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On demand - Sustainable manufacturing of Critical Spare Parts

On demand

The basic industry is important to Sweden's economy and is dependent on spare parts in order to function. Supply chains are often global, which has proven vulnerable when events in the outside world have an impact. The project aims to contribute to a resilient and competitive industry, by reducing the risk of disruptions in supply chains.

Project manager
Active
Additive manufacturing Production and manufacturing
Region Dalarna Region Gävleborg Region Värmland
Four years
Division: Division Digital Systems and Societal Transformation

A greater need to adapt the manufacturing industry based on adjustment needs and negative changes in our surrounding world is the background to the initiative. The project On demand - local and sustainable manufacturing of critical spare parts and components in 2033 will help companies become more resistant to external disturbances and at the same time create new business for local suppliers.

A test arena in a real environment

The initial work is based on creating a test arena where local companies and supply chains can be developed in a real environment, a so-called system demonstrator. The goal is for spare parts to be produced on demand, i.e. based on the customer's needs and delivered locally, quickly and with significantly less climate impact than today. Among other things, the initiative will explore more reliable solutions with 3D printing, where digital files are sent instead of physical components.

Participants will build a market and capacity for on-demand manufacturing, while developing and influencing technology, business models, infrastructure, policy and culture. The work has a long-term vision of ten years, but begins as a four-year project.

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Ola Wallberg

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Project end date: Additive manufacturing Sekundär områdes navigation:
Circular transition
Innovation management
Logistics

CircHelmet – Circular business opportunities for ski helmets

CircHelmet
CircHelmet

What are the opportunities to extend the life of ski helmets and contribute to increased circular flows? This project explored circular opportunities and their economic and environmental benefits for helmets used for rental.

Project manager
Completed
Circular transition Design Life cycle analysis Material transition
Region Jämtland Härjedalen Västra Götaland Region
52 months
Division: Do not use - Division Built Environment

A large proportion of the ski helmets sold in Sweden are used by ski resorts around the country and rented out as part of a complete set of ski equipment to the resorts' guests. When the helmets are considered worn out, they are sent for incineration. However, the sports industry, and especially rental-based businesses, are well placed to capitalise on the opportunities of circular business models as they have smooth, defined and easily accessible product flows. By taking a holistic approach to business models, product design, digital condition assessments, material circulation and rental processes, this project investigated the possibilities for more circular flows of ski helmets. 

The first part of the project focused on investigating opportunities to support circular flows by determining the condition of used helmets through digital condition assessments or by recycling helmets. The second part of the project examined the current helmet rental at Skistar's facilities and explored opportunities to increase the lifespan and utilisation rate of helmets and contribute to increased circular flows. A test to determine the impact of a ski helmet designed to facilitate maintenance and repair was conducted together with helmet supplier Disentis. In addition, the project also explored how a concept helmet can be designed to further increase longevity and contribute to circular flows through changing business models and rental processes. 

The project has contributed to increased knowledge of the economic and environmental benefits of different circular opportunities, and provided examples of how helmets can be designed for extended lifetime, circular flows and circular business models.

9. Industry, innovation and infrastructure
12. Responsible consumption and production
Project end date: Circular transition Sekundär områdes navigation:
Plastics
Production and manufacturing
Service innovation

Wet spinning

Name of service (page headline, shown in promos – maximum of 70 characters incl. spaces): Wet spinning Lead (include SEO-words and the main benefits for your target groups. Stick to one paragraph, maximum 2-3 sentences):

Wet spinning is a manufacturing process used to produce fibers from polymer solutions by extruding them into a coagulation bath, where the polymer solidifies into fibers. This method is called "wet" spinning because the process involves the use of a liquid coagulation bath.

Purpose/Benefit:

At the Fiber Development unit at RISE, we offer comprehensive research and development services for wet spinning of man-made fibers. We perform trials to develop and optimize wet spinning processes or to produce man-made fibers with certain properties for their testing. The trials can include exploring new polymer solvents, raw materials, and production techniques. By systematically testing and optimizing various parameters such as polymer concentration, wet spinning parameters, coagulation bath compositions etc., we fine-tune fiber properties to suit specific applications.

