VTT Impulse 2/2014

2/2014

MCI

VTT

A depth camera

sees behind movement

science Robotics – technology with major potential

technology Sensor of tomorrow

business Miniaturising devices to fit on your palm

VTT

2/2014

Automation solutions breaking through also in logistics.

Photo: Vesa Tyni

12 “Forest industry is an excellent example of how a sector can reform itself.” jyri häkämies

58

72 The claim that anything else can be made of lignin but money is no longer true.

Photo: Antonin Halas

KRISTIINA KRUUS

76

A depth camera tracks shopping centre visitors.

editorial

“Our ability to reinvent ourselves is the key to new economic growth.”

Jan Vapaavuori Minister of Economic Affairs

R&D investments yield clear payback

T

here is no point in downplaying Finland’s economic plight. A few weeks ago, the credit rating agency Standard & Poor’s told the world what many people had long known. Finland’s economic house has not been in order for some time. The Finnish economy has failed to return to its pre-­crisis growth levels; in fact, production has continued to decline. Our economy faces the double challenge of an economic downturn and deep, internal structural changes.

However, despite an A being knocked off our credit rating and an economic situation that is far from ideal, we should not despair. On the contrary, we must strive towards reforms that will make us stronger and smarter than ever.

Investing in research, education and product development has been our recipe for success before.

These are the trump cards on which we must again build our future.

In fact, the deeper the structural change and the greater the challenges posed by internationalisation, the greater a role such trump cards will play. The level of agility with which our companies reinvent themselves and meet future demand will depend on their quantity of expert employees and research

and product development. Our ability to reinvent ­ourselves is the key to new economic growth.

As greater emphasis is laid on our ability to reinvent ourselves and new innovations, multi-­ disciplinary actors engaged in applied research and innovation­– such as VTT – will be in a position­to act as drivers of the new economy. Last year, VTT was ­Finland’s third most active filer of patents.­ VTT’s expertise plays a role in 36 per cent of all Finnish innovations, including up to 50 per cent of the most challenging ones.

These figures alone suggest that capital invested in VTT has repaid itself over and over again in the form of export income and jobs. For Finland’s research activities to move up a level, structural reform is also required in its R&D sector. VTT’s long, successful history will enter a new chapter when it becomes a limited company at the turn of the year.

I feel certain that VTT will provide Finland with the kind of competitive factors based on which our land will reinvent itself and regain its status as a ­triple A country. I wish the reformed VTT good luck and the best of success in its critical mission on behalf of our country. n

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Contents 2/2014 vtt impulse now A glimpse of the future.............................. 6 Focal point................................................. 8 Exote Oy Automation gives packages wings......... 12

Photo: Vesa Tyni

Column..................................................... 19 Olli Ernvall

48

Kohtaamisia henkilö

8 science Science news...........................................................20 Clearing the way for new materials with ChemsSheet technology.................................22 Research scientists Pertti Koukkari, Risto Pajarre, Petteri Kangas, VTT Hybrid methods offer new solutions for metals recycling.................................................30 Research professor Olli Salmi, VTT Robotics – technology with multi-faceted potential....................................40 Research scientists Timo Salmi, Marketta Niemelä, Tapio Heikkilä, VTT 4 VTT Impulse

“The product is so good that the news is spread on the grapevine.”

OSMO mÄENPÄÄ

52

Phoo: Antonin Halas

Researchers can adapt wood biomass to multiple purposes.

62 technology

Technology news..............................................................46 Advancing cyber security on several fronts....................48 KYBER TEO project serves also industrial needs.

Sensor of tomorrow..........................................................52 Printed intelligence encompasses vast application potential

68

What’s going on in Australia?..........................................56 Ambassador of Australia Gerald Thomson visits VTT. We must maintain Finland as an attractive target for investment.............................58 Jyri Häkämies warns about challenges to growth and highlights opportunities available for Finnish companies.

Towards bioeconomy with the power of wood...............62 Wood is transformed into an increasing amount of materials.

business Business news.................................................................66 Finland is a good investment..........................................68 Finland holds top positions in various comparisons.

How to become the leading country in flexible energy production systems ...........................72 The Neo-Carbon Energy project studies the opportunities for a new energy system.

80

Spectral Engines aims at counting its turnover in tens of millions.

Tracking people...............................................................76 The depth camera pilot shows the benefits of technology.

Miniaturising devices to fit on your palm.......................80 The journey of Spectral Engines began from space technology.

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a glimpse of the future

Finland on its way towards low-carbon year 2050 What are the chances of Finland transferring to a low-carbon society? What are the alternatives and what kind of risks do they entail?

Text Marko Jääskeläinen

T

he Low-Carbon Finland 2050 Platform (LCFinPlat) Project, launched in 2012, studied Finland’s opportunities and challenges related to transfer into a low-carbon society by 2050.

In the project, VTT collaborated with a broad group of experts to come up with low-carbon pathways, and these were computationally analysed using scenario analysis methods, with the ultimate goal of drawing up a low-carbon roadmap for Finland.

VTT was responsible for the coordination of the project, with Tiina Koljonen acting as team leader. The project report presents alternative means by which Finland can achieve the greenhouse gas emission goals proposed by the EU by 2050, which means at least 80 per cent reductions in greenhouse gas emissions from the emission level of 1990. The project is one example of VTT’s foresight and scenario work, which helps actors within the sector prepare for future challenges.

The project participants were VTT, Government Institute for Economic Research (VATT), Metla, the Geological Survey of Finland (GTK) and Tekes. The parliamentary energy and climate committee used the results in its own work.

Starting points for scenario analysis The work performed under the LCFinPlat project­focuses on estimating cost-effective and ­environmentally sustainable methods for Finland to achieve the low-carbon goal and the impacts of emission goals on Finland’s national economy, ­sustainable use of natural resources and the Finnish energy system. Various pathways can be indicated for achieving a low-carbon society, and the basic premise for drawing up the scenarios was that they need to be sufficiently different, so that the future 6 VTT Impulse

could be assessed as extensively as possible from various perspectives.

In the light of the knowledge currently available to us, it is impossible to assess which of the pathways would be the best alternative for Finland. Therefore it is important to identify common denominators for all of them, as well as risks the choices possibly made can cause in the decades to come. It is clear, however, that 80 per cent reduction in emissions requires major steps and investments in all sectors of society­ and, accordingly, a radical change at the systemic level, the realisation of which calls for collective will and direction.

Globally binding climate agreement The Low-Carbon Finland 2050 Platform entails two important initial assumptions: a globally binding climate agreement based on a two-degree limit for global warming has been achieved, and the new low-emission technologies are developing rapidly enough, and they are available for market-based use. Therefore, from the present-day perspective, transfer into a low-carbon society entails major political challenges. In addition, significant investments are required in the development of new lowemission technologies and their launch into the markets. The current infrastructure – industrial facilities, and building and vehicle stock – with its slow pace of renewal poses an additional challenge.

Consequently, the impacts of any decisions and investments made today reach all the way to 2050.

From the Finnish point of view, an especially critical factor is commercialisation of Carbon Capture and Storage (CCS) systems sufficiently early.

– This is one of the key technologies that would be needed if we wish to maintain the current industrial system in Finland also in a low-carbon society, says Koljonen.

Changes in all sectors According to Koljonen, as regards the need to reduce emission, it is descriptive of the current situation that the will is there, but nothing concrete is being done.

– At the moment, there are very differing views when it comes to schedules, measures, and the amount of investments needed, she says.

Koljonen and Satu Helynen, Vice President, Operations, VTT, Smart Industry and Energy Systems, who was in the project steering group, both agree that the goal is so demanding that there are more solutions than one for reaching it. It is all about an entity of affairs.

– It extends into the fields of construction, housing, traffic, industry and energy production, and changes are needed within all of them, says Helynen, defining the scope.

According to Koljonen, when focusing on costefficiency, the reduction of emissions works most effectively in the industrial sector and traffic. The emissions from housing and waste treatment are largely reduced as a result of the existing policies, but additional measures will be needed, particularly after 2030. In the areas of agriculture and land use, on the other hand, the range of means available­for emission reduction is more limited, particularly if we wish to secure domestic food supply.

Four different scenarios In the project, four different low-carbon scenarios were established: Continuous growth, Standstill, Savings and Change. Each of the scenarios emphasises different technological choices and assumptions concerning, for example, societal structure (economic structure, industrial structure, social structure), and the development and introduction of new technologies.

The use of renewable energies increases in every scenario. In addition, the production of liquid biofuels should be increased substantially in Finland when gradually shifting to low-carbon society. In all scenarios, wind power emerges as the third key source of renewable energy alongside water and bioenergy. The production of solar power also increases in all scenarios, but particularly in the scenarios based on continuous growth and change, where smart energy systems and new energy storage technologies enable significant growth of distributed energy generation.

