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New Forest Products

New Forest Products. 2008 Provincial Leadership Forum. TOPIC SPONSOR. Joan Elangovan, M.Eng. Assistant Deputy Minister Ministry of Forests and Range.

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New Forest Products

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  1. New Forest Products 2008 Provincial Leadership Forum

  2. TOPIC SPONSOR Joan Elangovan, M.Eng. Assistant Deputy Minister Ministry of Forests and Range Joan Elangovan was appointed Assistant Deputy Minister for Corporate Services in January 2007. Her portfolio includes planning, policy and legislation; financial control and budget management; organization development; and information management and technology. Recently she has also become the executive lead for Value-Added Strategies. Joan joined the BC government in 1992. She worked in senior management positions in the social and economic development sectors, most recently, in the Ministry of Health, and the Ministry of Attorney General. Prior to joining the BC public service, she worked for Ontario Hydro. Joan has a Master of Engineering degree from the University of Toronto. In her spare time, Joan enjoys reading, music and travel. Joan and her husband live in Victoria. FOR-EX PLTM2008

  3. COMPETITIVE ISSUES John Talbot Performance Management, Strategic Business Development FP Innovations John Talbot has over thirty years of managerial experience in manufacturing, principally in the Province of British Columbia, Canada. Recent operating experience has been primarily in the wood products sector. John has intimate and practical knowledge of structural and value added wood manufacturing productivity issues, raw material supply, and strategic business planning / implementation. John, formerly the Executive Director - Value Added manufacturing at the Crown Corporation of Forest Renewal BC, has had specific careers in labour relations and sales and marketing - developing / and implementing of export marketing programs. FOR-EX PLTM2008

  4. ENGINEERED WOOD PRODUCTS Jean A. Cook, Ph.D. Manager Composite Products, Resource Group FP Innovations FORINTEK Jean Cook is currently Research Manager of two departments: Composite Products and Resource Characterisation. Jean holds a Ph.D. in Statistics from the University of Waterloo and joined Forintek in 1984 specialising in risk analysis – as applied to forest resource characterisation for value, product manufacturing process control and engineering properties of solid wood products. As part of the management team since 1990, Jean has enjoyed working in the multidisciplinary teams formed by the sector to resolve various technical trade and regulatory issues in international markets. She is currently the FPInnovations Board member of the Canadian Lumber Standards Accreditation Board and the Board member of the NSERC Strategic Network: ForValueNet. FOR-EX PLTM2008

  5. NEXT GENERATION PULP & PAPERNANOCRYSTALLINE CELLULOSEBIO-REFINING Gail Sherson, M. Eng. Director, Vancouver Laboratory and Program Manager Fibre Supply and Quality FP Innovations PAPRICAN Gail Sherson is with FPInnovations’ Paprican Division where she is Director of the Vancouver Laboratory and Manager of the Fibre Supply and Quality Research Program. Gail is a graduate of the University of British Columbia with degrees in Chemical Engineering and Pulp and Paper Engineering. Gail joined Paprican almost three years ago, bringing extensive industrial experience with International Paper, Champion International, Nexfor, Fletcher Challenge and MacMillan Bloedel. FOR-EX PLTM2008

  6. NEXT GENERATION BUILDING SYSTEMS Erol Karacabeyli, P.Eng. Manager Building Systems FP Innovations FORINTEK Erol Karacabeyli is a Registered Professional Engineer in British Columbia, Canada, and has over twenty years experience in the timber engineering research field. Holding two Masters Degrees he is a well-known specialist on seismic performance of timber structures, duration of load effects on lumber, panel and engineered wood products, and connections. Erol is currently the Manager of the Building Systems Department in Western Laboratory of Forintek. Erol is an influential member in many national and international codes and standards committees whose mandates encompass the safety and reliability of wood structures. Erol made significant contributions in wood engineering field, and published his findings in over 70 publications. FOR-EX PLTM2008

  7. Project Director Werner Hofstätter Project Director Corporate Services Division Ministry of Forests Werner Hofstätter holds an Honours Commerce Degree, a CSC, and has more than 25 years of experience working and consulting with all sizes of private and public sector organizations. He is currently Project Director of Value-Added Strategies in Corporate Services. He has held a variety of senior management and consulting positions in some of Canada’s largest organizations. He has worked with many industry sectors including transpor-tation, financial services, logistics and pulp & paper. In addition to publishing several articles on “Value-Based Management”, he has lectured in Finance at Carleton University. He is also a certified commercial diver, a trained volunteer fire-fighter and level III first responder. FOR-EX PLTM2008

  8. INNOVATIVE FOREST PRODUCTS MAXIMIZING VALUE FROM FOREST RESOURCES “…it is a time for us to look to the future of forestry. Maybe it looks a little different than the forest industry that I remember as a kid and the forest industry that I worked in the 1990’s.” Hon. Pat Bell, National Forest Day FOR-EX PLTM2008

