“In 2030, Stenungsund will become a manufacturing hub for sustainable products in the chemical industry. Our business is based on renewable raw materials and energy, and contributes to a sustainable society,” says Lars Josefsson, President of INEOS.

The vision of a sustainable society and a thriving chemical industry was developed in 2010 by chemical companies AGA, Akzo Nobel, Borealis, INEOS and Perstorp – all active in the chemical cluster in Stenungsund on the Swedish west coast. Their chemical products are found in tubes, cables, plastics, paints, detergents, fuels, medicines and thousands of other places.

After World War II there was a rapid development of products based on fossil fuels, particularly oil and gas. The term “plastic age” was coined in 1951 when the first plastics exhibition was held in Sweden, “All about plastics.”

Plastics are just one example of products manufactured in the chemical industry, and fossil fuels account for more than 90 percent of the raw materials. There are many reasons to try to break dependence on oil and gas, among them access to declining reserves together with the climate effects of burning fossil fuels.

Let’s look at how green chemistry, good business and a sustainable future can become a reality.

Chemistry is the science of opportunity

In 20 years, large-scale fossil-based chemical industries could be relegated to history’s scrap heap – if you believe the visionaries from Stenungsund.

The vision: “Sustainable Chemistry 2030″ is based on the interplay between a number of different components, including:

• Transition to renewable resources. This is about biological materials such as rapeseed oil, straw, wood chips, algae, sugar cane, and waste from forestry and agriculture.
• One man’s waste is another’s raw material. Household waste can be turned into gas that can be used to make the building blocks of plastics and other products. Other possible raw materials include industrial waste, recycled plastics and more. With new technology, it is now possible to separate undesirable constituents from cables and recycle thousands of tons of plastic cable.
• That one takes a holistic approach to sustainability issues and that companies cooperate with each other and the surrounding community. Some companies are processing renewable raw materials and selling the chemical building blocks to other companies thereby contributing to the next step in the chemical process.

This ‘Chemistry Cluster’ in Stenungsund aims to use biogas and bio-ethanol plants to process renewable raw materials and various waste products. Excess heat from factories is sold back to the district heating system, the trains run on renewable fuels and purchased electricity is produced from renewable sources. The common heating plant is run on renewable fuels and waste.

This is a new kind of industrial ecosystem that is already happening. The infrastructure is mostly in place.

The really big news is that the organic molecules like ethylene, propylene, and natural gas in the future will no longer come from oil and gas but from renewable sources. The chemical processes in the factories are the same as before and the end products do not change.

“We were an integrated cluster that started this process in 2010 and formed a common vision. It required many players to achieve it, including the collaboration with academia, politicians and other industries. Another crucial reason why we achieved our vision was that there was a common and long-term chemistry policy,” says Lars Josefsson, President of INEOS, at a seminar about 2030, where various speakers described how the project “Sustainable Chemistry 2030 “became a reality.

The future is already here

The focus on green chemistry and renewable raw materials has already begun in Stenungsund. Companies participating in the vision have begun the journey towards 2030, and here are some examples:

• Renewable fuel from rapeseed oil – In Stenungsund, Perstorp AB, has Scandinavia’s largest plant for the production of biodiesel (RME). It produces most of the renewable fuel components that today is part of Swedish diesel and Perstorp RME stands out in terms of sustainability. Life cycle analysis has shown that more than 60 percent of fossil carbon is replaced by biodiesel, compared with the EU criteria for bio-fuels of 35 percent.
• Durable cables – Borealis is a new high-pressure plant that manufactures durable cable products. It cost SEK 4 billion to build. The company is now focusing more on developing materials for high-quality cables, especially for long-distance electricity transmission, with a lifespan of 50 years. Borealis is a world leader in the development of cable materials and has a research department of about 100 people. Electrical cables for power are in great demand and contribute to solving the world energy supply.
• Environmentally friendly car washing – Every year, Akzo Nobel in Stenungsund spends about SEK 80 million on research and development. The company has developed products such as the water-based degreaser used in car washes. The products have revolutionized the cleaning of hard surfaces and in a paradigm shift have evolved from the use of solvent-based cleaners to aqueous degreasing.
• Renewable paint components – Since 2010, Perstorp has manufactured the world’s first renewable penta component (Voxtar) for aqueous alkyd paint. The raw materials consist of biomethanol and bioethanol. Voxtar is used to make about 15 percent of the ink and provides improved drying characteristics and stability.