– As regards energy consumption, it is assumed in every alternative that it will take a downward turn. The reduction of energy consumption is a part of the efforts for reducing emissions, notes Helynen.

One hypes, another one saves According to Koljonen, the most far-reaching of the four scenarios is the hyped Change scenario, where technologies are expected to take radical jumps in ways some of which may still be unknown to us. In addition, in this scenario, personal values and choices and, for example, the definition of work are presumed to have changed significantly. When combined, these factors facilitate even a slightly more scattered societal structure than the current one. Another presumption in the Change scenario was a radical change of the industrial structure, where the export industry provides products and services with a high added value for international markets.

The Savings scenario, on the other hand, takes a conservative approach in relation to technology.

– There, the starting point is that the EU takes a proactive approach to the emissions reduction target so that all new technologies have not yet entered market-based use, but the focus is on saving of energy, resource efficiency, and enhancement of energy use, says Koljonen.

In the Savings scenario, the basic premise is that cleantech exports are expected to grow, but the export products would be mainly based on energy efficiency and related service business operations.

This scenario’s strength is high energy self-sufficiency, but, correspondingly, its weakness is higher expenses of emissions reduction between 2030 and 2040 than in other low-carbon scenarios.

Information and affordable solutions A consumer survey was implemented as part of the project, with an aim to explore the attitudes, readiness, fears and wishes consumers have regarding a shift to low-carbon future. The goal to reduce greenhouse gas emissions was considered important: four out of five respondents agreed with this (79%), women considering it more important than men. 59 per cent of the respondents announced that they had systematically reduced their own greenhouse gas emission load.

The most important justifications for not doing so were the higher price than that of the conventional solution, difficulties in adopting such technologies and lack of information.

Provision of information to citizens is something both Koljonen and Helynen consider important.

– We have to be able to show that new technologies are functional and cost-effective to use.

Much more education will be needed, Koljonen points out. n VTT Impulse 7

An export product

tougher than nails

There’s a new Finnish hard metal that is making a noise in the world.

Long in the making, this product is poised to grab an increasing share of the protection material market in the defence industry – particularly in vehicle protection.

Industrial applications are being developed at present.

Text Sari Alhava Photo Vesa Tyni

I

n a war zone, vehicles of any kind from cars to tanks are huge moving targets.

Considerable­investments are made in ­protecting them from gunfire. The protection material market is currently dominated by aluminium oxide, silicon carbide and boron ­carbide. A new Finnish hard metal developed by VTT and Exote is now joining their ranks.

– We have been developing this new hard metal and its production method at VTT since the mid-1990s. In 2003, we established Exote Oy to ­produce and sell this metal-ceramic composite and sold the patent to the new company, says team leader Tomi Lindroos from VTT, describing the origins of the project.

The company was named after the new hard metal, also known as exote.

8 VTT Impulse

→

Osmo Mäenpää explains that the advantage of exote over steel is its weight-to-efficiency ratio.

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Photo: Patria

“We are now looking at applications where a traditional hard metal could be replaced with exote.”

– Our initial goal was to create a new hard metal for industrial use. The primus motor in this process was Pekka Lintula, at the time a Senior Scientist at VTT. He is a gun enthusiast, and it was his idea to test whether exote was bulletproof.

When he discovered that the material actually stopped bullets, he outlined a new range of applications, says Osmo Mäenpää from Exote Oy. Indeed, at the moment exote is being principally developed for ballistic protection, i.e. bulletproofing.

Unique application Established in 2003, Exote Oy is a completely privately owned limited liability company. It has some two dozen shareholders, almost all of them Finnish. The company occupies 600 square metres of production and office space in Raasepori and has a firing range built to Defence Forces standards.

The material properties of exote stem from its unique production process co-developed by VTT and Exote Oy. – How it is controlled and applied is known only to Exote Oy, says Mäenpää.

As always with industrial innovations, considerable interest has been shown by various parties trying to find out the composition of the new material. Mäenpää explains that while it is possi10 VTT Impulse

ble through analysis to find out its composition at the atomic level, it is nevertheless not possible to copy it without knowing the production method.

Almost exclusively for export When a fledgling company launches a new ­product on an international market, it helps to be able to have development partners as references.

– VTT is an establishment known and respected abroad. In the USA, local universities are often engaged by enterprises in product ­development, so in that sense our collaboration with the Tampere University of Technology looks good on our CV, says Mäenpää.

The admission of Exote Oy to Technology ­Programme 2010 of the Finnish Defence Forces earned the company a considerable amount of goodwill on the military market. The Defence Forces made a substantial financial investment in the further development of exote.

– The Defence Forces wish to help the Finnish SME s­ ector develop products with export potential. It is useful for them for Finland to have R&D and production in this sector. Because the Finnish market is not large enough to sustain a profitable­ business in this sector, we need exports, says Mäenpää, explaining the reasoning behind the partnership.

The company already has a finished commercial ballistic protection product that has been on the market for a few years. Virtually all exote sales go abroad. The principal market is the USA, which accounts for half of the military materiel market­of the entire world. Exote has also been sold to A ­ ustralia, South Africa and many European countries.

Exporting a product involving bulletproofing requires an export licence.

– The licence is granted by the Defence Forces if the Ministry for Foreign Affairs endorses it. A licence will not be granted for exports to countries that are currently at war, says Mäenpää.

Known worldwide Exote no longer needs to be promoted in the vehicle­protection industry.

– People in the sector all around the world are already familiar with our product. It is such a good product that word gets around by the grapevine. This is an excellent achievement for a small Finnish company, says Mäenpää.

However, even though the market is large and the product is good, possibly even the best there is, it is not easy for a newcomer to capture market­ share.

– There are three older products out there that people are used to using, and their producers have networks of contacts already in place. Meticulous

and patient efforts are required to gain a foothold on the market.

Mäenpää notes that the sales price of exote is competitive, being on a par with that of silicon carbide.

Skipping a step The sales process in the ballistics market has four steps. Producers of protection materials, including Exote, sell their products to the next step, the manufacturers of protection equipment. These manufacturers use the material to make protection panels, which they then sell to vehicle manufacturers. The completed bulletproof vehicles are then bought by the defence forces of various countries from the vehicle manufacturer.

Enterprises that produce protection equipment often aim to buy up enterprises that produce protection materials. Exote, however, has a bargaining point that will enable it to achieve success as an independent company.

– Exote panels can be attached directly to a vehicle, unlike ceramic panels. This means that we can also sell them directly to vehicle manufacturers. This represents an obvious competitive advantage, because without a separate mounting panel the vehicle will weigh less.

Exote has a better weight-to-efficiency ratio than steel: its specific gravity is lower than that of steel, but it is harder, more durable and more effective than steel.

– To simplify, we might say that a 7 mm thickness of exote plate is equivalent to about 20 mm of steel armour.

Good prospects The next step for Exote is to become a supplier of bulletproofing for major vehicle projects.

– We are also interested in civilian vehicles – anything where our product might be useful.

Bulletproof vests are also a possible area of development. Exote plate is light but can stop an armour-piercing bullet, which would make it very good for personal protection.

The industrial research is still continuing.

– We are now looking at applications where a traditional hard metal could be replaced with exote, says Lindroos.

One reason for the demand for replacing the currently most commonly used type of hard metal is the decreasing availability of one of its components, tungsten.

– Tungsten comes mainly from China. Supply cannot meet demand, and in the EU it is on the list of critical raw materials. It is estimated that its availability will continue to decline, which translates into opportunities for us, explains Mäenpää.

At the moment, VTT and the Tampere University of Technology continue to test the hardness, tensile strength and durability of the material. This will help determine the applications for which the material is suitable and explore the properties required for industrial use. There are plans to use exote for manufacturing crusher blades and cutters, components requiring abrasion resistance and tools for demanding products.

– In industrial applications, it may take years to finish a commercial product. This is a long-term process pursued by VTT, industrial enterprises and ourselves, and it is impossible to set a completion date, Mäenpää points out. n

Clear division of duties in product development VTT IS closely involved in the development of exote.

– The division of duties is clear. VTT has expertise in materials technology and science, so they focus on those things. We are in charge of developing the method and process, or production and sales, says Osmo Mäenpää, noting also that the collaboration is close and fruitful.

Tomi Lindroos reports that VTT has contributed and continues to contribute to the development of material properties.

– We study the characteristics of material mixes. In recent years, we have also been developing our materials technology consultation service. We use systematic analysis to determine which compositions are worth testing.

Developing exote has been a long road. The production process has been perfected over decades, and the material itself is still being tweaked as required for its various applications.

– Getting anywhere can sometimes take a really long time, much longer than we initially thought. But all p ­ arties feel that developing this product and its production method has been worth it. We want to be part of bringing this product to a wider market, says Lindroos.