  9. OBJECTIVE • Update you on some of the latest innovations in forest products and technologies • Generate discussion on what role, if any, the Government should play in creating an environment that encourages innovation and commercialization FOR-EX PLTM2008

  10. TODAY’S AGENDA • ENGINEERED WOOD PRODUCTS • NEXT GENERATION BUILDING SOLUTIONS • BIO-REFINING etc. • COMPETITIVE ISSUES • QUIZ, DISCUSSION andPRIZES FOR-EX PLTM2008

  11. FOR-EX PLTM2008

  12. Engineered Building Products What are they? Construction materials used for structural elements in buildings. Successful Engineered Products have • demonstrated and reliable performance in service and • are competitively priced Examples are steel, concrete and… FOR-EX PLTM2008

  13. Structural grades of lumber & panels that have recognized engineering properties 2004 FOR-EX PLTM2008

  14. The definition in the wood industry is:EWP = Composite wood substitutes for solid wood Better use of small and low grade logs (all species) Veneer Strip Lumber Parallam™ Oriented Strand Lumber Laminated Veneer Lumber FOR-EX PLTM2008

  15. Typical Wood Composite Manufacturing Process Drying Mat forming Stranding Resin blending Very high Temperature used (150 – 350 0C) Little resin used (<10%) Hot pressing* (up to 220 0C) Heat (*Courtesy of SBA) FOR-EX PLTM2008

  16. Reliability and Cost Competitiveness Process Interactions impact EWP Demand ALBERTA RESEARCH COUNCIL ? FOR-EX PLTM2008

  17. Solution: Look inside the process ALBERTA RESEARCH COUNCIL … START WITH SENSOR TECHNOLOGY… Relate process parameters to end product attributes • Moisture Meters in Dryers and Forming Line • Weight Scale in Forming Line • Thickness Gauges in Finishing Line FOR-EX PLTM2008

  18. Innovate to both reduce costs and improve end product attributes On-line measurement of wood MC to reduce energy costs and reduce plywood delamination $750,000 per mill, per year FOR-EX PLTM2008

  19. This poster provides several examples of other substitutes for solid lumber, timbers and beams FOR-EX PLTM2008

  20. Novel concepts – « open web studs » P FOR-EX PLTM2008

  21. An EWP Success Story OSB has captured 85% of the North American new home sheathing markets from plywood. Why? It is now perceived by the NA home construction industry as a lower price product that performs as well as plywood in home sheathing. It took 20+ years for OSB to capture significant market share from plywood in sheathing markets FOR-EX PLTM2008

  22. Cook Observation There is no shortage of new ideas for wood products and systems that COULD be used in construction Which have the potential to be perceived by the construction industry as viable substitutes for concrete and steel? I believe these are the “engineered wood products” that will attract sustained investment to the sector FOR-EX PLTM2008

  23. From commodity productsto building solutions Conception & engineering Solutions Integrated Systems Systems Support the design team Roofs Walls Flooring Indoor / Outdoor Systems Engineering & Process development LVL PSL Components Paneling & Siding Fencing & Decking Production & Distribution Commodity products Lumber Plywood OSB Knowledge Services Lars Sandberg, Timwood FOR-EX PLTM2008

  24. Opportunity for Wood: Non-Residential Buildings Prince George Airport Courtesy of Equilibrium Consulting FOR-EX PLTM2008

  25. US Non-Residential Buildings - Current and Potential Market Share 100% 90% 80% Additional that could be wood 70% 60% 74% Currently are wood-frame 50% 40% 49% 30% 20% 10% 19% 8% 0% % of area % of buildings Source: WPC 2006 FOR-EX PLTM2008

  26. Wood-Based Building Systems • Best bets • 6 Storey Light Wood Frame Construction (currently limited to 4) • 6-10 Storey Heavy Frame Buildings with Concrete Core (new) • Cross Laminated Timber Applications (new) • Roof and Floor Applications • Non-structural walls in Concrete & Masonry Buildings • Post Disaster/Low Cost Shelter FOR-EX PLTM2008

  27. First Best Bet: 6 storey Light wood-frame construction in Canada (currently limited to 4) • BC Premiere’s support made a difference • FPInnovations and CWC are supporting BC Building and Safety Policy Branch in pursuing regulatory changes to increase the limit on wood-construction from four to six storeys • Validation by US/Japan/Canada earthquake simulation test (FII support) (NEESWood) of a 6-storey wood-frame building (test specimen is built BC lumber) FOR-EX PLTM2008

  28. Second best bet: 6-10 storey Heavy Frame Buildings with Concrete Core • Developing several design concepts for use of wood in mid-rise construction, including hybrid wood/concrete and wood/steel FOR-EX PLTM2008