Then, now and in the future

There are many pieces to fall into place for the vision of “Sustainable Chemistry in 2030″ to be realized. As usual, it is a combination of factors relating to consumer demands, legislation, policy, education, and investment capital. Let us assume that we are sitting at a seminar in 2030 listening to explanations of why green chemistry created a thriving chemical industry. Perhaps the speakers present the following arguments:

• There were political instruments that were useful in creating sustainable chemistry. Politicians were far sighted, which made it possible for businesses to plan ahead and dare to invest in the conversion.
• Consumers continued to demand green products and actually bought such products to an increasing extent. The same applied to public tenders.
• Companies got wind in their sails, made money and continued to bet on the winning concept. Interest from investors increased and capital was used to invest in the Swedish chemical industry.
• The plastic and chemical industry succeeded in reaching out to the world and focused on changing their raw materials and promoting their benefits.
• Chemistry’s reputation grew and chemistry programs at colleges and universities became increasingly attractive. Working at a chemical company was a high status job. The industry’s commitment to innovation and collaboration with academia was a benefit to both sides.

The article was published in April 2012

Skin is the largest organ in our bodies, accounting for 16 percent of our weight. Skin has many functions, including protecting against outside influences such as shock, chemicals, microorganisms, ultraviolet radiation, heat and cold.

Skin is also important in regulating body temperature and touch.

Skin has a remarkable ability to care for itself and repair flaws, which is an essential prerequisite if we are to survive in a tough environment.

Many of us choose to use skin care products to enhance the natural protection and increase the feeling of comfort and pleasure. Skin and beauty care products made from natural ingredients have been around for thousands of years.

Recipes have been found in archaeological finds from China, the Middle East and Africa, and examples of the ingredients include ox bile and whipped ostrich eggs.

Since then a lot has happened and today’s products contain both natural and synthetic ingredients and come with advanced features.

But some people doubt the ingredients made of chemical products.

More than half of what you rub yourself with can enter the body and a skin lotion may contain more than twenty different chemicals.

There is an increased interest in the manufacturing methods of skin products and packaging.

Swedish company Estelle & Thild has invested in a totally organic line of skin care products for children and adults with concern about quality, health and the environment.

“Some years ago when I was looking for skin care products for my daughter, it occurred to me that there were no products that offered both high quality and that were environmentally friendly,” says Pernilla Rönnberg, President of Estelle & Thild.

“After thinking a lot about it and talking to various experts, I started a company with a holistic approach to environmentally sound products and packaging. It was also important to show that the products delivered on their promises and we therefore chose to certify them under an international environmental standard.”

Chemicals NOT used by Estelle & Thild include as parabens, mineral oils, lauryl sulphates, perfume, propylene glycols, synthetic emulsifiers and dyes.

“The organic ingredients are grown without using pesticides, and our products include Aloe Vera, which is considered one of nature’s most effective agents against skin irritation and is an excellent moisturizer,” says Rönnberg.

“Other ingredients come from plants such as oranges, avocados, cornflower, blueberries, figs, jojoba, chestnuts, almonds and more. Of course, we must protect the products against molds and microorganisms, but we only use antioxidants and preserving agents that are approved for organic products and at the lowest concentration possible,” says Rönnberg.

Ecocert Certification

The French certification body Ecocert Group was the first in the world to develop standards to provide certification of natural and organic cosmetics. Ecocert is the market leader in the control of organic products in Europe and the USA. The standards for skin care products were developed in 2003 and specify requirements relating to:

• Some chemicals should not be included in skin care products.
• Packaging should be biodegradable or recyclable.
• The percentage of the product that comes from natural products.

The certification includes examination of the contents and packaging of the product, its production and the texts that describe the product.

Estelle & Thild’s products meet the “Ecocert Organic” requirements. That means that at least 95 percent of the plant ingredients must be organically grown and that at least 95 percent of the total content must be of natural origin.

Finally, at least 10 percent of the skin care products (excluding water content) must contain organic ingredients. Organic farming means that chemical pesticides may not be used.

“Because of the high quality of our products in combination with the relatively expensive methods of production and certification costs, our products are not the cheapest on the market,” says company founder Rönnberg.

“We are confident that customers appreciate our commitment, our mild products and our design concept. It has become increasingly common for large department stores and pharmacy chains to contact us wanting our organic skincare products in their range.”

This article was published in March 2012

“It is the weight of the glass which sets the limit in combination with the type of hardware you are using in the window,” says Magnus Fransson, President of Kronfönster AB in Växjö, Sweden. “We are now pushing the boundaries and are introducing a window with four glass frames intended to be used in passive or ultra energy efficient houses.”