Method (what/which methods are used to perform the service):

With our expertise and know-how, we conduct trials at bench- or laboratory-scale, enabling feasibility studies for wet spinning process development and providing data for larger scale trials. Using our pilot-scale equipment and expertise in scaling up wet spinning technologies, we optimize the production processes and deliver larger quantities of fibers and yarns for testing and evaluation.

Bench-scale wet spinning

  • Two lines for wet spinning.
  • Flexible equipment with possibilities of inline coagulation, stretching and washing in sequential baths, spin finish application, drying and winding of filament yarn.
  • A library of spinnerets with different number of holes, hole diameters, L/D etc.
  • Dope volumes: from 5 mL to ca. 1 L.
  • Capacity: 1–100 g dry fiber per day.

Pilot-scale wet spinning

  • Two lines for continuous wet spinning.
  • A library of spinnerets and customized spinning head.
  • Counter-current washing.
  • Inline coagulation, stretching, washing, spin finish application, drying and winding options.
  • Spinning of both filament and staple fiber yarns.
  • Dope volumes: from 1 L.
  • Capacity: up to approximately 50 kg dry fiber per day.
Delivery (what does the client get after performed service – e.g. a report, certificate etc.):

Our goal is to deliver tailor-made wet spinning solutions that meet the unique requirements of each customer. Deliverables may include optimized process parameters summarized in a report or actually produced fibers with specific properties.

Area:
Material transition
Textile
Contact person (Enter one name per field. Activated personal contact pages will appear automatically): Axel Martinsson, Forskare
Wet spinning
Field measurements: No Price type: 1 Division: Division Materials and Industry Preparation: No preparation required Certification and marking: Not applicable Type of service: Testing / Analysis / Evaluation Instrument: Not applicable General area: Not applicable Delivery level: Not applicable
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Examples of our wet spinning equipment

 


Example of bench-scale wet spinning

Example of pilot-scale wet spinning

Our research topics

We focus on wet spinning of fibers from a variety of raw materials. The aim is to use virgin raw materials or to valorize polymers from textiles for recycling purposes. We work with such polymers as:

  • Polysaccharides, such as cellulose and its derivatives, alginate, chitin and chitosan.
  • Fibrillar proteins derived from wool and silk (keratin and fibroin).
  • Non-fibrillar proteins derived from plants and milk (pea protein isolate, soy protein isolate, zein, casein).

Viscose

Wet spinning technique is largely used for the production of viscose (rayon) fibers. In this method, cellulose dissolution is performed through xanthation with further extrusion through spinnerets into a coagulation bath where cellulose regenerates and solidifies into fibers. These fibers undergo washing, stretching and drying, and are largely used in textile application. We have a viscose pilot plant, where wet spinning of regenerated cellulose fibers can be performed at two different scales.

Novel wet spinning technologies

We work with the development of wet spinning processes for a range of bio-based materials using novel solvent systems, such as Ionic liquids, cold alkali. We have also expertise in air-gap spinning, for example from ionic liquids or NMMO.

Selected publications

Selected patents

  • Stigsson, L., Hagström, B., Köhnke, T., Hedlund, A., Bialik, M. (2018). Alkali recycle in cellulose spinning process (US10138578B2).
  • Hedlund, A., Köhnke, T. (2021). Process for spinning dissolved cellulose (US11208739B2).
  • Olsson, C., Hagström, B., Köhnke T. (2023). System for the production of a spinning dope composition (US11753482B2).

