created

Yes Yes, web is

formed

Assumed based on

dissolvability,

but complexity in recycling the solvent (see

case 2B)

Extruded to form a web with

fibres with a diameter of 0.1

mm.

5-6

Airgap spinning / Dry jet wet spinning: Cellulose fibres

Dissolution at 80 degrees C, completely

dissolved after 90 min

Viscose-like

material is created, tenacities above 50

cN/tex and initial

modulus of 34 GPa

No, a thread is created

The spin head allows only to create single spun fibres; a new system should be

designed in which the fibres coagulate in a

web rather than

a spun thread.

Fibre recycling similar to

viscose/rayon recycling.

Recycling of solvent by

evaporation

No 5-6

Sources [13]–[30]

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Case 2b cellulose solution

Introduction

Case 2A has shown that it is theoretically possible to produce a cellulose nonwoven

from a cellulose solution. The solvent for cellulose dissolution plays an important

role in the spin-ability and properties of cellulose. Four solvent-systems have been

determined that can dissolve cellulose while being subject to requirements like

environmental impact and toxicity: NaOH, urea and thiourea, Ionic liquids (ILs),

N-Methylmorpholine-N-oxide (NMMO) and Deep Eutectic solvents.


Solvents systems based on Sodium hydroxide (NaOH), urea and thiourea can be used in different compositions to

dissolve cellulose. The dissolving occurs in minutes at low temperatures (-10°C to 10°C). Fibre characteristics, when

spun from this system, are with a crystallinity similar to cellulose II (regenerated cellulose) and good mechanical

properties [31].

Ionic Liquids are complex salt structures that are environmental-friendly compared to conventional harmful cellulose

solvents used for viscose production. Cellulose dissolves in room temperature ILs and can be combined with

electrospinning technique [32], [33].

NMMO is the solvent currently used in the Lyocell-process that is less harmful than the volatile viscose process solvents.

Viscose type fibres can be created at temperatures in the range of 80°C to 100°C and solidify in an aqueous bath [34],

[35].

Deep Eutectic solvents are a class of ionic liquids from natural resources with the ability to dissolve cellulose. This new

class of liquids are biodegradable, non-flammable, non-volatile, non-toxic and biocompatible [36]. DESs have been used

in the electrospinning of PVA and Chitin [37], [38].

Potential partners

• Iolitec (ILs)

• Solvionic (ILs)

• Proionic (ILs)

• Lenzing (NMMO)

• Shrieve chemical products (DES patent holder)

Figure 4 Ionic liquids © BASF


http://www.iolitec.de/en

http://en.solvionic.com/

http://www.proionic.com/

http://www.lenzing.com/

https://patents.google.com/patent/US8022014B2/en

https://www.google.nl/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=2ahUKEwiBkdXp37nZAhUiD8AKHb4fA64QjRx6BAgAEAY&url=https://www.flickr.com/photos/basf/4837811270&psig=AOvVaw27aIcStnKjNV5pMTzYdAqa&ust=1519396666635504

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Requirements table

Concept Scalability Environmental

effects Material

availability Toxicity

Speed of solubility

TRL

NaOH, urea and thiourea in aqueous solution

Scalability complexity is

the low-temperature dissolution

When the solvents are diluted NaOH

and urea are unharmful.

Thiourea affects plant growth

All products readily

available

NaOH LD50 is 40 mg/kg; Thiourea

LD50 is 125 mg/kg furthermore it

inhibits the thyroid function, Urea LD50 is 8500

mg/kg

5 min, -10

to 8 °C 5

Ionic liquid: 1-ethyl-3-methylimidazolium chloride (CMIMCl), 1-butyl-3-methylimidazolium chloride (BMIMCl),

Tetrabutylphosphonium hydroxide, 1-ethyl-3-methylimidazolium acetate and 1-decyl-3-methylimidazolium chloride, 1-ethyl-3-methyl imidazolium diethyl phosphate, Lithium chloride/N, N-dimethylacetamide (LiCl/DMAc), 1-allyl-3-methylimidazolium chloride

High-temperature processability

ILs claimed to be a "green alternative" for harmful current cellulose solvents

Available but not in

industrial quantities

EMI was negative in the LLNA, the

irritancy assay, and the MEST

A few minutes up to hours at elevated

temperatures

2-3, not applied yet in the

papermaking

process

N-Methylmorpholine-N-oxide (NMMO)

Scalability is determined by

compatibility with

nonwoven spinning

techniques

Considered to be

the most environmental-friendly process,

>98% re

Commercially available

Toxic product and

explosive by-products are

created at elevated temperatures

N/A

8

(applied in

industrial scale)

Deep eutectic solvents (DESs): formic acid: choline chloride, lactic acid: choline chloride, acetic acid: choline chloride, lactic acid: betaine, and lactic acid: proline

Not presented at large scale however small

ecological footprint,

lower price, no waste in process and

no purification make it easier

to scale up the

technology

Biocompatible and biodegradable

Available on large scale

Nontoxic N/A 3-4

Sources: NaOH-Urea-Thiourea [31], [39]–[41], ILs [32], [33], [42]–[47], NMMO [48]–[50], DESs [36]–[38]

13


Case 3 cross-linking

Introduction

In paper production, water plays the general role as carrier and facilitator to the resultant paper properties. Especially

the facilitation of web formation and hydrogen bonds between the fibres enable the creation of paper as we know it.

In a scenario that reduces or eliminates water use, cellulosic fibres still need to form a strong web. It is important to be

aware of the cross-linking additives that are available to improve (nearly) dry formed paper sheets. In this scout,

multiple cross-linking additives have been searched. They can be categorised into three groups: Solution-based cross-

linkers for use in nearly-dry sheet formation, dry based cross-linkers for dry sheet formation and dry-based cross-linking

methods.