  29. Second best bet: 6 storey Heavy Frame Buildings with Concrete Core • Demonstration building in Quebec City; • Based on the objectives of Quebec’s use of wood in the non-residential sector policy (May 2008) • Has received go ahead from Régie du bâtiment pending a few modifications • 60 000 ft2 in total • Above ground structure combines concrete core and heavy glulam • Below ground parking garage in • reinforced concrete ( 53 parking spaces) • Total Height; 22.8 m • Built under the NBCC 2005 • LEED GOLD • Planned occupancy Fall 2009 Owner: CSN FONDACTIONArchitect: Gilles Huot, GHA Atelier d’architectureStructural Engineer: Bureau d’Études Spécialisées inc. FOR-EX PLTM2008

  30. Third best bet: Cross Laminated Timber Massive wood plates, X-lam or Jumbo plywood Murray Grove Building, London, GBWorld Tallest Wood Building FOR-EX PLTM2008

  31. Cross Laminated Timber Elevator shaft or stair case with CLT Courtesy of KLH FOR-EX PLTM2008

  32. Fourth best bet: Roof and Floor Applications Richmond Speed Skating Oval FOR-EX PLTM2008

  33. Fourth best bet: Roof and Floor Applications • High Strength to weight ratio makes wood systems very suitable Courtesy of CWC WoodWorks FOR-EX PLTM2008

  34. Fifth best bet: Non-structural walls in Concrete & Masonry Buildings Not common in North America Stockholm 2004 Wood Walls in Concrete Building FOR-EX PLTM2008

  35. Sixth best bet: Post-Disaster/Low Cost Shelter

  36. Recent disasters – houses destroyed • 2004 Tsunami 150,000 homes • 2005 Pakistan earthquake 500,000 homes • 2005 Hurricane Katrina 275,000 homes • 2006 Indonesia earthquake 140,000 homes Earthquake 2006 Java Hurricane 2005 USA FOR-EX PLTM2008

  37. Wood Framing – Proven Earthquake Performance Hyogo-ken Nambu (Kobe) quake, 1995 Undamaged houses – N. American framing Post WWII House Collapsed FOR-EX PLTM2008

  38. Earthquake simulation test in USA(showing no structural damage) FOR-EX PLTM2008

  39. CONCLUDING REMARKS • Wood-based building systems offer a lot of potential in new applications • FPInnovations launched an initiative “Next Generation Building Solutions” • Funded largely by NRCan • Multi-disciplinary collaborative research with design community • A large component in wood-based composites • Designed to play a major role in increasing use of wood in residential and non-residential construction FOR-EX PLTM2008

  40. Next Generation Building Solutions Example: FPInnovations Vancouver Laboratory FOR-EX PLTM2008

  41. Next Generation Pulps & Papers • Innovation & technology that take full advantage of Canada’s unique fibre characteristics FOR-EX PLTM2008

  42. Paper giving instant visible indication of pathogens. High speed manufacture: coating or printing. Intelligent Paper: Safety Sentinel Project University Partnerships Bio-reactive Paper Products • SARS mask: • detect viral contamination • deactivate the pathogen • protect the user FOR-EX PLTM2008

  43. Advanced Bioproducts – Nanocrystalline cellulose • Smallest physical sub-unit of cellulose • Crystallite dimensions, 200 nm long, 10 nm wide • 8,000 times thinner than a human hair. • FPInnovations Lab Process: Production, 2 kg/week • Ready for 1 tonne per day NCC demonstration plant FOR-EX PLTM2008

  44. Nanocrystalline Cellulose (NCC) crystalline region microfibril : amorphous region acid hydrolysis H2SO4 TEM image of nanocrystals FOR-EX PLTM2008

  45. Nano-Crystalline Cellulose (NCC) Nano-Crystalline Cellulose (NCC) Colour Opacity Porosity Stronger than Steel FOR-EX PLTM2008

  46. NCC in the Everyday World? FOR-EX PLTM2008

  47. The forest biorefinery: • An integrated set of processes • Multiple products, a single site: • Solid wood, panels • Pulp, paper • Heat, power • Transportation fuels • Chemicals • Maximize the value from each component of the feedstock FOR-EX PLTM2008

  48. FOR-EX PLTM2008

  49. Potential pathways to new products Residues Bark, sludge Synthesis products Gasification, pyrolysis Sludge, effluent Novel products (Bio) chemical processes Pulp mill Cellulose Pulp, Paper Chips Conventional processes Lignin Novel products Chemical processes Polymers Chemical processes Hemi- cellulose Ethanol, others Fermentation processes FOR-EX PLTM2008

  50. XXX Main pathways to fuels and chemicals • Lignin • Resins: $400+ per tonne of lignin • Substitute for carbon black in tires: $1000+ per tonne? • Carbon Fibres • Hemicellulose • Ethanol, lactic acid: • $300 per tonne of hemicellulose • Fuel, plastic precursor • Xylose, Xylitol (sugar substitute) • Polymer precursors: • $700+ per tonne FOR-EX PLTM2008

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