Project: A fiber-strengthening system for production of paperboard from recycled paper materials

-------_x000D_Goal:_x000D_-------_x000D_The goal of this project is to develop a new kind of eco-friendly paperboard that, amongst other things, can be used for the production of plasterboard. Plasterboard is a product of the building industry and consists of gypsum encased in two layers of paperboard. In this project we propose a modification of the cellulose fibers that are used in the production of the paperboard. A chemical functionalization of these cellulose fibers results in stronger fiber-fiber bonding, which increases the mechanical strength of the produced paperboard and allows to save up to 20% of pulp during paperboard production. This is a significant reduction of raw material and has direct impacts on energy consumption and CO2 emissions. The projected development of this cost-effective paperboard will therefore lead to the greening of a whole industry, which in turn contributes to the inevitable goal of the industrialized nations to lower CO2 emission by 20% until 2020. To do this we propose a consortium that includes the technology owner, a research institution and a major player from the building industry in order to combine valuable know-how with the industrial value-chain:_x000D__x000D_1. OrganoClick AB - a Swedish SME, hereinafter referred to as OC:_x000D_ Production, development and marketing of products used to functionalize bio-fiber through _x000D_ organocatalyzed chemical modification of the fibers_x000D_2. Mittuniversitetet - Mid Sweden University, hereinafter referred to as MU:_x000D_ The department of organic chemistry is performing leading frontier research in organic catalysis_x000D_3. Lafarge Platres - a French company, hereinafter referred to as LP:_x000D_ Worldwide No.3 in production of plasterboard_x000D_ _x000D_If successful, the new eco-friendly material will be ready to market immediately after conclusion of this project._x000D__x000D__x000D_-----------------_x000D_Background:_x000D_-----------------_x000D_Plasterboard is major component in the building industry where it is used for construction of internal walls and ceilings. Two parameters have impact on the strength of plasterboard, i. e. the thickness of the gypsum core and the tensile strength of the paperboard that encases the gypsum core. However, the role of the gypsum is COly to provide stiffness, stability and fire protection, whereas the tensile strength of the encasing paperboard is the key variable accounting for roughly 80% of the overall strength. The tensile strength is directly correlated to the surface weight of the paperboard and thus to the mass of the pulp used in its production. From an economic point of view this is critical, since the required pulp is the most expensive part in plasterboard production, whereas gypsum occurs as a by-product in the chemical industry (fgd-gypsum). Paper production is furthermore one of the most energy-consuming industrial processes that currently exists. A reduction of raw material during the production of paperboard will therefore significantly reduce the energy consumption with direct impacts on the carbon footprint._x000D__x000D_However, cutting surface weight also reduces the paper’s strength and stiffness, which would be counterproductive regarding its purpose in plasterboard production. The solution offered by OC is a chemical additive, based on biopolymers and green chemicals, that links and strengthens the fiber network in paper to allow reduction of raw material without lowering the paper’s stiffness or strength. Admixture of one mass-percentage of this additive increases the tensile strength of the produced paper by up to 50%, which explains the savings of raw material and the anticipated costs savings associated with it. This way it will be possible to produce encasing paperboard that is thinner and has a lower surface weight than the conventional used paperboard, while having comparable strength properties. For this innovative and eco-friendly technology OC was appointed as a climate solver by the World Wildlife Foundation in 2010, and is now one of the exclusive technology companies in the WWF's climate solver program (www.climatesolver.org). The technology is based on a method to enhance the fiber-fiber bonds in paper, using green chemicals and organic catalysts to alter the surface of the pulp fibers at the fiber-fiber junction areas._x000D__x000D__x000D_------_x000D_Aim:_x000D_------_x000D_The specific aims of this project are to:_x000D_ 1. further develop OC's technology to increase the inter-fiber bonding strength of recycled fibers used in_x000D_ paperboard production with application in plasterboard,_x000D_ 2. effectively reduce the amount of raw material used in paperboard production,_x000D_ 3. improve the strength quality and therefore usage of paper made from recycled paper _x000D_ 4. install a cost-effective production process, and_x000D_ 5. reduce the carbon footprint of the building industry by implementing the improved paperboard in_x000D_ plasterboard production.

Acronym Paperboard (Reference Number: 6820)
Duration 01/03/2012 - 31/08/2014
Project Topic Modification of recycled fibers with green chemicals results in a strengthening of the fiber network. This way up to 20% of raw material can be saved during the production of paperboard that is used in plasterboard. This reduces energy consumption and CO2 emission of the building industry.
Network Eurostars
Call Eurostars Cut-Off 7

Project partner

Number Name Role Country
3 Organoclick AB Coordinator Sweden
3 Mittuniversitetet, Department of Organic Chemistry Partner Sweden
3 Lafarge Platres Partner France