Development efforts at VTT have paid off in significant, measurable ways. The properties of the material have ­improved hugely: its tensile strength, for instance, has been increased by 60%. There are several versions of exote, each of which has been comprehensively tested not only in Finland but also in many other European countries and in the USA. Marketing efforts are mainly concentrated in the defence industry, specifically in vehicle protection. There are several exote projects in progress in this area. Mäenpää notes that the core area of exote applications may be found at level 3 and up in NATO standard STANAG 4569.

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n o i t a m o t au

gives packageS

wings

Automation brings efficiency and new growth opportunities to production logistics.

Text Ari Rytsy Photos iStockphoto

12  VTT Impulse

VTT Impulse  13

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n production logistics, the growth opportunities provided by automation are undeniable, regardless of the relatively slow pace of progress so far. At best, the change can generate totally new kind of business, which manifests itself as, for example, growth of electronic commerce.

Efficient flow of information and realtime tracking of products have contributed to shaping of the current consumer habits. Packages come and go efficiently from a warehouse to home door.

Last year, the US on-line retail giant Amazon introduced a mini RC helicopter Prime Air. Its operating principle is that it picks up the shipment from the warehouse chain, flies to the address fed into its system, and drops off the package on the customer’s steps.

According to Amazon, the system designed for an urban environment could be introduced within five years. Even though this idea may seem crazy, experts have not unequivocally condemned the functionality of the concept.

We are also discussing such topics as automatically driven cars and potential uses of the big data in electronic commerce. On the basis of a consumer’s on-line behaviour, the company can forecast his or her next purchase, so the product may be on its way to the consumer already at the moment he or she places the order.

– As far as other technological breakthroughs are concerned, for example, 3D printing and light nano materials are not directly linked with operational logistics, but with the help of them supply chains and their functioning can be changed. Products made of nano materials are lighter, which makes their distribution easier, estimates VTT Research Scientist Ville Hinkka.

Efficiency through information management Production logistics involves much more than mere physical processing of material flows.

Technologies and complex procurement networks have given information management a more pronounced role in the process than before. The overall functioning of a system has an impact on, for example, throughput times of products, accuracy of deliveries, and optimisation of production and warehousing. By developing these, companies improve their productivity, efficiency and competitiveness.

As concerns production processes, the progress made in automation manifests itself, for example, in product development of machinery manufacturers. Compared to actual manu­

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actors in the grocery sector are capable of electronic data transfer.

“The use of the EDI standard is economically justified.” facturing, production logistics, which mainly includes deliveries, handling and transfer and warehousing, has advanced at a more leisurely­ pace. This cannot be blamed on lack of concrete­ development within the fields of techno­logy suited for production logistics, though.

Karri Rantasila, Key Account Manager at VTT, underscores that companies have been performing automation of production logistics internally within closed systems for a long time. A more comprehensive goal, however, is to enhance the scope of automation, to extend it from a single company to include the entire supply chain.

– The overall flow of production logistics consists of money, raw materials, products and information. Money lives its own life within the framework of banking systems. The flow of goods and information, on the other hand, can be enhanced by using automation So far, this development has been slowed down by, for example, various incompatible standards and systems, says Rantasila.

EDI traffic increasing The basic prerequisite for enhanced automation of production logistics is the standardisation of data flows. This is referred to as EDI (Electronic

Data Interchange), which means automated transfer of data in electronic format between the data systems of various organisations.

The use of the EDI standard is economically justified when the volume of data to be transferred is large enough, or if the traffic of orders and invoices is otherwise busy enough. The use of the system becomes topical if a business partner of a company uses EDI traffic and requires it also from its partners.

The use of EDI expedites processing of data, lowers data transfer costs, makes processing of errors simpler and easier, and reduces the time required for business processes. EDI functions are most widely applied to transportation, purchases and warehousing, but also to, for example, payment transactions.

– The starting points for the development of EDI are good, since many Finnish companies already have their own ERP (Enterprise Resource Planning) systems in place. In the next phase, these two systems should be made communicate with each other, Rantasila notes.

Finding a common view is difficult because each company in the supply chain differs from the others in some way or another. Many SMEs are sceptical about automation due to the investment pressure it creates.

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“change can generate totally new kind of business.”

To make the situation easier, the General Industry Federation and GS1 Finland have embarked on a mission to digitalise delivery­ chains within the grocery trade, for which they are currently seeking Tekes funding. The purpose­of the project is to build an electronic data transfer system for the needs of the grocery sector. It can be operated as a cloudbased service using a smart phone, tablet or computer.­The goal is to introduce the same operation model in other sectors as well.

– Depending on the calculation method used, there are some 1,800–2,700 actors in the grocery sector. Currently, only 30 of them are capable of electronic data transfer between companies, says Kyösti Orre, Senior Adviser of logistics from the General Industry Federation, describing the development needs within the sector.

Will for harmonisation Seamless transfer of data opens up improved opportunities for mechanical automation of production logistics. Today, for example, RFID (Radio Frequency IDentification) technologies are being used for monitoring of goods traffic and storage circulation, and automatic identification. It facilitates, for example, rapid calculation of individual products included in a batch of palletised goods.

The data transmitted to the warehouse management system enables monitoring of sales and automatic ordering of the next batch of products at the optimal phase of storage circulation. In spite of all the opportunities this 16 VTT Impulse

technology could offer, the different practices at various companies still impose limitations on the use of technological solutions suited for logistic application.

–For example, in books trade, one chain of shops may use RFID tags in their products, but others may not. Even though it would be easy to place the tag in all books at the printing phase, due to this difference, it needs to be done manually. It all boils down to sub-optimisation, which is relatively more expensive than large-scale use of RFID, says Ville Hinkka.

Independent of its high price, sub-optimisation is still taking matters in a better direction small step at a time. The higher the volume of goods and material flows brought under the same system, the easier it is to raise the prevailing level of automation within the sector.

– With the launch of our project, several major actors within the groceries sector have expressed their interest in harmonisation of data transfer. They have understood that integration of data flows will also provide assistance for the management of the flow of goods. Automation, as well as different codes and tracking systems related to that, enhance error-free functioning of the system and, consequently, make it more efficient, underscored Orre.

Towards more extensive use Technology is not a value in itself in the automation of production logistics. For example, it is not reasonable to build storage automation in a company that dispatches a few packets a day. Instead, for example, WLAN- or GPSbased localisation is suited for, for instance, large warehouses, and tracking and identification of shipping containers, whereas computer vision is suited for quality assurance and reverse logistics.

All in all, the wide spectrum of technologies on the offer provides opportunities for implementation of automation solutions for various needs.

– In my opinion, the development of operational logistics and related automation methods is not in any way lagging behind manufacturing activities. It is more a question of at what stage it is possible to adopt such solutions to largescale use. For example, in Finland, only 40 per cent of goods traffic dispatch data is transferred in electronic format, when the corresponding figure in other Nordic countries is 90–95 per cent. In the first phase, we should have this type of functions standardised, notes Rantasila.

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Crisis preparedness needs to be improved

Crisis preparedness needs to be improved In addition to automation, production logistics can be improved by means of, for example, robotic solutions within warehouses. However, automation plays a more significant­ role in enhancing the effectiveness of entire s­ upply chains.

This will come to transform the way people work, in the same manner as tractors and threshers once did in ­agriculture.

– The amount of physical work will reduce. However, there remains a lot of functions for people in maintenance, correction of errors, and added value production, estimates Kyösti Orre.

Improved productivity and automation of the basic work sound promising, but the change has also its flip side.

A digitalised operating environment is heavily reliant on electricity and information security. This raises questions related to, for example, business secrets, hacking and privacy protection. Disturbances and problem situations are no longer local events, but crises that can shake the entire global supply network.

Companies are increasingly engaged in international cooperation to prevent major threats. Accordingly, identifying security threats and responding to them is one of the major factors in securing continuity of digital and automated ­supply chains.

– Different types of threats have existed for a long time, but they have changed over time. By the side of business threats, now we can also talk about information security and physical occupational safety of warehouse functions, which has improved as a result of automation and robotics,” says Karri Rantasila, summarising the development. n

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In addition to automation, production logistics can be improved by means of, for example, robotic solutions within warehouses. However, automation plays a more significant role in enhancing the effectiveness of entire supply chains. This will unquestionably come to transform the way people work, in the same manner as tractors and threshers once did in agriculture.

– The amount of physical work will reduce. However, there remains a lot of functions for people in maintenance, correction of errors, and added value production, estimates Kyösti Orre.

Improved productivity and automation­ of the basic work sound promising, but the change has also its flip side. A digitalised operating environment is heavily­ reliant on electricity and information security. This raises questions related to, for example, business secrets, hacking and privacy protection. Disturbances and problem situations are no longer local events, but crises that can shake the entire global supply network.