“We can produce a four-paned window in a 110 × 140 cm size, but if it is a fixed structure, it can be made larger. The advantages of a four-paned window are that the costs of heating decrease. This is of great interest to passive houses but the window can also be used in environments where you need extra sound insulation.”

Less heat loss through windows

Many older houses have double paned windows. The inner window, due to its lower temperature together with a human’s body temperature, gives a sense of draft. With better insulation, the window’s temperature is raised thereby creating more comfort. One way to achieve this is to add an extra panel of glass. In the 80s, adding an extra pane of glass to reduce energy usage was revolutionary.

The next stage of development in the 90s was to introduce windows with inert gases like argon between the panes. Since then, building technologies have advanced even further. In 2009, Kronfönster launched its ‘Passive House’ concept, a four-paned window, that is even more energy efficient.

The frame of the four-paned ‘Passive House Ultimate’ window is made of steel, PVC and composite materials. It is maintenance free and does not need to be painted. With four panes as standard, and seals, this window offers low heat loss and insulates from outside noise as well.

The next step

Is a window with five panes the next step, or is it the glass itself that will change?

“Five panes is technically possible but the challenge is to keep the standard 90mm window thickness. If you are going to make room for five panes of glass, you still need to ensure a 16-18 mm air cushion between the panes, which is a technical challenge,” says Fransson.

“We use a new generation of low emission glass. This means there is a thin metallic surface on the outside pane that works as a filter. This means that shortwave radiation or light can enter but long wave radiation in the form of heat cannot get out. Krypton gas in between the panes increases the insulation even more. The U value in a four paned window is 0.6, which is a Swedish insulation record.”

‘Material developments are moving fast and who knows what properties future windows will have?” concludes Fransson.

This article was published in March 2012

The cables used in such applications must be strong, durable and withstand pressures in terms of high temperatures and radioactivity. They should also have good environmental and health properties.

Important components that contribute to a cable’s proper functionality include plastic and rubber that contain halogens like chlorine, bromine and fluorine.

But such polymers give off toxic fumes when incinerated and certain flame retardants are questionable from a health and environmental standpoint, hence the interest in other solutions.

With a technique called ‘cross-linking,’ cables can be strong, durable and thin, yet produce a different kind of flame.

Swedish company Irradose has specialized in the production of high performance cables that operate in harsh environments. Their plant in Tierp, Sweden is unique in Scandinavia.

Cross-linked plastics

The technology behind cross-linking means that the plastic’s natural molecular chains are destroyed. The plastic strives to recreate the molecular chains and in the process creates new structures in the material to make it stronger.

The cross-linked material better withstands high temperatures while making it more resistant to harsh chemicals and mechanical stress. From a lifecycle perspective, this new material uses less material in the cables, making them thinner, and more easily manufactured. This creates both environmental and safety benefits.

“The cross-linking can be done in several ways, either with chemicals or by blasting the cables with electrons,” says Hans Forsgren, CEO of Irradose. “The radiation technique is reminiscent of an X-ray facility. The cables pass through two accelerators generating electron radiation, and new bonds are formed between the molecular chains in the plastic. We can irradiate several hundred meters of wire per minute.”

The facility is built like a bunker with 1.3-meter walls and ceilings. Several accelerators allow more efficient and better quality radiation. The radiation is one million volts, but consumes only 100 kilowatt per hour.

“The cross-linked products are easier to work with because they weigh 30 percent less than the old cables to be replaced. Electron radiation also means that we can use cheaper materials in parts of the production and get higher performance,” says Forsgren.

“Our method to handle polymers has less of a climate effect than other methods that use considerable more energy.”

With the Irradose method, irradiated cable is wrapped around dual electron guns. These electrons smash polyethylene chains. In the process, they release hydrogen. When the molecules are reunited cross-connections are created between the molecular chains. The cable sheath is now cross-linked and has also gotten stronger.

Many Application Areas

The use of high-performance cable products is wide and it’s not limited to nuclear power and defense markets. Cross-linked products are used in the transport sector and in the oil industry in offshore operations where standards are extra tough. Another interesting application is in the wiring of photovoltaic systems. This means that the cables have to be very durable and withstand at least 25 years of use in a demanding environment.

Fewer transports

Irradose was started in 2009, and since then it has become much easier for its customer Habia to utilize the electron irradiation technology.

Irradose’s and Habia’s factory in Söderfors are only 20 kilometers apart and daily transports occur between the plants.

Before, cables were sent to Germany by truck to be irradiated and the carbon dioxide emissions from the transportation amounted to about 14 tons per month.

Now the Tierp to Söderfors transport produces less than one ton of emissions.