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Biobased materials Sekundär områdes navigation:
Circular transition
Production and manufacturing
Biobased materials
Tjänstetyp tagg: Produkttillverkning

Development of dopes for wet and air-gap spinning

Name of service (page headline, shown in promos – maximum of 70 characters incl. spaces): Development of dopes for wet and air-gap spinning Lead (include SEO-words and the main benefits for your target groups. Stick to one paragraph, maximum 2-3 sentences):

An essential step in solution spinning is the development of spinning dopes (polymer solutions) with optimal properties. Precise control over dope properties is essential for ensuring proper extrusion and coagulation, thereby laying the foundation for a well-functioning solution spinning process for man-made fiber production.

Purpose/Benefit:

Spinning dope is a homogeneous solution made from a polymer dissolved in a solvent. The polymer can originate not only from virgin raw materials but also from polymer fractions for example to be extracted during textile recycling. The composition of spinning dope, molecular weight of the polymer, polymer concentration, dope temperature etc. can be tuned to allow polymer dissolution while limiting its degradation and providing reasonable dope properties, such as viscosity and storage stability. Getting right dope properties is crucial for enabling correct extrusion of filaments through spinneret capillaries into the coagulation bath, especially when multifilament spinning is required. There are also great opportunities to add functionality to the wet-spun fibers through targeted dope formulations.

Method (what/which methods are used to perform the service):

We develop spinning dopes suitable for multifilament solution spinning. Our capabilities include:

  • Equipment for polymer dissolution in different scales, including reactors, kneaders and high-shear mixers.
  • Filtration in various scales.
  • Deaeration.

We characterize dopes using methods such as:

  • Filterability.
  • Rheology.
  • Microscopy.
  • Particle analysis.
  • Polymer dissolution state and solvent-polymer interactions using SAXS/ WAXS.
Delivery (what does the client get after performed service – e.g. a report, certificate etc.):

Please contact us for more information for the delivery time and price.

Area: Material transition Contact person (Enter one name per field. Activated personal contact pages will appear automatically): Axel Martinsson, Forskare
Development of dopes (polymer solutions)
Field measurements: No Price type: 1 Division: Division Materials and Industry Preparation: No preparation required Certification and marking: Not applicable Type of service: Testing / Analysis / Evaluation Instrument: Not applicable General area: Not applicable Delivery level: Not applicable
axel.martinsson@ri.se,tobias.kohnke@ri.se
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Textiles Sekundär områdes navigation:
Circular transition
Production and manufacturing
Chemical products and processes
Tjänstetyp tagg: Konsultuppdrag

Care - Circular flows of plastic & textiles in healthcare

Care
Recycled products

How can disposable products in healthcare be collected and recycled safely and sustainably? This project conducted practical experiments that formed the basis for proposals on circular business models.

Koordinator
Completed
Material transition Medical devices Plastics Textile
Region Skåne Västra Götaland Region
18 månader
1 591 000 SEK
Division: Division Materials and Industry

The healthcare sector is a major consumer of single-use plastic products, a high-quality stream that currently only goes to energy recovery. The World Health Organization (WHO) estimates that about 85% of the total waste stream from healthcare is ‘non-hazardous’ and therefore potentially suitable for recycling.

The project aimed to identify business models and product designs with the potential to promote separate collection and recycling of plastic and textiles from the healthcare sector.

Practical collection and recycling trials of polypropylene (PP) were carried out. The collection trial took place in selected departments at Lund University Hospital in Region Skåne. By conducting larger collection trials, the project was able to evaluate actual volumes of risk-free plastic as well as quality assessments of the collected and recycled material, and gather information on the actual costs of separate handling of plastic intended for recycling.

In addition to the collection trial, recycling trials of the collected plastic were conducted, including pre-washing. The recycled plastic was evaluated for which products it could be used for, and a container for sharp objects was manufactured. The evaluation of plastic quality from the recycling trial formed the basis for design proposals for improved recycling. This was done in close collaboration with medtech companies and the region.