Category 1 – Nearly-dry-sheet formation: In this approach, materials assist

crosslinking when in (aqueous) solvent. This technique does not mitigate

the need for water, and therefore a drying step is still required. However,

it is possible that these cross-linkers can be applied in a low amount of

water to support the crosslinking of water for generating cross-linked bonds

besides the hydrogen bonds.

Category 2 – Dry-sheet formation: For this web formation approach cross-linking additives are added when paper is

dry-formed. Dry-sheet formation can be created using resins to bind paper fibres [51]. The dry formation can be enabled

using bio-based resins and binders.

Category 3 – Dry-based cross-linking methods: The third category encompasses techniques that facilitate solvent free

cross-linking. Two techniques have been observed: Mechanochemical crosslinking and dry-state surface treatment.

Potential partners

• Epson PaperLab (Cat 2)

• Senbis (Cat 2)

• UTwente - Dr.ir. Jos Paulusse, mechanochemistry (Cat 3)

• The Brown research group (Cat 3)

Figure 5 Cellulose crosslinking with citric acid © Cuadro et al. [226]


https://global.epson.com/innovation/paperlab/

https://senbis.com/en

https://www.utwente.nl/en/tnw/bnt/People/academic_staff/jos-paulusse/

http://www.thebrowneresearchgroup.co.uk/

14


Requirements table

Concept Environmental impact Safety CO2 emission reduction Energy reduction Cost-effective Material

availability TRL

Cat 1 – (Dialdehyde) carboxymethyl cellulose (CMC), EDC, adipic dihydrazide, polyelectrolyte complexes [52]–[57]

Low High N/A

In combination with EDC up to 500% and 100% in wet web strength can be achieved,

furthermore substantial energy reduction in the pre-treatment

process for NFC production

N/A High 3-4 (Lab scale)

Cat 2 – Gelatine (thermoformability) [58]

Directly none, indirectly from cattle industry

High N/A N/A

Inexpensive and facile method to

improve plasticity of fibre networks

Medium 3-4

Cat 1 – glutaraldehyde-chitosan, glutaraldehyde-PVA [59], [60]

Aquatic toxicity but can be biologically degraded

Is toxic, so may cause skin irritation, nausea, headache

and breath shortness

Assumed, as partial replacement in water-based production

No high-temperature curing is required to make strength paper.

Less expensive alternative for formaldehyde

High 3-4

Cat 1 – Ester crosslinking: Citric acid (CA), Polyamino carboxylic acid, 1,2,3,4-butane tetracarboxylic acid [61]–[64]

Low, bio-based Exposure to pure citric acid causes adverse effects

Depends, The crosslinker is an additional step in papermaking (using pad-dry-cure process).

Experimental studies must show if this material can be used to increase paper strength of dry-

formed papers

Similar to the previous requirement

It can be applied in an open, paper-like

production plant Available N/A

Cat 1 - Protein: Cellulose crosslinking protein (CCP & CBD) [65]

Environmental-friendly High N/A N/A Costly production Low 2-3

Cat 2 - Enzymatic binder: Laccase [66]

Low Low Assumed, as the laccases can be used to create

a glue-type cross-link as presented in the production of MDF board

Assumed, as dry fibres can be used for MDF production. The

"glue" should be examined for dry laid paper production and press

Yes, if mediator (4-hydroxybenzoic

acid) is used Medium

5-6 (Pilot)

Cat 3 – Dry surface treatment (DST) [67]

Depends on applied coating, For example when PLA is used the

environmental impact is low

High High if the coating material can exclude the use

of water as binder High if the coating material can

exclude the use of water as binder

Cost-effectiveness claimed, can also be used in coating and

sizing process

Depends on binder/polymer/coating

used

3-4

Cat 3 – Mechanochemical crosslinking with succinic anhydride [68]

Environmentally benign technique, however slow biodegradability of PVA

High Low, biggest benefit is the mitigation of toxic

solvents Mechanochemistry is energy

intensive N/A High 3-4

Cat 1 – Waterborne polyurethane (WPU) microemulsions [69]

Medium, uses nondegradable polyurethanes

Inert when PU is fully reacted when combusted CO and HCN are generated

When only used as linker in dry-formed sheets Similar to CO2 reduction Only if high paper quality is achieved

High 5-6

Cat 2 – Green binders for air-laid paper: Proteins, carbohydrates, lignin, phenolic compounds [70]

Low High Only if similar strength to wet-laid can be

reached. Only if similar strength to wet-laid

can be reached. Reasonably priced

Available in large

quantities 5-6

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Case 4 Alcohol as a carrier

Introduction

Water plays an important role in the production of paper. It acts as a swelling agent

for the cellulose fibres which enhance the mutual contact area. It serves as a solvent

for chemical additives, as suspending medium for solids and enables good dispersing

to create a uniform sheet [71]. Water is a strongly polar molecule. The dipole

moment (Figure 6) makes the oxygen partially negative and each hydrogen partially

positive. The dipole moment contributes to hydrogen bonding and explains many of

the properties of water (e.g. capillary action). One of this properties is the very high

specific heat capacity (4.181 J/(g·K) at 25 °C), as well as a high heat of vaporisation (2257 kJ/kg at the normal boiling

point). The high heat of vaporisation results in high energy demand for paper drying.


A possible solution space to reduce the energy consumption during paper production is the substitution of water with a

less polar molecule like alcohols. Compared with water the heat of vaporisation of different alcohols (methanol, ethanol,

n-propanol and n-butanol) is much lower which indicate the possibility to reduce the energy needed for paper drying.