This article was published in March 2012

In the nano world, the proportions are a millionth of a millimeter to a thousandth of a millimeter. The aim of nanotechnology is to study and manipulate matter on a molecular scale.

There are many practical applications of nanotechnology, such as electronics, coatings and cosmetics.

The forest industry is increasingly becoming interested in nanotechnology.

With nanotechnology, cellulose material can be durable, lightweight, environmentally friendly and cheap. Such high-performance materials can be used in advanced electronics like cars, aircrafts and medical products.

The technique is based on wood fibers broken down into their smallest components and then reassembled into new materials.

At the Royal Institute of Technology (KTH) in Stockholm, Professor Lars Berglund is leading research into nano-cellulose technology. Berglund is also director of the Wallenberg Wood Science Centre (WWSC) at KTH and Chalmers, Gothenburg, a new research center aimed to develop alternative uses of forest resources.

Disassembling cellulose fibers

“Nano-cellulose consists of fibrils that are about 10 nanometers thick. If fibrils are 100 times longer than they are thick, they have many interesting properties that may be utilized in various applications,” says Berglund.

“Bio-composites, reinforcing materials, and viscosity agents in the food industry are examples of this. Nano-cellulose is also biodegradable and more moisture resistant than the normal cell walls of wood.”

“Pressed together, the cellulose can form transparent films for use as barrier materials in packaging. Fibrils can also be mixed into the pulp for paper production and make the paper stronger by tying paper fibers together.”

How do you get the fibrils?

The cellulose fibers, one of the major components of wood, are made up of individual micro-fibrils. By opening the fiber cell wall the fibrils become available.

This is done through mechanical homogenization in combination with mechanical and chemical pre-treatment. Overall, it is a very energy intensive process.

The non-profit foundation Innventia has long worked on developing methods for exploiting nano-cellulose. It recently presented the world’s first pilot plant for production of nano-cellulose in higher volumes.

“The focus of our work was to develop an energy efficient process. We have obtained an energy savings of up to 98 percent,” says Mikael Ankerfors, who leads Innventia’s research into nano-cellulose materials.

“Reducing energy consumption is made possible through various pre-processing steps, which weakens the fibers so that they can more easily be ground down to the fibrils. On a laboratory scale, we could previously produce one kilogram of nano-cellulose a day, but in the new pilot plant we can do a ton per day.”

Magnetic nano-paper

In 2011, scientists at the WWSC presented their findings about magnetic nano-particles in super strong nano paper. The new nano paper is extremely lightweight, strong and flexible and can be used to prevent counterfeiting and to filter out metal particles.

“Magnetic nano-paper is easy to produce and has unique characteristics, but also shows the product’s potential in R&D for the forest industry,” says Professor Berglund at KTH. “Besides using magnetic nano-paper to prevent document fraud, other applications include implants for the human body, and in small motors and sensors. Compared with metallic magnetic materials, strong magnetic nano-paper is much more malleable. The new preparation method can also be used for other forest products.”

Nano-paper consists of very strong and flexible nano-fibrils from cellulose. The first thing that is produced is an extremely porous “airgel,” which contains only two percent cellulose fibrils. The remainder of the gel is made up of pores. Dipping the porous gel in a salt solution creates the magnetic particles. These are about 40 nanometers high and consist of a mixture of cobalt and iron oxide and bind very strongly to the cellulose.

The properties of the finished product can be controlled in several ways, for example by affecting the amount of magnetic particles formed. Further, the porous paper can be compressed so as to provide the required strength and flexibility.

This article was published in March 2012

Water is essential for all life on earth, but the availability and quality of water varies considerably in different parts of the world. Even in areas with access to good quality water, there may be situations that upset the lives of the population.

One example is the outbreak in 2010 of the microorganism Cryptosporidium in the drinking water in Östersund, Sweden. Approximately 27,000 people fell ill during the parasite’s ravages, which meant that more than half of the city’s inhabitants became sick with diarrhea. The outbreak is described as one of the largest ever in Europe.

When a large number of people fall ill in a limited geographical area, it is natural to suspect that drinking water is the source of the infection. However, it is relatively rare for the disease-causing organism to be detected in water samples. But in Östersund, the Cryptosporidium parasite was found in both lake water (water that is used for drinking after treatment) and in the outgoing sewage water.

The above case was widely reported in the media. As a result, many wondered if there are adequate water treatment methods to prevent similar outbreaks. Such methods are available and facilities for the treatment of sewage and drinking water have built up a barrier system to purify water from various types of pollution. The barriers are often a combination of mechanical, chemical and biological methods. One such barrier is the treatment of water with ozone gas. Ozone has proven to be effective against Cryptosporidium, but has many other applications for the purification of water.