The positive side of the development resulting from the existence of major threats is that companies are increasingly engaged in international co-operation to prevent them. Accordingly, identifying security threats and responding to them is one of the major factors in securing continuity of digital and automated supply chains.

– Different types of threats have existed for a long time, but they have changed over time. By the side of business threats, now we can also talk about information­ security and physical occupational safety of warehouse functions, which has improved as a result of automation­ and robotics,­says Karri Rantasila, summarising­the development.

column

Olli Ernvall Editor-in-chief VTT Impulse

“We should turn the state and corporate investments in R&D towards growth.”

R&D investments require long-term commitment

I

n international competitiveness and efficiency comparisons, Finland is known as one of the front-line players. The distinguished World Economic Forum (WEF) estimated in September that, in terms of competitiveness, the Finnish national economy ranks fourth in the world.

Last year, Finland held the third position in the same comparison. In June, Finland was ranked the most competitive and innovative country within the EU by the World Economic Forum.

Instead of ranking countries on the basis of short-term economic performance, these assessments measure the long-term competitiveness of national economies. In other words, all is well in Finland, right?

As Minister of Economic Affairs Jan Vapaavuori states in his editorial to this issue, it serves no use to sugar-coat the current economic situation, a revealing evidence of which is the lowering of Finland’s credit rating from class AAA to AA+.

Naturally, it is a good thing that our country’s performance is evaluated regularly using different indicators. However, if ignored or not taken seriously enough, these evaluations serve no purpose. Their contribution to us is most valuable when they tell us where were at, provide a glimpse of the future, and allow us to make conclusions on what we should do next.

Since our balance of payments has shown a deficit throughout the year, it reveals that Finland is becoming indebted to foreign countries.

Our balance of trade, included in the balance

of payments, shows that Finland imports more than it exports.

This kind of development does not rest on a solid foundation. Therefore, we may ask whether the reason for our surprisingly good ranking in the WEF evaluation is the fact that, in Finland, both the state and companies have earlier been making long-term investments in research and innovations – and much larger ones than other European countries. In terms of GDP, relatively speaking, our neighbouring country Sweden is investing the most in research and development, and it is increasing its R&D input! The country’s economy has improved.

Therefore, in Finland, we should now consider whether we are now reaping the last economic benefits produced by earlier large investments in R&D. In other words, the lowered credit rating could be taken as a strong signal that the investments of the state and companies in R&D should be increased. Particularly so, when we bear in mind that research and development – the results of applied research in particular – are the catalyst of economic growth. If we do not make bold investments in new technologies and innovation, even taking risks, we will lose our competitiveness in the increasingly tight global markets.

Fortune favours the bold decision-makers in companies and budget affairs, who instead of slimming down R&D operations, give new boost to our national economy. n

VTT Impulse 19

SCIENCE Better fabrics from textile waste A diagram and an electron microscope image of spontaneously aligned selfassembled material.

Aligning molecules in a new way How does one achieve nanometric-scale molecules align themselves into parallel nano structures at a millimetre length scale? A joint research project of Aalto University, Politecnico di Milano and VTT produced a new method for extending the controlled self-assembly of molecules from the nano scale to the millimetre scale without the interim phases needed earlier.

The technology exploits molecular self-assembly as kind of a template in the manufacture of nano devices, when one wants to scale molecular level structures up to the macroscopic level in a controlled manner.

Earlier, this work has required several interim steps, but this invention will reduce them significantly.

Printing method for thin film transistors The method developed by VTT facilitates manufacturing of thin film transistors using ­ roll-to­-roll techniques only. So far, the manufacturing process has relied on them only partly, which has made the mass production costs very high.

It is predicted that the markets for this technology will grow from their current value of three million dollars to around 180 million within ten years.

20 VTT Impulse

VTT is developing methods for restoring worn-out fibre to good-as-new condition. The current development focuses on methods for separating the cellulose molecules contained in textile waste, such as cotton, using efficient and environmentally friendly solvents. The fibrous components of worn fabric can be separated and returned to textile production as raw material. The end result can be a product of equivalent quality to the original, or even better.

New methods for electricity generation Research scientists at VTT have for the first time demonstrated a new technique for generating electrical energy. The new electricity generation method can be used to harvest energy such as mechanical vibration from the environment and convert it into electricity. Energy harvesters are needed in devices such as wireless energy-selfsufficient sensors and medical implants, where they could replace batteries. The method could be in industrial use within 3 to 6 years.

180 million

The markets for thin film transistors are expected to grow to around 180 million dollars within ten years.

SCIENCE

Recycling materials

Photo: Niina Stolt / Studio Onni

In 2012, Dr Olli Salmi was appointed Research Professor in Industrial Ecology and Recycling Technologies at VTT. Salmi runs the Mineral Economy innovation programme at VTT that focuses on the development of material efficiency. Before joining the VTT staff, Salmi worked in the private sector with sustainable urban planning in China and Finland.

Read more about these areas of research on the following pages.

olli salmi • Research Professor, Industrial Ecology, VTT • Doctor on Environmental and Community Development

VTT Impulse 21

new materials clearing the way for

with Chem­Sheet ­technology

Innovations based on computational thermodynamics are clearing the way for new materials and processes.

Text Pertti Koukkari, Risto Pajarre, Petteri Kangas

22 VTT Impulse

P

SCIENCE

ursuit for enhanced functionality is and materials science. Physico-chemical relacommon for materials and process tions are utilized for the purposes of developing research, both looking continuously structural and operational material properties for new solutions that save the usage and controlling the durability of materials under of materials while also being energy efficient various conditions. In a similar manner, the proand environmentally benign. The success of a cess technology aims at achieving optimal funcnew application is affected not only by its inter- tionality with a focus on both saving raw materinal physical and chemical interactions but also als and energy and reducing the environmental by the surrounding environment. The expert impacts of the overall process. group led by research professor Pertti Koukkari The chemical and physical interactions has developed new thermodynamic calcula- occurring in reactive flows and material struction methods, which can be diversely used for tures can be mathematically described using predicting and steering both manufacturing of the thermodynamic free energy. The minimifunctional materials and development of effi- zation of the free energy combines the basic laws of the thermodynamic theory and quanticient chemical and biochemical processes. fies all changes generIn 2007, Professor­ ated by the physical Koukkari and Senior­ The awarded method and chemical­driving Scientist Risto Pajarre were given the Best forces in v­ arious matehas generated several Paper Award of the rials. The spontanepractical solutions.

CAPLHAD Journal­ ously occurring­chem(1) for their publicaical change is guided tion on the constrained Gibbs energy minimiza- by the ­tendency of the reaction system to reach tion method (CFE). The paper presented, for the ­e quilibrium (Gibbs free energy minimum). first time, a method by which thermodynamic As thermodynamics also gives a mathematifree energy calculation can be generalized for cal form to the respective energetic changes, systems subdued to physical or dynamic work the approach provides its masters an access to factors. With the help of the method presented an efficient and systematic­ methodology for in the publication, it is possible to handle both managing­both material properties and behavtime-dependent kinetics and various physical iour of processes. Over the past few decades, the constraints in the classical thermodynamic cal- rapid development of computers has ­contributed culation routines, and thus significantly expand to transforming the abstract thermodynamic the scope of their deployment. Since then the theories­to practical solutions. Fortuitously, awarded method has been used in several prac- solving thermo­d ynamic problems does not tical applications that have been presented both ­usually require large computational capacity, as in VTT’s research reports and on international the numerical performance of personal work­ science forums. The new approach has also stations is quite sufficient in most cases. increased the interest in the use of VTT’s ChemConventional thermodynamic calculation­ Sheet calculation software around the world. methods focus on phase changes and on products­ Prof. Koukkari has now compiled the back- of chemical reactions as function of t­ emperature ground on the CFE method into a new publica- and pressure. Therefore the methods in wide tion in the VTT Technology publication series, international use are specifically­suited for caland two dissertations related to this demanding culating chemical equilibrium­compositions and for drawing diagrams describing­ multi­ subject are about to be finalised. component phase equilibria. Both approaches Inclusion of dynamic changes are extensively used in chemical­technology and material sciences. in equilibrium calculations Mastering of complex chemical and physiHowever, in practical processes equilibrium­ cal interactions is a lasting problem in process is seldom reached, or the composition of the

VTT Impulse 23

figure 1.

ChemSheet is suited for the modelling of complex and demanding industrial conditions. The research scientists pictured here have experience of creating models for varied purposes, ranging from thermal processing of biomass, and pulp and paper manufacturing to chemical and material technologies. From the left, Petteri Kangas, Anna Kalliola and Risto Pajarre. In the background, a ChemSheet model of copper flash smelting process.

material being processed is affected also by other than purely chemical factors. Accordingly, a new approach was needed for problems in which both the time dynamics of the chemical change and various physical preconditions must be taken into account. The scientific s­ ignificance of the CFE method is expressly linked to its ability to define the thermodynamic potentials of the constituents of the system in a versatile manner, and, in accordance with the second law, also during the change, not just in a state of equilibrium. It therefore also facilitates calculation of cases in which the change can be effected in the reverse (non-spontaneous) direction by application of external energy input, for example, when charging batteries using electric current.

