Researchers at the Department of Energy’s Oak Ridge National Laboratory have discovered a new method to process nanocellulose, derived from plants, that can reduce energy needs by 21%. This method uses a solvent of sodium hydroxide and urea in water, which decreases the production cost of nanocellulosic fiber. Nanocellulose is a strong, lightweight biomaterial that is ideal for 3D-printing structures like sustainable housing and vehicle assemblies, supporting the transition to a circular bioeconomy.
The research team, including scientists from ORNL, the University of Tennessee, Knoxville, and the University of Maine’s Process Development Center, aimed to find a more efficient way to produce nanocellulosic fiber. Nanocellulose is a form of cell walls in plants that is up to eight times stronger than steel. By leveraging computer simulations that mimic atom and molecule interactions in the solvents and cellulose, they were able to identify a solvent pretreatment method that significantly reduced energy consumption during the fibrillation process.
The simulations were conducted on the world’s fastest supercomputer for open science, Frontier, as part of the Oak Ridge Leadership Computing Facility. Lead researcher Jeremy Smith stated that these simulations offer detailed insight into why a process works, not just whether it works. The team confirmed the effectiveness of the solvent pretreatment through pilot-scale experiments, which showed a 21% energy savings compared to traditional methods and found that resulting fibers had similar mechanical strength to conventionally produced nanofibrils.
Using the winning solvent, researchers estimated potential electricity savings equivalent to the amount needed to power a house for a month. The team plans to continue exploring pathways for cost-effective nanocellulose production, including new drying processes. They aim to predict the best combination of nanocellulose and polymers to create fiber-reinforced composites for advanced manufacturing systems, supporting the development of sustainable and carbon-neutral materials for 3D printing applications and beyond.
The project is supported by the DOE’s Advanced Materials and Manufacturing Technologies Office and the partnership between ORNL and U-Maine known as the Hub & Spoke Sustainable Materials & Manufacturing Alliance for Renewable Technologies Program. By combining computational, materials science, manufacturing, and forestry knowledge, the team aims to develop targeted solutions for sustainable biomaterial production and building infrastructure. The research also aligns with the goals of the Manufacturing Demonstration Facility at ORNL to transform U.S. manufacturing through innovative collaborations.
Overall, the research conducted by the team at ORNL represents a significant step towards creating strong, affordable, and carbon-neutral materials for 3D printing applications and addressing challenges like the housing shortage. Through the development of efficient nanocellulose production methods and collaborations across disciplines, the team is paving the way for a more sustainable and environmentally friendly approach to material manufacturing and infrastructure development.