Primo Zone is one such company that has developed an energy efficient method of generating ozone gas.

Ozone degrades rapidly

Ozone is formed from oxygen zapped at high voltages. The gas is unstable and therefore quickly reverts to oxygen. If ozone is to be used for water treatment it should be produced on site using an ozone generator.

“Traditionally, ozone generators were maintenance intensive and required a lot of energy,” says Anders Schening, CEO of Primo Zone.

“Our ozone generators are efficient. Our solution uses 70 percent less energy and less oxygen compared to conventional generators, which is a significant technological leap. We believe that the use of ozone has environmental advantages over the traditional chlorination of water. Chlorination produces dangerous by-products that pollute.”

Cold plasma method

Ozone can be generated using several industrial methods including corona discharge, cold plasma and UV light. Since ozone is a highly reactive substance, generators must be constructed with resilient materials such as stainless steel, aluminum or glass.

Producing ozone with the corona discharge method is very common in industrial applications and involves channeling air into a pipe with a strong electric field to create plasma. This method generates ozone at concentrations of between six and 12 percent.

Primo Zone’s generators use cold plasma technology. Cold plasma is a gas that is partially ionized and that can be created at room temperature or lower temperatures. The process is based on pure oxygen being ionized between two electrodes separated by an insulating barrier (dielectric barrier). This method consumes less energy than other methods and can produce higher concentrations of ozone, 14 to 20 percent concentrations.

The many uses of ozone

“It is a great advantage that our ozone generators are small, energy efficient and can generate high concentrations of ozone,” says Schening. “The water treatment market is big and there are numerous applications that are of interest to us. In addition to the purification of drinking water there is the purification of process water in manufacturing, and the re-circulating of water in fish farms.”

Some other examples of Primo Zone’s ozone generators include:

Disinfection of drinking water in Finland

Oulun Vesi WTP in Hintta, Finland replaced their old ozone generators with a Primo Zone system, including two low-energy Primo Zone ® GM12 ozone generators. Ozone is used for the disinfection of drinking water and to remove tastes and smells. The system purifies and distributes about 800 cubic meters of water per hour from a nearby river to Hintta residents.

Pilot plant for the control of bacteria in Helsingborg

The Öresundsverket in Helsingborg is one of the largest sewage treatment plants in Sweden that uses biological phosphorus removal. This means that no chemicals are added to purify water from phosphorus.

One problem is that during the late winter and spring a special type of bacteria emerges which causes major problems in water treatment processes. One way to control them is to treat the wastewater with ozone.

In this project, Primo Zone could examine and verify the ozone dose to achieve optimal results. This pilot project is part of a joint study between Lund University, NSVA (Northwest Skåne’s Water and Wastewater AB) and VA-South.

The article was published in January 2012

On the slopes between Riksgränsen, Sweden and Narvik, Norway huge energy savings are possible.

Starting and stopping a train pulling 8,000 tons of iron ore puts a lot of pressure on brake pads, wheels and rails. The potential for environmental and capacity gains are great if one can optimize the train’s movements and drive it in an ‘eco-friendly’ fashion.

Swedish company Transrail has developed the CATO (Computer-Aided Train Operation) system to streamline train movements. CATO improves punctuality, reduces energy consumption, increases line capacity, improves work conditions for the driver, and reduces wear and tear.

The idea of CATO is to exploit time slots when trains wait at signals or pass stations. The system is currently being installed by LKAB on the Malmbanan, in northern Sweden, and by the Arlanda Express, the train service to and from Stockholm’s Arlanda airport.

Computers analyze and control train speed

“Optimal operation of traffic on an entire line with individual trains can not be achieved with conventional signaling systems,” says Per Leander, President of Transrail Sweden AB. “The driver needs to know when the train will arrive at the next station or signal, and how the train should be run in order to arrive at the right time. The timing and speed are affected by many factors and to choose the optimal speed profile requires feeding continuous information to the driver. That is what CATO does.”

CATO consists of a computer and a display that is installed in the train’s pilothouse. It is connected to the Transport Administration’s train control systems and monitors current traffic situations like delays, speeds of each train and locations taking into account meetings with other trains and timetables.

The central computer calculates the train travel times in order to be able to run without stopping or unnecessary braking and arrive on time. The current timetable is transmitted to trains via GSM-R digital radio.

This information is then calculated into a velocity profile displayed onboard that allows trains to meet the traffic management plan, and to drive as energy efficiently as possible.