The computational programs developed by VTT have been commercialised in collaboration with the German SME GTT Technologies GmbH, which markets and distributes thermodynamic calculation software and databases worldwide. VTT’s ChemSheet software has been a part of this product family since 1999. ChemSheet and the simulation program for industrial rotary kiln systems (KilnSimu) are being used in more than 20 countries by both research and industry. In Japan the programs are represented 24 VTT Impulse

by the Tokyo-based SME RCCM. Furthermore, the Finnish SME Process Flow Ltd OY, specialising in process simulation services, has also been involved in the international collaboration (see figure 2).

Process technology: energy savings and new solutions Customers for VTT’s advanced thermochemical­ modelling represent a wide range of industrial fields including energy and power production, pulp and paper manufacturing, chemical, metallurgical and steel industries. In many cases complex reactions occur in reactors with challenging conditions where direct measurements are but impossible. The new method allows for the computational simulation of such processes with high level of accuracy. As the thermodynamic method also takes into account the chemical and energy changes concurrently significant improvements in raw material and energy efficiencies of the process can be achieved simply by adjusting the operational conditions on the basis of the computer simulation. For example, in zinc recycling taking place in a rotary kiln reactor­at high temperatures, it has thus been possible to reduce the carbon footprint of the kiln by as

much as 40 per cent. The new process, which applied ChemSheet modelling in its developing stage, was recently approved as European BAT (Best Available Technology).

While many of the conventional process models­ are focussing on the main reaction components, ChemSheet with its systematic thermo­dynamic description covers all system elements and compounds. Consequently, harmful emissions and potential by-products are also included in the detailed simulation analysis.

Such approach has been applied, for example, at the UBE Industries cement factories in Japan for the elimination of undesired chlorides and sulphates from the cement manufacturing process. Additional applications in Finland include removal of non-process compounds from the chemical recovery circuit of pulp-making plants.

It is characteristic to ChemSheet versatility that in Japan the focus is on gas circulation of cement kilns operating at above 1,400-degree temperatures and in Finland on control of foreign substances in forest industry’s water circulation ­systems.

Another typical industrial application is the introduction of a totally new process chemistry concept with the help of successful simula-

figure 2.

The software developed by VTT has been internationally commercialised in collaboration with GTT TECHNOLOGIES GmbH.

The thermochemistry can be combined with 3-dimensional fluid dynamic (CFD) modeling when doing detailed simulations of complex reactors. The figure shows temperature distributions received with a combined CFD and thermodynamic model for a counter-current rotary kiln. The colour code below gives the radial temperature distribution in the gas phase and the curves above the iterative solution of the axial average temperature of the solid ’bed phase’. In the 2-way coupling the thermodynamic and aerodynamic model apply sequential boundary conditions from each other and give the best simulation result. (http://www.kilnsimu-fks.com/ 2014) VTT Impulse 25

The adoption of the CFE method has opened many new doors in materials science.

tion; one example of this was the extensive transfer to neutral paper manufacturing processes implemented in the industry in the early 2000s. In this case, the key innovation was to include the builtin electric charge of cellulose fibre – so-called ion exchange potential of the fibres – in the paper making­chemistry models by using the CFE technique. By using the thermodynamic ion exchange potential in the calculations, it was possible to control­the acidity of machine stock and to define the renewed dosages of chemicals required for the neutral operating conditions.

The challenge today is the in-line production of precipitated calcium carbonate (In-Line PCC, to be used as filler and pigment) by direct crystallization process in the paper machine pipeline. To reach this goal, VTT researchers collaborate with the Savonlinna based SME Wetend Technologies Oy, which markets and develops the in-line technology. The pilot tests conducted by Wetend in 2014 have produced momentous new results to achieve such a breakthrough technology. The In-Line PCC techno­logy, with highly competitive production costs, provides­major benefits to its users by forming strong fibre carbonate composite structures, by replacing valuable fibres in paper and board with

A number of new kinds of phase diagrams can be calculated using the CFE method.

figure 3.

On the left, a phase diagram describing eutectic melting of tin-bismuth (Sn-Sb) alloy, one for the bulk material and the other for a 10-nanometre scale particle (the asterisk shows the experimental measuring point). The surface energy of nano-scale particles lowers the melting point of the alloy. (Lee, Penttilä & al., JOM-J Min. Met. Mat. S. 2005) On the right, the topology of boiling points and dew points in reactive mixture of ethanol and acetic acid shown as ‘iso-affinity surfaces’ in relation to the extent of reaction ( ξ ). The reactive phase diagrams could be helpful when developing efficient recovery processes for new biochemicals. (Koukkari& Pajarre, Pure App. Chem. 2011)

26 VTT Impulse

figure 4.

Rotary kilns are widely used in different applications of the process industry.

filler materials and by cleaning the plant’s water circulation.

Future challenges in BAT technologies and process control The on-going global digitalisation of process industry provides new opportunities and brings new challenges for the thermodynamic methodology. Many of the traditional technologies within process industries have been designed at a time when advanced computer techniques, such as ChemSheet, were not available. Modelling has been found to be a tool of paramount importance when developing new BAT-level techniques and striving for maximum efficiency with minimal environmental impacts.

The multi-component models of unit processes can be further coupled with the control system for the entire process. If the process-­ specific time constants allow, even thermodynamic models can be used as components in the automation software. An example is the ChemSheet simulation of the Xstrata Nickel ­c ompany’s multi-phase nickel smelter in Canada,­which is used as support for the online control of the multi-stage process. Similar solutions are currently­being studied and developed in Finland in the ongoing SHOK (Strate-

gic Centre for Science, Technology and Innovation) programme­projects. The other up-to­-date field for process­ applications includes various undertakings to improve recovery and recycling­of process­chemicals and to develop new industrial­Cleantech solutions. For example in Austria, ChemSheet has been used when developing technology­for the recycling of phosphate nutrients from recycled­sewage sludges.

New openings in materials science Even though VTT researchers have mainly focused on the renewal of process technologies, the usage of CFE methods has also produced several new openings in material sciences. In materials technology, the challenge is in most cases the mastering of the structure-propertyperformance chain. Advanced thermodynamics­ often helps to reach practical solutions by its predictions of work functions in various material­ combinations. VTT researchers look for international collaboration to explore new areas of materials research, yet also publications on ChemSheet provide information of novel CFE technology developments. The new techno­ logy offers, for example, a means to examine the functionality of surface layers formed in alloys and mixtures in their manufacturing phase and VTT Impulse 27

Recycling and Cleantech are topical application fields. affecting both their processing conditions and product end uses. The Norwegian SINTEF research institute has used ChemSheet surface phase analysis both for the development of the smelting process of siliciferous metal alloys (ferro-silicon) and again in research and development of the surface properties of polycrystalline silicon used in solar cells. In Japan, Osaka University and its collaborators have applied surface energy research to the manufacturing technologies of new magnetic materials of high susceptibility. The objective has been to take advantage of the surface energy of nanosize powders so that the magnetisation of the alloy product is optimised with reduced input of the expensive highly magnetized component. In the development of bending displays, the problem is how to find materials with high enough electrical conductivity, but also with sufficient surface cohesion at the grain boundaries. With the help of calculation models linking the interactions of surface energy and material composition it is possible to study suitable material combinations where both of these properties are optimised.

The challenges of nuclear technology include a range of chemical problems, where multicomponent thermodynamics is a must. Such is the prevention of potential radioactive emissions of caesium and iodine compounds which may form during serious accidents. With the help of ChemSheet, VTT has linked the Gibbs’ian thermochemistry as part of the US-made MELCOR nuclear power plant simulation software, and this combined technology has been awarded qualification as a tool abiding the requirements of nuclear safety related work set by the Nuclear Regulatory Commission (NRC) in the U.S.A. In addition, quite recently research scientist Henri Loukusa has written a new Gibbs energy minimization program in order to calculate 28  VTT Impulse

figure 5.

The phase diagrams for carbon containing Fe-Cr (iron-chromium) alloy. The phase structure of the paraequilibrium (below) is much more simple than global equilibrium (above). Mastering of paraequilibria supports the development of high-strength steels.

(Pelton, Koukkari & al. J. Chem. Thermodynamics 2014)

Process solutions

figure 6.

New solution models for multicomponent solution equilibria are needed for various cleantech and mining applications. On the left solubilities of sulphate salts for hot (100 C) aqueous solutions. (Pajarre 2014).