Research shows a major downside for the use of alcohols in paper production as the paper strength properties will

greatly decrease. Besides, the use of highly flammable and explosive alcohols at such a large scale is a point of attention.

At last the recyclability must be investigated to make the use of alcohols economically interesting.

Potential partners

• National Centre for Research and Development, Poland


Figure 6 Dipole moment of water (H2O) © Riccardo Rovinetti

http://www.ncbr.gov.pl/en/

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Requirements table

Medium

Heat of

Vaporization

(kJ/kg)

Braking Length

(m)

Tear Resistance

(mN)

Breaking

Energy (J) Process Safety

Water 2257 8020 581 0.169 None

Methanol 1104 3940 400 0.104 Highly flammable,

Explosive

Ethanol 841 3690 379 0.102 Highly flammable,

Explosive

n-Propanol 760 3020 304 0.096 Highly flammable,

Explosive

n-Butanol 590 1800 177 0.055 Highly flammable,

Explosive

Sources [72], [73]

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Case 5 Supercritical solution

Introduction

In a supercritical solution, the temperature and pressure are brought above the critical point. In the supercritical state,

the distinction between gas and liquid becomes closer to each other because the density of the liquid and gas phase

become more equal. Supercriticality can be advantageous because products tend to dissolve better in a supercritical

solution. The thermos-physical properties can be varied by adjusting operating pressure and temperature. Processes

involving supercritical fluids require less energy and can be more environmentally friendly than solvent-based processes,

due to their physical and chemical properties [74]. Therefore, it is interesting to explore if supercriticality can be applied

to the papermaking process as dispersing solution.

Supercriticality can be used to dissolve cellulose in water. Under

normal conditions, cellulose is insoluble in water but when brought

to supercritical point cellulose can dissolve [75]. Cellulose dissolves

due to a reduction of hydrogen bonds between water molecules and

nearly ceases to exist above 573 K. The self-organisation of the water

molecules decrease, and therefore the crystalline cellulose can be

more easily dissolved [75].


The dissolved cellulose can be recrystallised when forced through a nozzle into a low-pressure chamber. This process

is known as Rapid Expansion of Supercritical Solutions (RESS). The advantage of this process is good control of particle

size, particle distribution and morphology. Although nothing is explicitly stated about a paper-web like structure, Jung

and Parrut (2001) suggest that RESS can be used for the formation of fibres (cellulose II. [76], [77]). Also, the

advantage of good distribution with RESS indicates that a web-like structure can be created. Water would in the low-

pressure chamber be well above liquid phase and turns into steam.

Potential partners

• Steritech

• ThyssenKrupp

• Aalto University – Lasse Tolonen ([email protected])

Figure 7 Energy Efficiency and Management in Food Processing Facilities © Wang, L. [78]


http://www.steritech.eu.com/company.html

http://www.thyssenkrupp-industrial-solutions.com/

18


Requirements table

Technique Energy reduction potential Commercial viability Scalability Open process

compatibility TRL

Pulp/cellulose in

supercritical

solution

Estimated low as high pressure

and temperature are involved.

Beneficial is the one-step

process. Energy use is stated as

comparable to conventional

solvent-solid extraction [78]

Techniques available,

solely based on product

properties.

For scalable

production, large

pressure tanks are

required.

The current

setup only

shows

recrystallisation

in expansion

vessel.

2

Sources [74], [75], [77], [79]–[84]

19


Case 6 Supercritical Drying

Introduction

To remove liquid from a suspension super criticality can be used.

Super criticality means that the substance temperature and pressure

are brought above the critical point. In this state the distinction

between gas and liquid disappears, the density of the liquid and gas

phase becomes equal. Super criticality is advantageous because it has

a lower viscosity and diffusivity than liquid. The literature describes

two methods using super criticality: supercritical drying and

supercritical extraction.


Supercritical (carbon dioxide) drying is a relatively new process to remove liquids (e.g. water) from solid (porous)

materials. Water can also be used in supercritical drying however it has a high critical point requiring high pressure and

temperature (22MPa, 647K [82]). To reduce energy use in aqueous drying the water can be washed out with ethanol

or acetone which is subsequently removed by CO2 under high pressure [82], [85]. Four supercritical drying methods

could be applied for water removal in the papermaking process [86], [87]:

• Supercritical gas drying (SCGD) uses liquid CO2 to replace the water after which it is raised to supercritical level.

• Supercritical organic solvent drying (SCOD) where the organic solvent with CO2 is raised to a supercritical state.

• Supercritical mixture solvent drying (SCMD) in which solvent is mixed with CO2 (g) and raised to the

supercritical state of the mixture.

• Spray drying with the assistance of supercritical gas (SASD) is a combination of the supercritical state and spray

drying wherein the substance is sprayed in a chamber and dried.

Potential partners

• Waters

• Suflux

• CO2dry / Feyecon

Figure 8 Schematic of a supercritical CO2 drying system © Zhenzong et al. [85]


http://www.waters.com/waters/en_DK/Supercritical-Fluid-Extraction-%28SFE%29-Systems/nav.htm?cid=10146521&locale=en_DK

http://suflux.com/

http://www.co2dry.com/

20


Requirements table

Sources [85], [86], [88]–[100]

Method

High-

speed

process

Low CO2

emissions

from process

Cost-effective Safety Energy

reduction

High

paper

strength

Closed

/ open

system TRL

Supercritical -

• gas drying

(SCGD)

• organic solvent

drying (SCOD)

• mixture solvent

drying (SCMD)

• spray method

supercritical

drying (SASD)

Depending

on

technique

drying

times can

be long or

short.

CO2 can be

reused, although

some amount is

lost during

depressurisation.

Is a standard

dehydration

technique, applied in

many industries.