“We are convinced that computer-aided control of the train will become increasingly common in the future, even though the system may seem complex today,” says Leander. “CATO contributes to optimal train running and reduces driver stress. The goal of our project was not to develop a finished product but that is what it has become.”

The eco-driving of ore trains

Mining company LKAB is particularly interested in CATO. LKAB has purchased a CATO-license and installation in all IORE locomotives is underway.

The ambition is to achieve maximum utilization of the ore line between Riksgränsen and Luleå and to become 20 percent more energy efficient.

Ore train locomotives (IORE) are already equipped with technology for energy recovery: when the train engine brakes, the motors turn into generators. This is particularly valuable on the slopes between Riksgränsen, Sweden and Narvik, Norway.

The energy gains between Malmberget and Luleå are also big. With CATO, ore trains run smoother, energy use is minimized, while the wear on the brakes, wheels and rails is reduced.

The system also increases punctuality thereby improving capacity on the ore line.

High-speed trains with eco-driving

The Arlanda Express bought CATO as part of the company’s environmental and punctuality efforts.

“CATO orders from LKAB and Arlanda Express mean that this new technology is here to stay. We have discussions with other railway companies,” says Leander. “CATO provides the opportunity for substantial improvements in rail service.”

The article was published in January 2012

A dress made of soy fiber

Trade in textiles is highly international. Many different industries are involved in the cultivation of natural fibers – or the production of man-made fibers. Cotton farming, sheep farming, forestry, petrochemical and transportation are all industries that affect the textile trade.

Environmental impacts occur throughout the production chain and most attention is paid to water consumption, chemical use, and waste and greenhouse gas emissions. In recent years, consumers and various NGOs have expressed interest in the social conditions of textile production.

In many manufacturing processes chemicals are involved and are often added to the product in order to achieve different functions. For example: antibacterial treatment of sports apparel, flame treatment of upholstery fabrics, the impregnation of all-weather clothes, and the addition of biocides to prevent mold and insects are added for transport and storage.

The textile industry has taken several initiatives to reduce its environmental impact and improve social conditions. One such example is the Better Cotton Initiative, which H & M, IKEA, GAP, Adidas and several other companies have joined forces with to transform conventional cotton production. And then there are lists of hazardous chemical substances to be avoided at all stages in the textile industry.

Finally, there are several different eco-labels for textiles such as Oeko-Tex, Nordic Ecolabelling, the Swan, the EU Ecolabel and Swedish Society Good Environmental Choice.

Several Swedish textile designers and researchers have tackled the question of sustainability from the point of view of starting with smart and environmentally friendly textiles. New fibers and smart textiles provide both environmental benefits and materials with new functions.

Eco-materials development

Textiles often consist of several types of materials, in different combinations. Natural fibers consist of cotton, flax, hemp, wool, coir, or silk and synthetic fibers may comprise polyester, polyamide, polyurethane and cellulose. The textile industry is working to green-ify both fiber types.

“Environmentally friendly fashion does not necessarily mean a return to traditional natural materials, such as linen, cotton and hemp,” says designer and manager Camilla Norrback at Camilla Norrback AB.

“In my role as a designer, I have explored new materials and garments made of bamboo, recycled PET bottles and soy fibers. Work on eco-friendly collections began ten years ago and in 2005 I created the term “Ecoluxuary.” Our ambition is to combine high quality, design and artistic freedom with sustainable development.”

“We recently began using soy fiber, a soft and comfortable textile material with good heat preservation capabilities. Soy fiber is referred to as a vegetable cashmere and is a byproduct from the production of tofu and soy milk.”

Another example of new materials and production methods in the fashion industry is Tencel, a soft and lightweight fabric with many uses. Tencel, which is the most common brand of the Lyocell fiber, is made from cellulose. Production takes place, however, in a closed system in which chemicals can be reused many times. The result is lower chemical consumption and reduced greenhouse gas emissions compared to other cellulose materials. Tencelt fibers are also biodegradable.

Smart Textiles

At the School of Textiles in Borås, Linda Worbin conducts research on smart textiles. Smart textiles are materials that can sense and react to their surroundings. Smart textiles include clothes that remain cool when it is hot; or clothes that can actively control the sound absorption in a room; or curtains that light up at night.

“Initially I investigate materials from an aesthetic and functional perspective, but I see great potential in contributing to sustainable development,” says Worbin.

“If the fabrics can change their pattern, shape or structure, we get a variety of expressions from the same material. From an environmental perspective, this is of great importance as most of us feel the need to replace and change clothes and other textiles often. Smart textiles can have multiple lives, which is advantageous in view of resource use and waste issues.”