On the right : Validation of the chemical safety model for nuclear power plants. The pH control of the water pools in the nuclear plant safety system is designed to prevent the release of radioactive compounds into the atmosphere. (Penttilä et al. 2009).

the amounts of different chemical compounds formed in nuclear fuel. Tens of fission products are formed through fission in nuclear fuel during irradiation. Their chemistry affects the material properties of fuel rods, which are important in safety analyses of nuclear reactors. The modelling of the chemistry of this complex system is almost impossible with other than thermodynamic methods.

Strength and corrosion-resistance for steel products Steel industry has been a key user of the conventional phase diagrams mentioned at the beginning. Steel gains its properties, besides from the alloy components used, also from the phase changes occurring in the solidification processes during casting. Such changes may further take place in annealing and rolling. They seldom lead to equilibrium compositions, but are targeted to a product with specific physical, mechanical and chemical properties that often are reached with a particular (non-equilibrium) phase structure.

For example, in manufacturing ultra-highstrength steels, so-called paraequilibria can be

applied, where non-metallic substances (such as carbon) are apt to reach equilibrium while metallic components (such as iron, chromium, and nickel) occur at constant ratios in the various phases. The manufacturing of these special alloys is proven with practical experience.

The constrained Gibbs free energy technique then provides new possibilities for developments when the theoretical paraequilibrium phase descriptions can be leveraged through computer simulation. While the paraequilibria calculations follow the same principles as those used for kinetically constrained chemical processes, in steelmaking it is also possible to use other methods offered by CFE technology. For example, thermodynamic models on mechanical processing (rolling) or, e.g. on magnetically controlled austenite/ferrite changes may help in the development of new product properties.

Another excellent example of a material application­utilizing ChemSheet technology is the SteaMax expert system developed within Valmet Power. SteaMax is used for material durability control and corrosion prevention in new biofuel boilers supplied by Valmet for VTT Impulse  29

The CFE simulation of combustion engines is a new interesting focus area.

pertti koukkari Dr (Tech.) Pertti Koukkari acts as research professor of sustainable chemical processes and systems at VTT’s Process Chemistry business area.

Professor Koukkari is specialised in application of multi-phase chemical thermodynamics on the development of cost-effective process solutions and functional materials.

The free energy technologies and ChemSheet and KilnSimu calculation programs, developed at VTT under his leadership, are globally recognised and used by industry, universities, and research institutes in more than 20 countries.

30 VTT Impulse

power production. In this technology it is essential to maintain high efficiency with reduced emissions notwithstanding the varying composition and quality of the biomass and waste fuels.

They characteristically contain high amounts of alkali metals and chlorine, often in combination with low amounts of sulfur.

The presence of these elements increases the risk for operational problems such as corrosion, fouling and bed sintering. SteaMax expert system based on the ChemSheet program helps to avoid service malfunctions and to secure operating life of critical plant components. In plant design, it applies both for determining the maximum steam temperature and for the selection of heat exchanger materials and superheater locations. During operation, SteaMax can be used to find the optimum fuel mixture for the boiler, e.g. to find the maximum allowed fraction of a high chlorine waste fraction. Thus, the innovative ChemSheet based system also has opened a lead to a new service business based on customer needs while operating the plant with different fuel mixtures and when solving maintenance problems.

Publications and theses The recent issue of the VTT Technology series published by professor Koukkari presents the new method by simple basic examples. The ­dissertation by M.Sc. (Eng.) Risto Pajarre at Aalto University describes, besides the thermodynamics of the CFE technique, also a number­of new application fields, such as boundary surface­phenomena of key importance in material­sciences­ and the interaction of external force fields and chemical changes.

The thesis of Lic.Sc.(Tech.) Petteri Kangas on the use of CFE technology in the development of new simulation models for gasification and pyrolysis technologies is also on its final stretches at Åbo Akademi university. “A thermodynamic approach provides a common basis for easy comparison of raw material and energy efficiencies between different thermal processing technologies,” says Lic. Kangas.

“An interesting area of application is the chemical and thermodynamic simulation of combustion engines, where optimisation of the use of, for example, new biofuels will constitute a future challenge. The traditional combustion technology models are either chemically simplified thermodynamic energy models or mechanistic chemistry models, consisting of several hundreds, or even tens of thousands

figure 7.

Examples of modelling of the demanding unit processes of forest industry and thermal conversion of biomass.

Left: enrichment of sulfur and alkali metals in the flue gases of the recovery boiler. In the CFE super-equilibrium model sulfur and alkali compounds are determined with enrichment constraints while the rest of the flue gas is in local equilibrium. (Kangas et al., J-FOR 2013).

Middle: The main components formed in biomass gasification. The CFE model includes kinetic constraints for the formation of methane, tars and char. The rest of the system reaches thermodynamic equilibrium. (Kangas et al., Fuel 2014).

Right: Carbon conversion of biomass during pyrolysis. The CFE-model includes constraint for the pyrolysis reaction of solid biomass. (Kangas et al., Energy & Fuels 2014).

reaction equations.­Using the ­latter, it is difficult to manage­the thermodynamic variables­that are essential in engine technology.­In this application, the international benchmark used for VTT’s CFE technology is the RCCE (rate controlled chemical equilibrium) modelling technology developed at MIT in the 1990s-2000s, particularly focussed in combining the reaction kinetics and Gibbs’ian thermo­dynamics of combustion processes. Constrained Gibbs free energy techniques could leverage the benefits of various techniques and still produce sufficient information on both state properties and combustion chemistry for practical applications”, says Kangas. n

1 Calphad Journal, published since the 1970s, is a special publication, focusing on computational thermodynamics of material structures. It is held in high esteem within the material sciences sector in particular. Over the past few decades, the computation methods of phase diagrams and chemical equilibria developed by the Calphad community have been adopted all over the world, and they are currently applied by both universities and the industry. Computer simulations based on Calphad methods have played a crucial role in the strong development within the material sciences over the past few decades.

VTT Impulse 31

metals recycling Hybrid methods offer new solutions for

VTT has developed methods for recovery of critical and valuable metals. The methods include mechanical pre-treatment, bio and hydro metallurgy as well as biosorption.

Text Olli Salmi, John Bachér, Jarno Mäkinen, Justin Salminen

32 VTT Impulse

A

SCIENCE

great number of research, innovation sustainability of the products with the new substiand policy actions in the mineral sec- tute materials. When no substitutes exist, increastor have been initiated in recent years ing attention needs to be paid to the recovery of within the EU and in Finland1. These small concentrations of a great number of valuactions aim to improve the opportunities for able metal raw materials (Salminen et.al. 2014). sustainable growth in the mineral sector, for Similarly, at the upstream end, the large volumes creating more jobs in Europe and for secur- of side-streams that are currently being landing the raw material needs of European indus- filled at mines and around processing sites contries. In addition, Finnish on-going or recent tain a number of business-critical raw materials. programmes, such as the Tekes Green Growth Compared to just a few decades ago, these mateand Functional Materials programmes and the rials are now being given substantial interest, with FIMECC SHOK, support the development of a efforts to understand their end-use and the conmore sustainable and technologically stronger comitant business logic for efficient recovery. mineral sector.

This article addresses the recovery potenWhat is missing from the arena is a way to link tial of a number of critical and valuable raw the intensive R&D&I efforts that have been put materials through a hybrid system combinon the upstream end of the mineral value chain – ing mechanical separation, bio and hydrometthe mine – and on the downstream end – the end- allurgical processes as well as biosorption. For of-life products. This missing link emerges in part the sake of simplicity, we use the example of a from a natural discontinuity in the mineral value printed circuit assembly (PCA) which contains chain: mineral commodities are traded on the the major components attached on the surface global market place, and in practice there is lit- of the printed circuit board (PCB) for the recovtle vertical integration from primary raw materi- ery of gold, copper and plastics. The basic flow als to final products. The value chain discontinu- sheet (Figure 1), however, can be applied to a ity applies to commodities, e.g. nickel or copper, number of different flows and end product categories, including conwhich have a long hissumer goods, industrial tory of volume-intensive intermediates, process end use applications and substituting business- side streams and tailings. well defined global specifications. When, however, critical raw materials All recovery processes include pre-treatment considering raw materiin applications calls stages, concentrate proals that in the future are expected to become busifor a completely new duction and extractive metallurgy. Both pyroness critical for a numdesign philosophy. metallurgy and hydrober of industries, the metallurgy (including entire innovation ecosysbiohydrometallurg y) tem in the mineral sector requires further development. Downstream may be applied depending on the composition in the value chain, substituting business-criti- and mineralogy of the feed. cal raw materials in applications calls for a comThis paper is constructed so as to follow the pletely new design philosophy, which broadens logic of the flow sheet in Figure 1. First, we the design problem into understanding the origin describe the dismantling, crushing and flotation and recyclability of potentially cheaper and less segments of the process. Second, we proceed critical materials, while ensuring the functionality to describing the recovery of copper through (i.e. the high technology features) and ecological bioleaching from the light fraction, as well as The EU Raw Materials Initiative (2008), Finnish natural resource strategy (2009), the national mineral strategy (2010), the ad hoc list of critical raw materials for the EU (2010), the EU Roadmap for Resource Efficient Europe (2011), the Tekes Green Mining Programme (2011), the European Innovation Partnership (EIP) on Raw Materials (2012), the ERECON European Rare Earth Competence Network (2013), and the upcoming Knowledge and Innovation Community (KIC) on raw materials. The list is an example and not comprehensive.