However, operation

and equipment costs

are high. CO2 dry

claims up to 30%

lower investment

costs. Scalability

required.

Working

under

high

pressure

may

oppose

risks in

production

CO2 drying

energy depends

on operating

temperature and

pressure

required. CO2Dry

claims up to 50%

energy reduction

(compared to

freeze-drying)

Nanopaper

is three

times

stronger

than

normal.

Structure

remains

intact

Closed

2 - 3 for

paper

6+ for

food

Figure 9 Schematic visualization of supercritical drying techniques © Zheng et al. [86]

21


Case 7 Electro Dewatering

Introduction

Electrical assisted mechanical dewatering, known

as electro-dewatering, is considered as one of the

most effective hybrid processes for the

improvement of wastewater sludge dewatering

efficiency. The operating conditions of the electric

field and pressure used in the electrically assisted

mechanical dewatering are sufficient to remove a

significant proportion of the water that cannot be

removed using mechanical dewatering

technologies alone. Thus electro-dewatering has

the potential to be viable for a range of slurries, which either could not be sufficiently dewatered or would otherwise

require extreme conditions using conventional dewatering devices. [101]–[104]. Some research showed the occurrence

of electrolysis when applying sufficient high electrical fields. Electrolysis of water can be of interest as it produces H2

and O2. However, electrolysis is a high energy consuming process. With 100% theoretical efficiency it requires 13,2

GJ/t of water. This is, in comparison with the energy consumption during the current drying section (3,6 – 6,2 GJ/t of

water [105]) 2 to 3,5 times higher. The current industrial state of the art show 70% electrolysis efficiency. The maximum

theoretical efficiency of a fuel cell is 83%. Calculating with these numbers (18,9 GJ input and 11,0 GJ recovery per ton

of electrolysed water) the net energy consumption will be 7,9 GJ/t of water. Electrolysis will therefore not yield a profit

in terms of energy use. However, it can be an interesting option from an economic point of view.


Electro dewatering has the potential to assist in the press section of the current paper production process. Research on

the efficiency of the technique is mainly done in the field of wastewater sludge dewatering. It has been shown that

electro dewatering can be used to remove a significant proportion of the inherent water from conditioned activated

wastewater sludge. It can remove from 10 to 24% of additional water, which cannot be accessed by the conventional

mechanical dewatering process alone. The energy used to reach the additional dryness is significantly lower (10–25%

lower) than that required for thermal drying techniques [102]. Research on the dewatering of cellulosic pulp and paper

waste sludge shows a long dewatering time to get moisture content (55%) similar to the one obtained in the factory

by mechanical methods. However, this comparison is difficult and non-concluding because of the difference of the

applied mechanical compression forces. Advantage seems to be that the cake is better prepared to be hot air dried

[105].

Figure 10: Mechanical dewatering and electro-dewatering with the different mechanisms © Mahmoud et al. [1]


22


As no research is found on the effect of electro dewatering in paper production, the ability to predict possible

enhancements is limited. As seen in the waste sludge experiments the process speed will be a challenge to keep up

with the current paper production speed.

Potential partners

• Energos

• Bluewin

• The Laboratory of Thermal, Energetic and Processes, University of Pau, France

Requirements table

Technique Potential Energy

Reduction Substantial Water

Removal Speed of Process Water Reusability

Electro Dewatering

10 – 25% of additional dryness compared with

thermal drying technique

10 – 24% additional water than mechanical

dewatering

20 – 250 minutes contact time for waste

sludge

Same as current mechanical press

process

Sources [101]–[106]

http://energospolska.com.pl/

http://www.bluewin.kr/

http://latep.univ-pau.fr/fr/index.html

23


Case 8 Ultrasonic Dewatering

Introduction

Ultrasound is sound waves (ultrasonic waves) with frequencies higher

than the upper audible limit of human hearing (from 20 kHz up to

several gigahertz). It is no different from 'normal' (audible) sound in

its physical properties. The applications of ultrasonic waves are

divided into two groups: low and high intensity. Low-intensity

ultrasonic waves are those wherein the objective is to obtain

information about the propagation medium without producing any

modification in its state. On the contrary, high-intensity applications

are those wherein the ultrasonic energy is used to create permanent

changes in the treated medium [107]. High-intensity ultrasound is suitable for dewatering and drying of moisture

containing solids (ultrasonic dewatering) without the introduction of heat. Studies to ultrasonic dewatering are mainly

in the field of food processing, and more recently some research is done in the field of fabric drying.


Ultrasonic dewatering can be of interest in reducing the moisture content of paper before entering the drying section

or to replace the drying section completely. Two different ultrasonic dewatering techniques are identified.

Ultrasonic Assisted convective (hot air) drying resulting in an acceleration of heat and mass transfer and reduction

of the drying time without a significant increase in product temperature [108]. The drying time for the convective drying

of clipfish can be reduced by 43% with the application of airborne ultrasound at an intensity 25 W kg−1. The change in

the drying rate is more significant at the beginning of the drying process than at the end [109]. However, one of the

main difficulties in the application of ultrasonically assisted drying is to achieve efficient generation and transmission of

ultrasonic energy from the transducers to the product while ensuring easy adaptability to conventional drying processes

[107], [110].

Direct Contact Ultrasonic drying involves placing the ultrasonic transducer in direct contact with the material. A high-

frequency vibration atomises water turning it into a cold mist [111]. The good acoustic impedance matching between

the vibrating plate of the transducer and the material favours the deep penetration of acoustic energy and increases

the effectiveness of the process [107]. A demonstration unit was fabricated to show the efficacy of the process and its

energy saving compared to the thermal drying process. The preliminary results showed that the energy consumption

of the direct contact ultrasonic press drier which was made of the metal mesh-based transducer was five times less

than the latent heat of evaporation at water contents greater than 20% [112].