Mistra Future Fashion

Mistra, the Foundation for Strategic Environmental Research, is investing SEK 40 million over four years in a research program called Mistra Future Fashion.

“Let fashion lead society towards a more sustainable future,” says Britt-Inger Andersson, responsible for idea development at Mistra. “We want to lift up the fashion industry and show its different dimensions. Fashion is a business that is facing major global and environmental challenges. But there is a lot of creativity and innovation in the field.”

The Mistra research program includes the following focus areas:

• Changing markets and business models
• Design Processes and innovative materials
• Sustainable consumption and consumer behavior
• Policy instruments

“Part of Future Fashion is all about new fibers, and there is a lot happening in this area in terms of both traditional fibers and new materials,” says Andersson.

“As consumers, we will surely want to use cotton in the future, but it must be produced in a more sustainable way. The water waste and use of chemicals in cotton cultivation is currently unacceptable. We should ensure the better use of resources and recycle the fibers.”

“Today’s new technologies, innovative materials and international initiatives are promising. Furthermore, young people’s interest in fashion can create high potential for change. The fashion industry is global, and new approaches can quickly make an impact,” says Andersson.

The article was published in January 2012

Storing energy in ponds is nothing new, but renewable energy sources demand more regulating power.

Wind power and other renewable energy sources will replace current European coal-fired plants. The new energy sources may be green, but they also contribute to a more volatile energy production. Wind and solar power are not as easy to regulate as coal and nuclear power plants. This means that effective regulation systems are becoming increasingly important.

As demand for electricity does not correlate with production – people want their lamps lit even when there is no wind or when it is cloudy – producing an energy surplus is the name of the game when the conditions are good. This excess must then be stored and used when production possibilities are diminished.

Pump power is part of the solution

Pump power is a technique used to store energy, where the energy surplus is used to pump water from a low-lying reservoir to one at a higher altitude. This excess energy is thus converted into potential energy. When production cannot keep up with demand, when the wind dies down for example, the water can be directed to turbines that generate power in a classic hydroelectric setup.

In addition to regulating production from renewable energy sources, pump power allows nuclear power plants to continue producing electricity at their most efficient level.

Vattenfall’s German pump power plants

Many companies operate pump power plants. Vattenfall has, eight in Germany, all of which are controlled centrally by a plant in Goldisthal.

The upper dam in Goldisthal has a circumference of about three and a half kilometers, and holds twelve million cubic meters of water. That’s enough to produce electricity at maximum capacity for eight hours. The water flows from the upper to the lower pond through two tubes that are 800 meters long and has a vertical drop of 302 meters, passing through turbines that can generate 1,060 megawatts (MW).

In total, the eight sites that are controlled by Goldisthal generate 2810 MW, with an efficiency of up to 80 percent. The high efficiency combined with the fact that the operating mode of the turbines can be changed between 100 and 200 times a day allows the plants to store energy in the most efficient way.

The world’s largest pumped storage power plant is in Virginia, USA. The Bath Country Pumped Storage Station has a capacity of over 3000 MW. The soil and rock mass that was moved to build the plant would create a mountain over 300 meters high. And the concrete that was used could make a 320 kilometer-long highway. The height difference between the two large dams is 385 meters, and the water can flow at a rate of 852 cubic meters per second. This allows the water level in the upper pond to vary by as much as 32 meters.

Future developments

There are proposals to build pump power facilities completely run on renewable energy. In this way, the plant generates the energy needed to pump the water between the dams. Such plants therefore run totally on renewable energy stocks.

There are other proposals to for example generate electricity with ocean tides by allowing water to flow into a pond when it is high tide, and out at low tide thereby generating electricity.

Is there a future for energy-guzzling plants?

Despite continuous technological development, a pump power plant is a net consumer of energy. Because of friction and energy losses more energy is used to pump the water uphill than can be extracted when discharged down through the turbines. In an environment where energy efficiency is the height of fashion, it may seem odd that the interest in pumping power remains high.

Pump power’s advantage however, is that it represents a much needed, balancing complement to the volatile renewable energy production that is steadily increasing. The need for regulating power will continue to increase at the same rate as the renewable energy sources are being rolled out. Therefore, the interest in the easy-regulated pump power system will continue to increase.

The article was published in January 2012

Dellencat, a modern catamaran

Sweden is a major innovator when it comes to developing technology to find new uses for wood. Recent research and development focuses for example on construction products, bio fuels, food, chemicals, products for surface treatment, bio-composites, clothing, nanotechnology and much more.

