02 Oct Developments in use of MFC for End Market Applications
Specialty Papers US – 2nd October 2018
Tom Larson
Technology Implementation Manager
- A Technology Joint Venture between Imerys and Omya
- Partners commercialize FiberLean® MFC Products
- FiberLean provides technical support to partners in commercialization of FiberLean® MFC products
- FiberLean develops FiberLean® MFC products and applications
- Global reach across all relevant industries
What is MFC?
MFC Properties
- Very high aspect ratio
- Very high surface are
- Increased hydrogen bonding potential
- Highly viscous when suspended in water
- Wide variety of applications
Constraints
High energy costsEquipment capabilityTransportation
FiberLean® MFC is the solution to these constraints
FiberLean is the leading global producer of MFC
Industrial process
- Robust, reliable and scalable plants
- Multiple customer implementations on-going
- Satellite plants for paper and packaging customers
- Total installed capacity 50k dmt/y of FiberLean® MFC (10k dmt/y fibrils)
- Growing portfolio of Intellectual Property and Applications
Range of composite types are possible
- FiberLean process has the flexibility to be used with a range of fiber/mineral types – including recycled.
- Intrinsic properties of both minerals and fibers are tailored to each application. MFC content can be varied.
Product forms
Slurry – Available supply via satellite plant built on-site
- Low solids (~2% fiber solids) due to high viscosity
- For trials: delivered in IBC tanks or road tanker
- Press cake – Available for trials, delivered in IBC bags
- ~15% fiber solids ‘crumble’, requires re-dispersion
- High Solids – Future supply via merchant plant
- ≥25% fiber solids ‘pellets’, requires re-dispersion
Product forms
Slurry |
Press Cake |
Bottles (lab trials) 10 liter (2.65 US Gallon) = 200 g (~8 oz) dry MFC Barrels (pilot trials) 220 liter (60 US Gallon) = 4.4 kg (~10 lb) dry MFC IBC Tanks (pilot & full scale trials) 1000 liter (265 US Gallon) = 20 kg (~44 lb) dry MFC Trucks/ ISO tanks (full scale trials) 25 meter3 (6600 US Gallon) = 500 kg (~1100 lb) dry MFC |
IBC Bags (full scale trials) Bag weight ~ 1000 kg (~2200 lb) = 150 kg (~330 lb) dry MFC |
Largest shipments to date supplied for trials: 80 Transitanks = 1600 kg (~3500 lb) dry MFC 7 Trucks = 3500 kg (~7700 lb) dry MFC |
Largest shipments to date supplied for trials: 292 bags = ~44 tonnes (~48 short tons) of dry MFC |
Regulatory Clearance
Cleared through Environment Canada, Health Canada, US EPA and US FDA (FCN 1582, 1887, for 5 wt.% fibrils in packaging board)
- BfR application filed for consideration under recommendations XXXVI, XXXVI/1, XXXVI/2, and XXXVI/3
FiberLean® MFC in Paper
- When added to paper-based products, the intrinsic properties of MFC/filler composites are utilized
- High surface area fibril network provides:
- More hydrogen bonding sites = improved strength
- Closed sheet structure = improved coating hold-out and surface properties
- Which in turn provides opportunities for:
- Use of additional filler for improved optical properties and reduced costs
- Improved paper properties
Higher filler loading in uncoated woodfree papers using MFC-mineral composites
- Full scale UWF results with 1 and 2% MFC addition
Despite some loss in Tensile, higher filler levels are possible due to the enhanced wet web strength
Note: These are pilot trial results using 450 ml CSF, 30% Pine / 70% Euca furnish and GCC filler
The most important effect of MFC for filler increase is the impact on initial wet web strength |
Improved base paper to make better coated papers using MFC-mineral composites
- Full scale UWF results with 1.5% MFC addition
MFC in the Base Improves Coating Hold-out
80 g/m² woodfree paper was prepared on a pilot paper machine
- 70% Eucalyptus / 30% Pine (450 CSF)
- 20% GCC filler
- 0% and 2% MFC
- No sizing added
- Paper was coated with:
- GCC / Kaolin formulation (10 pph Latex)
- Coat-weights between 6 to 14 g/m²
- Supercalendared
- Less coating penetration when using MFC due to smoother and more closed surface structure of the base
Improved properties at equal coat-weight or equivalent properties at lower coat-weights when using MFC
FiberLean® MFC in Packaging
- Similarly to MFC/mineral composites in paper, we see similar attributes when applied to packaging:
- Enhanced bonding strength
- Enhanced opacity/coverage of outer plies
- Improved surface properties/porosity of outer plies
- Dematerialization and improved printability opportunities are presented
MFC/Mineral composites in folding boxboard
|
|
Strength from MFC can be successfully traded for better bulk/stiffness and higher productivity
- The “adjustment” made here is making the mid-ply pulp coarser, i.e. reducing the refining energy.
Folding Boxboard application, full scale results
- Filler increase and basis weight reduction in top/back layers:
- 2.25% MFC in each
- +10% filler in each, 4 g/m² of top layer and 3 g/m² of bottom replaced by middle layer
- Conditions chosen to maintain stiffness
- Machine speed, filler retention and runnability maintained
- Specification maintained at a reduced cost:
- Bending stiffness and brightness unchanged
- Significantly improved smoothness
White Top Liner application, full scale results
- Filler increase and basis weight reduction:
- 2.5% MFC in white layer
- +9% filler in the white layer
- 10 g/m² of top layer replaced by brown layer
- Conditions chosen to maintain brightness
- Machine speed, filler retention and runnability maintained
- Specification maintained at a reduced cost:
- Minor changes in strength properties
- Large reduction in air permeability
- 40% increase in Scott Bond
- Potential for higher filler increase and brightness
Two approaches to using MFC-mineral composite to make white top liner
NPD – Wet-end coating on top of the wire section
- MFC-mineral composite applied as a low solids slurry on top of the still consolidating base layer.
- The composite has the ability to stay on the surface without penetrating into the base.
- The top layer is drained using existing foils and vacuum boxes.
- Pressing and drying as normal for the combined coating and base board.
- The top layer is strong and has good adhesion while offering coverage, low porosity, smoothness and excellent printability.
NPD – Pilot trial application of 30 g/m² dry MFC-mineral composite at 500 m/min on top of 70 g/m² base
- High mineral content / MFC composite layers applied at the wet-end provide:
- Excellent surface properties and printability = an alternative way to produce WTL
- Low mineral content / MFC composite layers applied at the wet-end provide:
- Mechanical property re-enforcement
- Excellent surface properties (closed, smooth structure) – ideal for coatings / specialty coatings (barrier etc.)
- Barrier properties of MFC
Consumers are demanding alternatives to plastic…
Is this an opportunity for Specialty Papers/MFC?
Summary
|
|