Figure11 Ultrasonic Drying © ORNL


24


Potential partners

• Herrmann Ultrasonics + Video

• Oak Ridge National Laboratory (ORNL)

Requirements table


Reduction Scalability

Paper Quality

Affection Continuous Process

Ultrasonic Assisted 30%

Challenge to achieve

efficient transmission of the

ultrasound on large scale

Not tested on paper Yes

Direct Contact

Ultrasonic Up to 80%

No restriction on the

ultrasonic surface Not tested on paper Yes

Sources [107]–[113]

https://www.herrmannultraschall.com/en/home/

https://www.youtube.com/watch?v=8mOCTruI28Q&list=UUWXK4RquscYLobmUkTriX7A&index=8

https://www.ornl.gov/partnerships/ultrasonic-drying

25


Case 9 Osmotic Dewatering

Introduction

Osmosis is the movement of a solvent through a semi-permeable

membrane into a region with a solution of higher osmotic value (e.g.

higher dissolved salt concentration), in the direction to equalise the

solute concentration (osmotic value) of the two sides. Osmosis may

thus be used for separation of water from a solid/water mixture. The

process results in a concentration of the feed stream and dilution of

the highly concentrated stream (referred to as the draw solution).


Forward osmosis is an engineering process utilising natural osmosis whereby the water from the feed stream passes

through a semi-permeable membrane which has the advantages of low energy requirements. The method can

potentially be used to assist in the press section of the current paper production process to reduce the moist amount

before entering the drying section. Research on this technique focusses on wastewater sludge dewatering, water

treatment and food processing. As the process will dilute the draw solution and reduce its osmotic value, Reverse

osmosis can be used to restore the needed osmotic value. Reverse osmosis uses pressure to force the water through a

semi-permeable membrane from an area of high osmotic value to an area of low osmotic value. Research in the field

of sludge dewatering has shown a solids level of 70-80% with a process speed of 8 L/h per m2 of membrane surface

[114].

As no research focuses on the effect of forwarding osmosis in paper production, the ability to predict possible

enhancements is limited. As seen in the waste sludge experiments the process speed will be a challenge to keep up

with the current paper production speed.

Potential partners

• HTI Water

• CSIRO

Figure 12: Forward osmosis vs Reverse osmosis


http://www.htiwater.com/default.html

https://www.csiro.au/en/Research/AF/Areas/Food/Making-new-sustainable-foods/Forward-osmosis

26


Requirements table


Reduction Substantial Water

Removal Speed of Process Water Reusability

Forward osmosis N/A 70-80% solids level with sludge waste

Slow. Up to 15 L/h per m2 of

membrane surface

Water reusable with the use of reverse

osmosis

Sources [114]–[118]

27


Case 10 Microwave Drying

Introduction

Microwaves heat up materials by dielectric heating. The dipole moment

of water enables molecular friction when radiated with microwaves.

Therefore, products heat up homogenously and efficiently, especially

when consisting of water. The advantages of microwave heating are

efficient heating of materials in a very short timeframe (up to 10 times

faster than convection heating) and requiring little space (10% of floor

space [119]).


Microwave drying is explored in many fields, and therefore a lot of different set-ups exist. Four categories have been

distinguished that could be applied: Continuous microwave dryer (belt technology), Microwave vacuum based

dehydration, Microwave-osmotic dehydration and microwave-assisted hot air drying.

1. Continuous microwave dryer (belt technology) is a drying technique where multiple microwave generators are

placed perpendicular to a drying belt. The technique is used to dry materials like wood, board and ceramics

[120].

2. In microwave vacuum (MWV) based dehydration microwave technology is combined with a vacuum system. In

vacuum, water vaporises at much lower temperatures with better heat distribution. Energy consumption is

estimated 2.98-7.7 MJ/kg while 4.45-6.50MJ/kg is the estimation of conventional air-drying energy use [121].

3. Microwave-osmotic dehydration (MWOD) uses osmotic dehydration to increase moisture loss speed of,

especially fruit products. The moisture loss compared to other techniques was 30 to 94% faster [122].

4. Microwave-assisted hot air drying (MWHA) is a combination of hot air ventilation and microwave power [123].

The general challenge with the microwave technique for drying is defining the optimal values for parameters like

frequency (Hz), power (W) and assistive drying techniques (hot-air, vacuum, osmotic, freeze).

Potential partners

• Romill

• Pueschner

• Process technologies

Figure 13 An industrial scale belt microwave dryer © Thermex Thermatron


http://www.romill.cz/en/microwave

http://www.pueschner.com/en/microwave-technology/microwave-drying

http://processtechnologies.org.uk/

28


Requirements table

Concept Scalability Paper quality Attainabil

ity Continuo

us Energy reduction

potential TRL

Microwave: Microwave belt drier, Continuous microwave dryer, Microwave-Osmotic Dehydration, Microwave-Vacuum-Based Dehydration, Microwave-assisted hot air drying

Yes, is industrially applied in many

industries and uses less than 10% of convection drying

floor space. However, the optimal

characteristics for large-scale paper

application need to be developed.

All properties were found to

be either enhanced or at the same level.

Microwaves enhance bonding strength

between fibres [124].

Needs to be tailored

and experiment

ed with microwave suppliers

Yes, using a belt drying system

Microwave drying is regarded as an efficient

technology. Heat is generated principally in

the product and a significant time

reduction can be achieved. In research

has been estimated that microwave technology

can achieve 20% energy reduction.