1

VTT Impulse 33

Mobile phones

Dismantling (Manual and mechanical

Au recovery with biosorpition Yield 80-90% in one stage

figure 1.

Simplified flowsheet for a hybrid recovery process for metals from a printed circuit assembly.

Printed circuit assembly

Au leaching Non-cyanide (CI-CIO, thiourea)

Au recovery by solvent extraction (SX) Yield >90% in one stage → gold purification Residual solids to noise walls, gas, etc...

the final treatment of the residual organic and inorganic flow. Third, we describe the process of recovering gold with a non-cyanide leaching process combined with biosorption and solvent extraction. Fourth, and finally, we describe some preliminary concepts of recovering copper from both the heavy and light fractions and conclude with recommendation for the future use of the process model.

Pre-treatment of PCA Due to their heterogeneous nature, waste materials are rarely suitable for recovery processes as such. Mechanical pre-treatment is needed to produce concentrated fractions that can be processed further. We selected mobile phones as case material because of the high level of metals concentration in their PCAs. The dominant metal in PCA is copper, with concentra-

figure 2.

Grade versus recovery of Cu. The enrichment ratio versus the recovery of copper in the sink metal concentrate fraction.

34 VTT Impulse

Crushing and Sieving

Hydrometallurgy base metals leaching, Cu primary target

Flotation (removal of plastics)

Heavy fracation (flotation underflow) Metals, Au, REE CU>40%

Cu recovery (selective precipitation, cementation, electrowinning) Bioleaching Cu leaching (Cu yield >90%)

Froth Plastics and some metals Cu <10%

tions of between 15 % and 27 % depending on the PCA’s host device (Ogunniyi and Vermaak, 2009; UNEP, 2013). In our study, the copper concentration was roughly 25%. In addition, high precious metal concentrations are present in sophisticated and complex applications such as mobile phones and computers (UNEP, 2013).

Metals such as silver, gold and palladium are used in connectors in order to increase the conductivity and to reduce oxidation (Luda, 2012).

Mechanical tests included unit processes such as crushing, sieving, magnetic separation, eddy current separation and sensor-based separation as well as manual sorting. As a result of the pre-treatment of mobile phones, a PCA-rich fraction corresponding to slightly above 20% of the feed quantity was produced. During the mobile phone experiments, it was observed that manual sorting produced better quality PCA

than mechanical processing. Therefore, further mechanical treatment of PCA by flotation was carried out on the manually sorted PCA fraction. Prior to flotation, PCAs were crushed into a grain size below 250 Âľm. In addition, the liberation degree of metals was increased by crushing. This is essential for efficient separation. It avoids the risk of hybrid-particle-aggregates with many different mixed materials separating as such and not as individual component fractions. The flotation experiments focused on separating plastics that contain e.g. antimony, bromines and chlorides, which cause corrosion problems later especially in the pyrometallurgy process and which add to the impurities of the hydrometallurgical process.

In the flotation process, hydrophobic particles are separated from hydrophilic particles by blowing air into a sludge containing both types of particles. Hydrophobic particles are picked up by air bubbles and travel to the top of the sludge and can then be skimmed off mechanically. The experiments were conducted with a full factorial design where the variable parameters were agitation speed, aeration rate and pulp density. Based on the full factorial experiment design including three centre points, 11 experiments were carried out. During each experiment lasting 30 minutes, five sub-samples were taken from the froth. The efficiency of flotation was evaluated by enrichment ratios and recoveries of monitored elements (Cu, Au, Cl and Si) over the flotation time.

The froth fractions produced were analysed with a portable XRF analyser in order to determine the efficiency of the flotation by recovery rates and enrichment ratios. The enrichment ratio versus the recovery of copper is presented in Figure 2.

Table 1.

the liberation degree of metals was increased by crushing.

Figure 2 shows that experiments 8 and 6 were able to enrich the copper concentration more than 1.5 times the concentration in the feed.

The copper concentrations of experiment 8 were approximately 43% in the metal concentrate and around 9% in the froth. Both experiments 6 and 8 with the highest enrichment ratio had a high pulp density and agitation speed, which indicates a strong effect on the enrichment.

The effect of aeration was not as strong as for the enrichment ratio; however, it improved the recovery rate. Experiment number 4 was clearly non-selective in relation to copper compared with the other experiments. The low agitation and high pulp density and aeration probably produced unfavourable circumstances for selective flotation, at which time copper particles ended up both in the froth and metal concentrate. Comparing the copper recovery rates and enrichment ratios of this study with the results obtained by Ogunniyi (Ogunniyi and Vermaak, 2009), the enrichment ratios were slightly lower in this study. However, the recovery rates in this study were considerably higher. One reason for the difference may be explained by the different content, particle size and shapes of the feed as well as the parameters used.

Enrichment ratios (ER) and recovery rates for copper, gold, chlorine and silicon.

SUBSTANCE

COPPER

GOLD

CHLORINE

SILICON

Recover %

ER

Recover %

ER

Recover %

ER

Recover %

ER

EXP 1

98

1,12

91

1,04

84

0,958

80

0,922

EXP 2

97

1,17

88

1,06

88

0,979

83

0,922

EXP 3

96

1,24

83

1,08

79

0,947

73

0,873

EXP 4

61

1,14

59

1,11

42

0,779

35

0,665

EXP 5

83

1,37

73

1,20

61

0,922

47

0,720

EXP 6

78

1,56

62

1,25

43

0,816

32

0,607

EXP 7

89

1,45

75

1,22

55

0,888

42

0,684

EXP 8

81

1,70

61

1,28

35

0,731

21

0,439

EXP 9

77

1,49

63

1,20

42

0,803

31

0,597

EXP 10

91

1,40

77

1,18

63

0,911

52

0,749

EXP 11

93

1,43

76

1,16

60

0,880

51

0,750 VTT Impulseâ&#x20AC;&#x201A; 35

equation 1– 4

S0 + 1.5 O2 + H2O → 2 H+ + SO42-

(1)

chemical

(2)

2 Fe2+ + 0.5 O2 + 2 H+ → 2 Fe3+ + H2O

microbial

(3)

2 Fe3+ + Cu0 ←→ 2 Fe2+ + Cu2+

chemical

(4)

+

2+

The enrichment ratios and recovery rates for Au, Cl and Si are presented in Table 1.

The flotation experiments showed that metals were enriched with froth flotation to the metal concentrate while most of the plastics, resins and other harmful elements were separated to froth. The full factorial flotation experiments revealed that the most optimal copper enrichments were obtained with a pulp density of 20%, an agitation speed of 1,200 rpm, and an aeration amount of 3,000 ml/ min, at which time copper could be enriched from approximately 25% to 45% with a recovery of 85%.

Bioleaching of copper and side stream treatment According to elemental analysis, the PCA froth still contained high levels of copper (153 g/ kg). Therefore, additional treatment and metal recovery operation were needed. Because of its low-cost and low technology requirement, acid bioleaching, was combined with low hazardous emissions. Moreover, promising results on the bioleaching of printed circuit boards have been presented in the literature (Liang et al. 2013; Liang et al. 2010; Xiang et al. 2010; Yang et al.

2009; Zhu et al. 2011).

Acid bioleaching technology relies on autotrophic bacteria, such as Acidithiobacillus thiooxidans and At. ferrooxidans, which are well known for their ability to oxidize reduced sulphur compounds or elemental sulphur so as to produce sulphuric acid. In addition, At. ferrooxidans and Leptospirillum ferrooxidans are known to oxidize iron from the ferrous to ferric state (Sand et al.

2001; Watling, 2006). Even though WEEE and PCA are very unconventional materials for autotrophic microorganisms, the leaching chemistry shown in equations 1–4 has been observed (Liang et al. 2013; Xiang et al. 2010; Yang et al. 2009; Zhu et al. 2011).