Some key findings from the project are that the health care personnel is very good at source sorting (>98% correct) but that there is a lack of space in hospitals for source sorting. There is no actor for post-sorting of this type of product. Recyclers are skeptical about plastic from hospitals because of concerns about contamination and incorrect sorting of sharp objects. Plastic volumes from healthcare are relatively small to contribute alone to, for example, chemical recycling; they need to be collected with other streams to become large enough. Plastic from healthcare is interesting because it is regulated and therefore does not contain hazardous additives. The quality of the plastic from the collection showed good properties, as only polypropylene was collected, giving the recycled material had a quality comparable to virgin homo-polypropylene of lower grade. The textiles collected were recycled at lab scale, and more process optimization is needed to achieve good textile quality from the recycled material.

Jamilla Nilsson

Projektledare
+46 10 516 57 95 Read more about Jamilla
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9. Industry, innovation and infrastructure
12. Responsible consumption and production
17. Partnerships for the goals
Project end date: Circular transition Sekundär områdes navigation:
Plastics
Textiles
Production and manufacturing
Health and life science

Replacing fossil carbon with lignin in electrodes

Lignin in electrodes
Substitution of fossil carbon with lignin in furnace electrodes for the metallurgical industry

The metallurgical industry uses large amounts of fossil-based carbon, but the pressure to switch to bio-based carbon is high. This project aims to replace some fossil carbon with the bio-based substance lignin in graphite electrodes.

Project manager
Active
Bioeconomy
Four years
10 737 449 SEK
Division: Division Bioeconomy

The metallurgical industry is a part of the manufacturing sector that focuses on the production, processing and shaping of metals and metallic materials. It is a multifaceted industry that underpins many other sectors such as construction, automotive and electronics, but also medical technology - sectors where both aluminum and steel are important materials. This makes both the aluminum and steel industries important parts of the broader metallurgical sector.

Binds the fibers together

The metallurgical industry currently uses large quantities of fossil-based coal. The largest consumer of petroleum coke, the residual product of crude oil refining that is often used as a fuel and reducing agent in various industrial processes, is the aluminum industry. The second largest user is the steel industry. The metallurgical industry is thus under great pressure to replace fossil-based coals with bio-based coals. One possible source of bio-based carbon is lignin, the binder that holds wood fibers together and gives it strength. The lignin can be extracted from the pulp production at paper and pulp mills through the LignoBoost process. This is a Swedish separation process that allows lignin to be considered as a valuable resource and utilized. The technology to extract lignin was developed in the 1990s by researchers at RISE and Chalmers and is today owned by Valmet.

Possible collaboration

This project brings together two of Sweden's largest industries, the forest and steel industries, for possible collaboration. As a result of this collaboration, new strategies will be developed to replace some fossil carbon with lignin in graphite electrodes. Graphite is used as an important component of electrodes in electric arc furnaces used in steelmaking. In this project, lignin will be used to replace some of the fossil carbon in these electrodes. Different ways of modifying the lignin to better suit the application will be investigated. The results will then be verified in prototype electrodes.

Peter Rättö

Scientific advisor
+46 10 228 46 41 Read more about Peter
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9. Industry, innovation and infrastructure
Valmet Södra KTH Kungliga Tekniska Högskolan Elkem Carbon Solutions
Project end date: Biobased materials Sekundär områdes navigation:
Circular transition
Energy and electrification
Production and manufacturing
Biobased circular processes

The Circular Car

The Circular Car
The Circular Car

Transport accounts for almost a third of Sweden's greenhouse gas emissions and the car industry has ambitious targets to reduce the emissions. The project Circular Car project aims to support new and established actors in the work of jointly accelerating the circular transition of the automotive industry.

Coordinator
Active
Automated vehicles Batteries Circular transition Electromobility Upskilling
3 years
4 943 267 SEK
Division: Division Materials and Industry

The Circular Car project, including committed actors from the entire value chain in the automotive industry, will accelerate the circular transition. With a systems perspective, the actors will, through new knowledge, foresight, knowledge transfer, tests and evaluations, produce relevant measures and action plans for a more circularly adapted car fleet 2045.

The project includes work packages such as foresight and trends, policy and regulations, circular economy business ecosystem, user mapping and analysis, design for longer life, disassembly for remanufacturing and environmental assessment. 