6+

Sources [119]–[123], [125]–[135]

29


Case 11 Hygroscopic drying

Introduction

Hygroscopic materials are materials that extract moisture from their

surroundings. The effect can be viewed as a similar process to osmotic

extraction; the moisture is directed to the regions with high adsorption

potential until the vapour pressure inside the hygroscopic

material/desiccant is in equilibrium with the outside air. Hygroscopic

materials function at room temperatures making them ideal for in-house

dehumidifiers [136]. Materials that are known for their hygroscopic

behaviour are cellulose, salts, silica gels, activated carbon, borax, alum

and zeolites [137]. The primary downside for desiccants is their slow

adsorption speed (hours) [138], [139].


Desiccants adsorb moisture from air based on the difference in vapour pressure. Therefore, to apply desiccants in

papermaking, water needs to be turned into moisture enabling a vapour pressure difference. To facilitate the moisture

extraction water could be moisturised using a continuous dry air flow. This air flow can be combined with a desiccant

wheel system [140]. The desiccant wheel is a

circular system where dry air can be used to

moisturise water from, for example, paper

that subsequently is dehumidified by the

desiccant in the rotary wheel. When the

desiccant is saturated, it can be dehumidified

itself by a stream of heated air or using

microwave technology [141].

Potential partners

• Atlas Copco

• Hoval

• Novatec

Figure 15 Schematic visualization of desiccant setup. © Zhang et al. [144]

Figure 146 Picture of solid silica gel desiccant © Tradekorea.com


http://www.atlascopco.com/en-sd/compressors/products/air-dryers/desiccant-air-dryers

http://www.atlascopco.com/en-sd/compressors/products/air-dryers/desiccant-air-dryers

http://www.hovalpartners.com/

http://www.novatec.com/

30


Requirements table

Concept Sustainable

energy reduction

Doesn’t affect quality of paper

Scalability Cost-

effective “Easy” water absorption

Re-usability of the crystal

TRL

Desiccant drying

A significant energy

consumption reduction can be achieved

when combined with fluidised bed

and solar

The technique is applied to dry

delicate and heat sensitive structures as flowers and as a means to conserve

product characteristics. It is therefore assumed that the quality of

paper is not

affected

The technology is not applied in a belt-like continuous structure. It is a time-consuming

batch process

Is a low-cost drying

method

Desiccants are applied as

dehumidifiers and do not have a rapid adsorptive power of water in the liquid state. Therefore first water should be moisturised to

be adsorbed.

The desiccant was reused

over five times without loss of functionality. The desiccant

can be regenerated

using a stream of hot air that extracts the

moisture

1-2 (for

paper)

Sources [69], [136], [138]–[140], [142]–[146]

31


Case 12 Superheated Steam

Introduction

Superheated steam is steam at a higher temperature

than its vaporisation point with the corresponding

pressure and is generated by heating the saturated

steam obtained by boiling water. Drying with

superheated steam have some advantages over

conventional convective drying; Lower energy use

due to the possibility of reusing the latent heat of

evaporation, higher heat transfer coefficient that

leads to a reduction in drying time and the potential

of new product quality specifications [147], [148].


Superheated steam drying is not a new concept in paper drying and is an alternative to replace the current drying

section.

Superheated Steam Impingement Drying is one of the possible future designs for the paper industry. This

technique is in development and advantages are expected in energy savings, reduction in equipment size and paper

quality properties [149]. Research on paper quality dried with superheated steam reports an increase in strength,

toughness and tensile index [150]. The lower temperature of superheated steam caused by the vaporisation of water

during the drying process will not result in condensation, as the temperature is higher than the saturation temperature

and stays in superheated condition. The excess steam can be recovered with the use of mechanical compression of

vapour [147]. Suggestions are made to combine superheated steam drying with a supplementary heat source (e.g.

microwave) to speed up the drying rate [151].

Potential partners

• Fraunhofer

• CDS

Figure 16 Superheated steam drying at atmospheric pressure © Fraunhofer


https://www.igb.fraunhofer.de/content/dam/igb/en/documents/brochures/PT/1711_BR-pt_Dampftrocknung_en.pdf

http://www.cds-group.co.uk/biodri/index.asp

32


Requirements table


Reduction Steam regeneration Scalability Pressure

Superheated steam impingement drying

Up to 50% Mechanical vapour

recompression Tests in pilot

scale Process at atmospheric

pressure

Sources [147]–[152]

33


Case 13 FOAM FORMING

Introduction

The role of water is undisputable in the papermaking process. Water

is used as a swelling agent; it increases the contact area between

fibres, it is used a solvent for additives, it is the suspending and

dispersing medium, and it facilitates the creation of hydrogen bonds

[71]. Therefore, completely removing water from the papermaking

process requires technology that needs to replace all the functions of

water. Instead of completely removing water from the process there

might also be solutions that enable web-forming using a reduced

amount of water. The benefit of such a technique would be that water

can still be used to enable hydrogen bonding and as a swelling agent, while less drying energy is required. Techniques

that facilitate such a forming system are foam forming and the use of strength additives like zwitterions that increase

the coulombic interaction between the fibres.


Foam forming is a technique developed by VTT that uses microbubbles to create a very dense foam. The foam can be

laid on an adapted papermaking machine. As air is combined with water, less water is required to suspend pulp while

maintaining the creation of paper-like materials. Expected savings will be up to 30% in drying energy and overall 20%

in energy reduction while using less raw materials [153].

Zwitterions are not a forming technique but rather an additive that can be used to increase the paper strength.

Zwitterions increase the coulombic interaction between the fibres. The coulombic interaction in paper strength has been

researched extensively as the primary bond for paper strength. Zwitterions could be added to the mixture when paper

is formed with low water content (using steam formation) after a waterless laying technique [73], [154].