The competence Center EcoBuild (see box below), at the SP Technical Research Institute, has as a mandate to develop bio- and forest-based raw materials into innovative, eco-efficient and durable wood-based products.

EcoBuild’s ambition is to cooperate with industry and universities, and at the moment is cooperating with more than 30 large and small companies.

One of the smallest is boat builder Dellencat.

To build wooden boats is hardly new, but Dellencat stands for innovation and environmental compatibility in the design of wooden catamarans.

Modified wood as construction material

A key component to Dellencat’s success has been the use of ‘modified wood.’

“Wood impregnated with conventional wood preservatives has never been popular among boat builders,” says Jan-Åke Malmqvist, one of the founders of Dellencat.

“But modified wood can be the starting point for a new approach in the boat building industry. Our goal is to build environmentally friendly boats in terms of material selection, surface protection (coating), and propulsion. One example is that solar cells on the sails supplement electric motors for propulsion.”

Weight, strength and stability are of utmost importance in construction materials for boats. Additionally, the materials must be flexible and resistant to degradation by rot, shipworms and UV light.

“With modified timber, we see no obstacles to meeting those requirements,” says Malmqvist. “In the catamaran, we use modified wood in a laminate with fiberglass and epoxy resins. In development, we also have marine optimized fittings made of recycled PET plastics that yield an even higher weight to power ratio.”

The choice of materials was made together with EcoBuild. The following methods for the modification of wood is recommended:

• Heat treatment (thermal modification). Heat-treated wood is heated to high temperatures (180-240 ° C) in an oxygen-free environment. The result is a dimensionally stable material with high resistance to rot.
• Furfurylation. In this case, treated wood with an aqueous solution of Furfury alcohol and catalysts is cured in a subsequent drying step. As an example, this process gives Swedish maple the appearance and characteristics of tropical woods like teak and mahogany. This process provides dimensional stability, strength, hardness, and resistance to rot and insect pests.
• Acetylation. With this process, the wood is modified through pressure treatment with acetic anhydride, which react with the wood at elevated temperatures and residual chemicals (mainly acetic acid) is driven off by drying processes. The method gives results similar to furfurylation but does not affect the wood’s color.

Different companies working with EcoBuild manufacture this modified wood for the catamaran. The competence center also provides the opportunity to test material properties. The center has a unique pilot plant for wood modification, which among other processes, includes innovative microwave technology, to streamline the acetylation process to make it cheaper and better.

The catamaran’s eco profile

Dellencat’s first catamaran under construction is 11 meters long, 6 meters wide, weighs 3.5 tons and has a sail area of 55 square meters. Despite its large dimensions, its draft is only 0.9 meters.

The catamaran has four staterooms, a lounge, a kitchen, one bathroom, a large sun deck and can accommodate up to 12 people.

Hull platting consists of a 12 mm-thick strip of knot-free pine from Hälsingland, not a modified wood material.

In this case, it is first and foremost about learning the special hull construction techniques with strip-plank. The plan is to implement and supplement the concept of modified wood as the structural hull material. All the wood is sealed with epoxy and then reinforced construction with epoxy-impregnated fiberglass. This wood material yields hull strength, insulation and buoyancy, and the epoxy is a very dense and strong material.

Boat builder Richard Woods designed the Flic 37 boat model. It has already been built in about 25 copies at other shipyards in the world, but with the new catamaran from Dellencat it has the thoughtful environmental profile. Another feature is that the boat hull is continuously monitored using 16 measurement points with moisture sensors that are placed in the hull below the waterline. The sensors alert to moisture or water entering the hull.

What are the advantages of a catamaran compared to a traditional single-hulled boat? A catamaran’s advantage with buoyancy on two hulls puts the superstructure between them. The large distance between the hulls in relation to the length makes the construction very stable. One simply has more square meters of usable space at a lower cost than the equivalent single-hulled boat. A catamaran also has a very shallow draft and can navigate shallow bays. A catamaran is usually faster and easier to sail than a single-hulled boat with the same sail area and weight.

EcoBuild Showcase

“Dellencat is a showcase for EcoBuild. When completed, this will be the first boat built with modified wood and become a symbol for many of the projects aimed towards eco-efficient use of forest resources, “says Jan-Åke Malmqvist.

“We are part of Project 9 within EcoBuild and the vision is to develop and build catamarans with hulls made of thin planks of modified wood, bio-based acrylic-based binders and strong cellulose fabrics. One possibility is to include panels and moldings from modified wood fibers and bio-based resins. Another possibility is to use fiber reinforced thermoplastic elastomer (TPE) reinforced with nano-cellulose, “says Malmqvist.

The article was published in January 2012