Hanna Linden

Senior forskare
+46 10 228 46 75 Read more about Hanna
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5. Gender equality
9. Industry, innovation and infrastructure
11. Sustainable cities and communities
12. Responsible consumption and production
13. Climate action
17. Partnerships for the goals
Project end date: Offer-pages: Remanufacturing, reuse and repair in the manufacturing industry Circular transition Sekundär områdes navigation:
Automotive and future transport
Materials and durability

Durability - Key in the Material Transition

Corrosion depending on manufacturing technique Photo: RISE

We find ourselves in a pivotal era, where we are fundamentally reconsidering our approach to material usage. This shift demands a move towards a significantly more efficient utilization of the Earth's resources. To ensure genuinely sustainable outcomes, numerous factors must be considered. What does the material need to withstand? And for how long must it endure?

The global challenges confronting humanity are undeniable. Sea levels are rising, temperatures are hitting unprecedented highs, and ecosystems are in upheaval. Simultaneously, global anxieties are mounting, with conflicts encroaching ever closer to home. Change is imperative and already underway.

New legislation aimed at reversing climate trends is being implemented with increasing frequency. Large-scale initiatives like Net Zero Industry are being launched, alongside investments in new energy sources and robust defence strategies. Swedish and European industries are facing an immense transition. At its core lies the necessity for sustainable and resilient materials, supported by a flexible and rapid infrastructure for their implementation.

"The energy transition, total defence, and sustainability are certainly the focal points of current discussions, and they are closely interconnected," confirms Rikard Norling, Market Manager within Materials and Production at RISE.

An Evolving Energy Sector

Rikard specializes in durable materials, a critical element in the material transition.

"The push for renewable energy and the quest for a reliable energy supply have sparked a transformation of the energy system. While nuclear power isn't a novel concept, the current discourse surrounding it has shifted considerably. Concurrently, efforts are underway to bolster the contributions of wind, solar, and wave power. What binds these energy sources together is their shared reliance on material solutions," Rikard explains.

"Wind and solar energy production fluctuates, subjecting materials in base power plants designed for steady output to heightened strain. Likewise, wave power grapples with durability and corrosion challenges. Meanwhile, advancements in nuclear power entail fresh demands on materials. Within existing nuclear facilities, the focus predominantly centers on material longevity, ensuring safe operation over many years."

Put simply, the energy sector has a significant interest in materials that are both sustainable and durable. Merely being environmentally sustainable isn't sufficient; they must also be resilient enough to withstand the demanding conditions they encounter and have a lifespan suited to their specific use.

"This is an area we focus extensively on at RISE. We offer both standardized testing and customized testing. For instance, we set up test rigs that replicate real operating conditions, albeit in an accelerated form. We deal with a wide range of materials, from various plastics to metallic materials like stainless steel, brass alloys, or aluminium. Achieving the right durability is always a trade-off depending on the application. Our goal is to produce products with a low environmental footprint that last as long as necessary. If a product has an unnecessarily high durability, it often becomes needlessly expensive to manufacture. Conversely, if a product has insufficient durability, it needs frequent replacement, leading to resource wastage and negative environmental impacts. It's a delicate balance," says Rikard.

Durable Solutions for Crisis and Conflict

In terms of total defence, material characteristics and durability are paramount, alongside the ability to swiftly and flexibly generate components.

"A part of our total defence efforts involves devising methods for promptly generating spare parts under conditions of restricted delivery capabilities. One avenue we explore is additive manufacturing, commonly referred to as 3D printing. It presents a somewhat different approach: there's an operational product that has performed well but urgently requires replacement. Additive manufacturing allows for the rapid production of components, although at times, their properties may deviate from the original. Despite similarities in name, the materials used can exhibit varying characteristics when manufactured in a new way. We're extensively involved in assessing the process parameters necessary in additive manufacturing to ensure the desired durability properties," explains Rikard.

