BELLA Pilot
BELLA Pilot – Breakthrough CO2 reducing process for Cellulose-based additives
Publieke samenvatting / Public summary
Aanleiding
Europe aims to reduce its dependence on fossil resources and meet climate goals through a transition to a biobased, circular economy. The Dutch Klimaatakkoord translates this ambition nationally. A key challenge lies in developing renewable materials that match fossil-based alternatives in performance, affordability, and sustainability. Since 2007, Sappi has researched microfibrillated cellulose (MFC) and in 2020 launched Valida, a patented MFC technology with valuable functionalities. However, its broader adoption is hindered by energy-intensive production. The current batch-based presents limitation, results in high moisture content (97%), and causes logistical challenges and elevated CO2 emissions. Sappi therefore aims to develop a radically more energy-efficient and scalable production method. This involves significant technical challenges and innovation beyond the state-of-the-art. DEI+ support is essential to realize this pilot phase and overcome key bottlenecks in the path to large-scale, sustainable MFC production.
Doelstelling
The goal of this project is to upscale Sappi's microfibrillated cellulose (MFC) production to pilot scale while significantly reducing energy consumption and CO2 emissions. Specifically, Sappi aims to achieve a 50% energy reduction in wet MFC production via ozonation pre-treatment and co-refining approach, and a 40% energy reduction in dry MFC production through improved spray-drying techniques. The pilot will validate the technical feasibility, reproducibility, and product quality of the optimized process. If successful, the outcomes will contribute directly to DEI+ targets by enabling more sustainable production methods, reducing industrial energy use and lowering greenhouse gas emissions. This pilot is a critical step toward developing a full-scale demonstration process and aligns with the DEI+ objectives by addressing energy efficiency in an innovative, high-potential biobased material value chain. The project also contributes to long-term CO2 reduction goals in line with the Dutch Klimaatakkoord and European Green Deal ambitions.
Korte omschrijving
The project consists of four work packages. WP1 (Sappi) ensures effective project management through planning, monitoring, reporting, and stakeholder communication. WP2 (Sappi and partners including Xylem, Poeth, Stolz) focuses on upscaling the ozone-based pre-treatment for wet MFC production, evaluating energy reduction and performance in pilot formulations for cosmetic applications. WP3 (Sappi and partners including Celabor, Dorst, Meggle, Tecoma) validates and scales the spray-drying process to produce dry MFCs with reduced energy input while retaining product functionality after redispersion. WP4 (Sappi) conducts practical testing of both wet and dry MFCs in real-life end-use formulations (e.g., hair dye), benchmarking them against current alternatives and optimizing production. Each work package contains defined deliverables and go/no-go moments to assess progress and determine continuation.
Resultaat
The project will deliver a validated pilot-scale production process for microfibrillated cellulose (MFC), demonstrating at least a 50% energy reduction for wet MFC and 40% for dry MFC, while maintaining product quality and reproducibility. The technical feasibility of ozonation pre-treatment and spray-drying technologies at pilot-scale will be proven under realistic conditions. The project will result in a comprehensive report outlining results, performance benchmarks, energy and CO2-reduction outcomes, and technical recommendations for industrial scale-up. The pilot outcomes will confirm that the new production process is significantly more energy-efficient and scalable. These insights form the foundation for a follow-up demonstration project aimed at industrial production of dry Valida. The project thus contributes directly to the DEI+ objectives by reducing industrial energy use and CO2 emissions in a high-potential biobased value chain.
Europe aims to reduce its dependence on fossil resources and meet climate goals through a transition to a biobased, circular economy. The Dutch Klimaatakkoord translates this ambition nationally. A key challenge lies in developing renewable materials that match fossil-based alternatives in performance, affordability, and sustainability. Since 2007, Sappi has researched microfibrillated cellulose (MFC) and in 2020 launched Valida, a patented MFC technology with valuable functionalities. However, its broader adoption is hindered by energy-intensive production. The current batch-based presents limitation, results in high moisture content (97%), and causes logistical challenges and elevated CO2 emissions. Sappi therefore aims to develop a radically more energy-efficient and scalable production method. This involves significant technical challenges and innovation beyond the state-of-the-art. DEI+ support is essential to realize this pilot phase and overcome key bottlenecks in the path to large-scale, sustainable MFC production.
Doelstelling
The goal of this project is to upscale Sappi's microfibrillated cellulose (MFC) production to pilot scale while significantly reducing energy consumption and CO2 emissions. Specifically, Sappi aims to achieve a 50% energy reduction in wet MFC production via ozonation pre-treatment and co-refining approach, and a 40% energy reduction in dry MFC production through improved spray-drying techniques. The pilot will validate the technical feasibility, reproducibility, and product quality of the optimized process. If successful, the outcomes will contribute directly to DEI+ targets by enabling more sustainable production methods, reducing industrial energy use and lowering greenhouse gas emissions. This pilot is a critical step toward developing a full-scale demonstration process and aligns with the DEI+ objectives by addressing energy efficiency in an innovative, high-potential biobased material value chain. The project also contributes to long-term CO2 reduction goals in line with the Dutch Klimaatakkoord and European Green Deal ambitions.
Korte omschrijving
The project consists of four work packages. WP1 (Sappi) ensures effective project management through planning, monitoring, reporting, and stakeholder communication. WP2 (Sappi and partners including Xylem, Poeth, Stolz) focuses on upscaling the ozone-based pre-treatment for wet MFC production, evaluating energy reduction and performance in pilot formulations for cosmetic applications. WP3 (Sappi and partners including Celabor, Dorst, Meggle, Tecoma) validates and scales the spray-drying process to produce dry MFCs with reduced energy input while retaining product functionality after redispersion. WP4 (Sappi) conducts practical testing of both wet and dry MFCs in real-life end-use formulations (e.g., hair dye), benchmarking them against current alternatives and optimizing production. Each work package contains defined deliverables and go/no-go moments to assess progress and determine continuation.
Resultaat
The project will deliver a validated pilot-scale production process for microfibrillated cellulose (MFC), demonstrating at least a 50% energy reduction for wet MFC and 40% for dry MFC, while maintaining product quality and reproducibility. The technical feasibility of ozonation pre-treatment and spray-drying technologies at pilot-scale will be proven under realistic conditions. The project will result in a comprehensive report outlining results, performance benchmarks, energy and CO2-reduction outcomes, and technical recommendations for industrial scale-up. The pilot outcomes will confirm that the new production process is significantly more energy-efficient and scalable. These insights form the foundation for a follow-up demonstration project aimed at industrial production of dry Valida. The project thus contributes directly to the DEI+ objectives by reducing industrial energy use and CO2 emissions in a high-potential biobased value chain.
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