Potential partners

• VTT

• Valmet

Figure 17 Pilot plant of VTT's foam forming system © VTT


http://www.vttresearch.com/services/bioeconomy/light-weight-bio-based-structures/novel-web-production-concepts/foam-forming-platform

http://www.valmet.com/media/articles/all-articles/foam-forming/

https://www.google.nl/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=2ahUKEwj0m6XSv7TZAhXHesAKHcEzA7MQjRx6BAgAEAY&url=http://www.goodnewsfinland.com/finnish-foam-forming-technology-receives-eur-3-6-million-boost/&psig=AOvVaw1uPVGuzruSr7bwplyDB_dF&ust=1519216217915084

34


Requirements table

Concept Speed of

process

Cost-

effectiveness

Energy

reduction Scalability Emission reduction TRL

Foam forming 1000m/min 60-85% of

current cost 20% Yes

Up to 30% reduction

in drying energy 6 (pilot stage)

Sources [153], [155]–[157]

35


Appendix I: Complete technology list

1. Air-laying: A technique very common in papermaking for paper products like napkins and tissues. In contrast

to the “wet” papermaking process, in air-laid production of paper air is used as the medium to create the

nonwoven. Challenges will be in creating paper with similar strength and characteristics as normal paper. [158]

[159] [6]

2. Carding: A technique to create non-woven sheets with mechanical force. Fibers are mechanically placed in

interlocking positions with needle-like structures. Likewise to air-laying, the challenge will be to use binders that

strengthen the paper. [158] [159] [160] [161]

3. Centrifugal Force spinning: A technique that use a centrifugal force to position the fibers in a web that are

extruded or sprayed at the center of the centrifuge. The technology is primarily used for specialist nonwovens

like membranes. Not yet commercially applied. [162]

4. Cross-linking additives: This technique can be applied to reduce the amount of water required as additional

ingredient to papermaking techniques. The cross-linkers can be added to increase paper strength and entangle

the web structure. [163] [158] [164] [165] [166]

5. Electrospinning: This technique uses electric force to create charged fibers from a polymer melt or a polymer

solution. The fibers can be sprayed to create a nonwoven mesh that can be interconnected. The challenge will

be to dissolve kraft pulp in a sustainable process to create cellulose fibers. [167] [168] [169] [170]

6. Gel-spinning: This technique comprises a gel that is pressed through a nozzle (spuitmond) to create fibers.

The raw material needs to be fed in a gel. The challenge will be to create a raw material that can be used by a

gel-spinning system. [52]

7. Spunbonding I/S: Spunbonding is a process similar to the gel spinning process where the raw material is fed

as a polymer solution or a polymer melt that is pressed through a set of nozzles to create a nonwoven web.

The technique is already commercially applied in the creation of polymer nonwovens. [171] [158]

8. Melt/solution blowing: The melt/solution blowing technique forces the creation of fibers accompanied by air

onto a carrier. Due to the spray-like flow a fiber web is created on the carrier. Similar to other melt spinning

techniques the challenge will be to dissolve the kraft pulp in order to create the web. [158] [172]

9. Needlepunching: Like carding needle punching uses a somewhat similar strategy. Needles are used to

entangle the fibers to form a web. Unlike carding the fibers are not rolled but pressed with needles perpendicular

to the web. Although this is a very old technology the application to paper will depend on the ability to handle

smaller size fibers. [158] [173]

10. Sonication to entangle fiber network: Sonication is a technique that use “waves” to disorder the state of

materials. The technique can be used to fibrillate the fibers. [174]

11. EPSON Paperlab: The Epson paper lab is an example of a complete “dry” paper recycling technique. It uses

waste office paper as input and creates a reusable sheet of paper as output. It goes through the stages of

fiberizing-binding-forming without additional water use. A binder is introduced in the binding stage to bond the

paper.

12. Alcohols (Methanol, Ethanol, N-propanol, N-butanol): Replacing water with alcohol as solvents.

Challenge will be to overcome the lower dipole moment of the alcohols. Tear strength and breaking length are

substantially lower for alcohols. [72]

36


13. Supercritical and near-critical fluids: Not directly introduced as a solvent to replace water. However, the

use or supercritical and near critical fluids are claimed to have high success rates in enabling production

processes and reaction. Besides, they are sustainable alternatives. [175]

14. Ionic liquids: Ionic liquids are fluid salts that are used as a medium to increase reactions and change the

characteristics of the materials dissolved in the liquids. They can dissolve cellulose (and kraft pulp) enabling

new applications in web formation. This is discussed in the results of case 1. Challenge will be the regeneration

of the solvent and application in bulk. [176]

15. SO2-ethanol-water (cellulose dissolving): Similar to the role ionic liquids have. However, a safer and less

toxic solvent than acid sulfate that is currently used for dissolving cellulose in the Lyocell (rayon) process. [177]

16. Spray coating (airbrushing, e.g.): Spray coating is a technique where a solution or melt is forced through

a nozzle to create a homogeneous spray. The coating technique can be used to replace the relatively wet size

press process. [178] [179] [180]

17. Brushing: Is the technique where a brush is applied to spread a viscous fluid on a surface. [180]

18. Casting: Casting can be applied in two ways. The first is by casting the film or coating on the surface itself.

The second is to pre-cast the coating in a mold and then apply it on the surface. This results in a two-component

system. [181] [182] [183]

19. Centrifugal powder coating: In this technique, centrifugal force is applied to spray a powdered coating on

a surface. The challenge will be to adopt the centrifugal system in the current paper process. [184]

20. Coating materials, as a replacement for starch: This is not a technique but merely a water-use mitigation

option by enabling other (bio-based) materials as a replacement for starch that has similar characteristics but

less water use (higher solid content). Materials from the food and medicine industry are introduced. [185]

21. Electrostatic coating: This is a technique that create a spray that adds a charge to the coat. If the to be

coated surface is charged as well with an opposite charge the coat and surface attract each other. The challenge

will be to apply this in the papermaking process and the negative effects of electrostatic forces that may occur.