Increased Need for Regulation

When prioritizing sustainability, speed, and flexibility, not to mention production costs, is there a danger that durability might be overlooked or neglected? Is durability addressed in legislation with same emphasis as, for instance, carbon emissions?

"Legislation, typically in the form of mandatory standards, does not always consider material properties and durability, so there is a need for a stronger emphasis on this aspect. There are clear cases where it should be addressed, such as in the Drinking Water Directive. Otherwise, there is a potential risk of resilience issues in water supply over time and an increased likelihood of expensive water damage. RISE strives to be proactive in this arena by actively participating in policy discussions and contributing to the development of new standards across various forums," states Rikard.
 

In need of help?

RISE is active throughout the entire value chain of sustainable production and material transition, leveraging our expertise, test facilities, and innovation networks. Our specialists cover circular transition strategies for a more sustainable economy, processes and systems for high-quality recycling and reuse, future material production, and the development of traceable, durable, and quality-assured circular materials.

Reach out to us for a tailored discussion addressing your company's specific needs and challenges. Together, we can ensure the durability of your materials in real-world applications.

Rikard Norling

Gruppchef
+46 10 228 48 89 Read more about Rikard
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Corrosion Sekundär områdes navigation:
Circular transition
Additive manufacturing
Energy and electrification
Total defence and crisis preparedness

'Black mass' analysis for battery recycling

Name of service (page headline, shown in promos – maximum of 70 characters incl. spaces): 'Black mass' analysis for battery recycling Lead (include SEO-words and the main benefits for your target groups. Stick to one paragraph, maximum 2-3 sentences):

To pave the way for optimizing battery recycling processes, a proper analysis of ‘black mass’ and spent battery components before and after recycling is very important. 

Purpose/Benefit:

‘Black mass’ is the industry term used to describe the product obtained from crushing and shredding spent Li-ion batteries. It comprises a mixture of elements, including graphite, lithium, manganese, nickel, cobalt, electrolyte, separator, impurities, etc. 

A comprehensive analysis protocol is essential for evaluating the black mass derived from various battery chemistries. This protocol should encompass all necessary property assessments before and after the recycling process. By identifying potential hazards and mitigating associated risks, the protocol ensures safe and efficient recycling operations.

Method (what/which methods are used to perform the service):

Explore our Characterization 

  • Metals and impurities: The determination of compositions in ‘black mass’ and related materials  can be effectively carried out using techniques such Inductively Coupled Plasma - Optical Emission Spectrometry ICP-OES, Inductively Coupled Plasma - Mass Spectrometry ICP-MS, X-ray fluorescence XRF.
  • Level of moisture: The level of  moisture in the ‘black mass’ is determined using titration.
  • HF-content: The content of HF can be determined using titration.
  • PF6-content: The content of PF6 can be determined using Ion Chromatography, IC.
  • Morphological analysis and particle size determination:  The morphological characteristics, grain size, and composition can be determined using Scanning Electron microscopy SEM+EDS
  • Electrolyte analysis using Gas chromatography–mass spectrometry GC-MS:

Gas chromatography-mass spectrometry is an analytical technique that is highly effective for analyzing ‘black mass’ such as determining the composition of carbonates. For example ethylene carbonate, propylene  carbonate, diethyl carbonate, ethyl methyl carbonate etc. 

Delivery (what does the client get after performed service – e.g. a report, certificate etc.):

Report and results

Area: Batteries Contact person (Enter one name per field. Activated personal contact pages will appear automatically):
Moufida Mansouri, Senior researcher
Fredrik Solhage, Enhetschef
Black mass samples
Field measurements: No Price type: 1 Division: Division Materials and Industry Preparation: No preparation required Certification and marking: Not applicable Type of service: Testing / Analysis / Evaluation Instrument: Not applicable General area: Not applicable Delivery level: Non-accredited
moufida.mansouri@ri.se,fredrik.solhage@ri.se
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Batteries Sekundär områdes navigation:
Circular transition
Metrology
Chemical and biological analysis
Tjänstetyp tagg: Provning