[186] [187] [179]

22. Hot-melt coating: Coatings (like waxes) can be applied as a hot melt to mitigate the use of solvent and

therefore the drying process. [184]

23. Increase solid content: An approach to reduce the water content in the coat and thereby to reduce the

amount of water required. [188] [189]

24. Knife coating technique: This technique is somewhat similar to the size-press technique. However, the knife

coating technique allows to dose the amount of coat applied. Also, it allows application of more viscous fluids.

[190]

25. Bar coating: This technique uses a metering rod that “scrapes” excess coating of the surface. Changing the

diameter of the wire tunes the quantity of the applied coating. [191]

26. Crosslinkers: Cross linkers can be applied to the mixture of the paper to strengthen the paper internally and

can be added to the starch coating. [192]

27. Dry lamination: A technique that applies a “dry” second layer on the substrate. [193]

28. Dry powder coating (e.g., mechanofusion): A coating that is applied as a dry substance by force (air or

press) [194] [195]

29. Extrusion lamination/coating: Similar to dry lamination, although the coating is applied as a hot melt and

extruded in the process. [193] [196]

37


30. Hot-melt laminating (e.g., compress): This technique shows similarities to dry lamination, a second roll

with the laminate is combined with the substrate roll. When combined, heat is applied to bond the laminate

with the substrate. [191] [193]

31. Photocurable coating (UV, cross-linking): This coating is cured using a light source like UV. [197] [198]

[199] [200]

32. Plasma pre-treatment and flash evaporation treatment: This technique uses a two-component system.

A plasma pre-treatment is required to change the surface characteristics. The flash evaporation treatment

applies a thick coating. The challenge will be to apply the batch-process in the continuous papermaking process.

[201]

33. Water-based self-drying, fast curing coating: An additive added to the coating suspension allows quick

drying at room temperature in 1-3 hrs. [202]

34. Chemical Vapor Deposition (CVD): A batch coating technique in a vacuum that allows depositing high-

quality coats. This technology is state of the art. The challenge will be to implement the technique in the

continuous, high speed, papermaking process. Systems are the developed towards continuous CVD. [203]

35. Electrostatic dry powder coating: : This is a technique that create a spray that adds a charge to the coat.

If the to be coated surface is charged as well with an opposite charge the coat and surface attract each other.

The challenge will be to apply this in the papermaking process and the negative effects of electrostatic forces

that may occur. [204]

36. Heat Exchanger - Is a device that transfers the heat from the exhaust air to the fresh inlet air. The air streams

are separated by a solid wall. Where are lots of different designs but the principle is the same. [205]

37. Membrane Heat Exchanger - The principle of this device is the same as a normal heat exchanger. The

exhaust air and the inlet air are separated by a semi-permeable membrane, which will recover the exhaust air

moisture into the inlet air. [206] [207]

38. Heat Exchanger with Heat Pump - The principle of this device is the same as a normal heat exchanger.

The separated heat pump will compress pre-warmed gasses into a hot liquid which will extra heat the inlet air.

[208]

39. Mechanical Vapor Recompression - Is a device that recompressed the exhaust air. It involves taking vapor

(usually water vapor) at, or a little above, atmospheric pressure and adding energy to it by compression. The

result is a smaller volume of vapor, at a higher temperature and pressure, which can be used to do useful work.

[209]

40. Heat recovery steam generator - An energy heat exchanger that recovers heat from a hot gas stream. It

produces steam that can be reused in the process. [210]

41. Self-heat Recuperation - Is a technology that facilitates recirculation of not only latent heat but also sensible

heat in a process, and helps to reduce the energy consumption of the process by using compressors and self-

heat exchangers based on exergy recuperation. [211] [212] [213]

42. Infrared Drying - A technique that use the infrared spectrum of light to heat objects. [214] [215]

43. Microwave Drying - A technique that use electromagnetic radiation with high frequencies to create friction of

the water molecules. [216] [108]

44. Ultrasonic Drying - A technique that basically works like a humidifier. An ultrasonic humidifier uses a ceramic

diaphragm (piezoelectric transducer) vibrating at an ultrasonic frequency to create water droplets. [217] [113]

[218]

38


45. Osmotic Dewatering - A technique that is based on the principle of osmosis. Osmosis is the spontaneous

movement of solvent molecules (through a semi-permeable membrane) into a region of higher solute

concentration, in the direction that tends to equalize the solute concentrations on the two sides. [219]

46. Electro Dewatering - A technology in which a conventional dewatering mechanism such a pressure

dewatering is combined with electro kinetic effects to realize an improved liquid/solids separation. [104] [220]

[221]

47. Heated Press Section - Preheating the paper (and water) before the press section will lead to increased

dewatering efficiency. [222]

48. Freeze Drying - A technique that works by freezing the material and then reducing the surrounding pressure

to allow the frozen water in the material to sublime directly from the solid phase to the gas phase. [223]

49. Belt Press Dewatering (Vacuum & Mechanical) - Is an industrial machine, used for solid/liquid separation

processes. The process of filtration is primarily obtained by passing a pair of filtering cloths and belts through

a system of rollers. [224] [225]

50. Superheated Steam Drying - The superheated steam acts both as heat source and as drying medium to

take away the evaporated water. [149]

39


Bibliography

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CSF4 Breakthrough technology roadmap · Fourteen of them are described in depth in this document. ... three-level scale is determined based on the potential emission ... low power

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