According to these equations, a simple bioleaching monitoring method was established for measuring the pH, oxidation-reduction potential (ORP) and dissolved Fe2+ and Cu2+ concentrations. As PCA froth tends to create a neutral-pH and rather strongly buffered solution with water, the thriving of sulphur oxidizing microorganisms and production of sulphuric acid (equation 1) reduces the pH and keeps the solution acidic. On the other hand, when iron oxidizing microorganisms are thriving, 36 VTT Impulse

microbial

Cu + H + O2 → Cu + H2O 0

they oxidize Fe2+ to Fe3+ (equation 3), resulting in a severe increase in ORP and a decrease in Fe2+ concentration.

Bioleaching experiments of PCA froth with acidophilic culture proceeded from the adaptation of microorganisms to preliminary experiments, followed by optimisation of leaching parameters and finally a test run with a scaled up bioreactor. In most of the experiments abiotic sulphuric acid leaching experiments were also carried out in order to verify whether microorganisms improved the leaching rate of copper. Mixed acidophilic culture, enriched from a sulphide ore mine site (Halinen et al. 2009) and containing At. ferrooxidans, At. thiooxidans/albertensis, At. caldus, L. ferrooxidans, Sb. thermosulfidooxidans, Sb. thermotolerans and some members of the Alicyclobacillus genus was used.

The adaptation of the culture for PCA froth and subsequent preliminary bioleaching experiments were conducted in the presence of modified K9-media, 10 g/l S0 and 4.5 g/l Fe2+. Due to the unconventional material, strong sulphuric acid was introduced to reach pH 2, which is optimal for the majority of the bioleaching microorganisms (Rawlings, 2002). It was seen that microorganisms were able to maintain the pH or even further acidify the sample and simultaneously cause a rapid increase in ORP and a collapse in Fe2+, illustrating the thriving of both sulphur and iron oxidizers. However, copper concentrations were lower than with abiotic sulphuric acid leaching and the kinetics slower. The maximum tolerated PCA pulp density was about 50 g/l, which is well in line with the literature (Liang et al. 2010; Xiang et al. 2010; Zhu et al. 2011).

To increase the recovery rate and leaching kinetics of copper, bioleaching parameters were optimised. Fe2+ concentrations of 0, 4.5 and 9.0 g/l were introduced to a system with a PCA froth pulp density of 20 g/l in the presence of modified K9 media and 10 g/l S0. The copper concentrations achieved in the bioleaching solution according to 0, 4.5 and 9.0 g/l of Fe2+ and abiotic sulphuric acid leaching were 1.6 g/l, 2.2 g/l, 2.6 g/l and 2.6 g/l respectively. It is clear that ferric iron attack plays a vital role in the rapid dissolution of copper, and bioleaching can outrun the abiotic sulphuric acid leaching when the process is operated at around pH 2. However, as seen

stream recovery processes. The gold process, however, currently requires the use of cyanide, which makes recovery both costly and prone to environmental risk. To complete the PCA recovery route with sustainable alternatives, we ran trials with non-cyanide leaching and biosorption. It has recently been shown that certain biomasses can bind heavy metals and gold due to either active cell defence mechanisms or negatively charged cell walls structures. In spite of these promising results, however, traditional biosorption methods utilising freely-suspended biomass is inadequate for industrial applications, mainly due to challenges in the separation of the biomass from the treated solution. Therefore, research has moved on to immobilisation of the biomass into different kinds of immobilizing matrices (Das, 2010; Khoo & Ting, 2001).

Our approach was to take advantage of the ability of certain fungi to produce thick filamentous meshes which can cause self-immobilization of the biomass to a certain form, suitable for industrial applications.

Self-immobilized mats of P. chrysosporium with an average weight of 0.05 g and a diameter of 5 cm were placed on filtration columns and 20 ml of two mine site waters (named as MW1 and MW2, concentrations presented in Table 2) were run freely through the mats. Filtrates were analysed with ICP-MS and ICP-AES for metals and sulphate.

Table 3 shows the treated mine site waters and removal efficiencies. Surprisingly, self-immobi-

from equations 1 and 3, addition of extra Fe2+ also consumes extra sulphuric acid. Optimum process conditions need to be determined so that ferric iron and acid attack give the best results with minimum chemical costs.

The bioleaching system was further optimised with a scaled up bioreactor (3 litre CSTR-type).

Production of ferric iron and sulphuric acid was separated from the treatment of PCA froth by cultivating the microorganisms in a two-step mode; the first step favoured the sulphur oxidizers in the presence of modified K9 media, 2.5 g/l S0 and 0.4 g/l Fe2+; and second step produced ferric iron with the addition of 7.8 g/l Fe2+. The new cultivation procedure produced a leaching solution with parameters of pH 1.1, ORP of +865 mV (SHE) and 7.4 g/l Fe3+. This solution was used to treat PCA froth with a pulp density of 50 g/l, resulting in a 3 day copper dissolution of 99%. During the actual leaching, the pH rose to 1.6, where it was maintained with strong sulphuric acid. Bioleaching was found to be a very specific method for copper leaching, as the only major metallic elements in the solution were copper and iron, 6.8 g/l and 7.0 g/l, respectively. Therefore, later recovery of copper from bioleaching solution should be rather simple and economical.

Gold recovery through leaching and biosorption The heavy fraction from the PCA flotation process contains a high concentration of valuable metals for which there are well proven main-

table 2.

Concentrations (mg/l) and pH in studied mine site waste waters MW1 and MW2 Cd

Cu

Mn

Ni

Zn

Fe

As

Sb

Se

SO4

pH

MW1

0,29

14

45

0,53

311

675

0,03

-

0,02

23550

2,3

MW2

0,001

0,05

1,1

0,03

0,4

1,0

0,85

0,06

0,02

6170

7,9

table 3.

Concentrations (mg/l) in treated mine site waters and removal efficiency (RE %).

MMER: Metal Mining Effluent Regulations for effluent discharge limits for metal mines (maximum authorized monthly mean concentration, mg/l) (Environment Canada, 2012) Cd

Cu

Mn

Ni

Zn

Fe

As

Sb

Se

SO4

MW1

0,03

1,3

3,8

0,05

30

33

0,002

-

0,001

2050

RE %

91 %

91 %

92 %

91 %

90 %

95 %

94 %

-

94 %

91 %

MW2

-

0,004

0,09

0,002

0,04

0,13

0,07

0,005

0,002

672

RE %

-

91 %

92 %

92 %

91 %

86 %

92 %

92 %

91 %

89 %

0,5

0,5

MMER

0,3

0,5

VTT Impulseâ&#x20AC;&#x201A; 37

lized mats of P. chrysosporium were adsorbing unselectively all the elements studied with an efficiency of 86 â&#x20AC;&#x201C; 92 %, despite different initial concentrations and pH values. When treated, mine site waters are compared to Metal Mining Effluent Regulations for effluent discharge limits for metal mines (maximum authorized monthly mean concentration, mg/l) (Environment Canada, 2012), it is seen that MW2 meets the requirements, but MW1 for Cu and Zn does not. Therefore, when treating very badly contaminated waters, some pre-treatment operations are required (e.g. precipitation with lime).

Biosorbents have been reported to be selective for gold and other precious metals (Das, 2010).

Encouraged by this, a self-immobilized mat of P. chrysosporium (dry biomass weight 0.53 g) on a fabric bottom layer was placed on filtration columns (d = 5 cm), and 60 ml of artificial chloride-hypochlorite gold process leachate (composition presented in Table 4) was run freely through the mat. Filtrate was analysed with ICPMS and ICP-AES for elements and sulphate.

Figure 3 presents the removal degree of elements when an artificial chloride-hypochlorite leachate was filtered through a self-immobilized mat of P. chrysosporium. Gold was seen to adsorb effectively on the biomass, while all the other elements were poorly adsorbed. The gold adsorption capacity of P. chrysosporium mat was approximately 32 mg/g biomass (0.16 mmol/g), which is in line with the capacities of biosorbents reviewed by Das (2010). However, this particular biosorption application neglects drawbacks observed with freely-suspended systems.

Conclusions and future steps The increasing use of secondary raw materials including waste electrical and electronic equipment is an essential feature of sustainability in the metallurgical industry. The use of these secondary raw materials for metal extraction is driven by legislative, political, environmental and economic drivers. Metals have traditionally been a good source of wealth and income for the recycling industry due to their relatively simple treatment processes and high prices. For base metals, the recycling processes are firmly estab-

table 4.

Art-Au 38â&#x20AC;&#x201A; VTT Impulse

lished and are approaching a closed recycling loop. Take the stainless steel of Outokumpu as an example: currently about 80%of the end product is comprised of recycled materials. Critical metals found in consumer products such as phosphors, electrical appliances, touch screens, permanent magnets and glass surfaces are, however, still to find suitable recycling systems.

In this article, we have presented a recycling system that combines new angles on mechanical pre-treatment with bioleaching and bioadsorption. The resulting metal recovery rates are significantly better than those with the traditional pyro-metallurgical pathway. However, with the efficient market processes for precious metals and copper in place, we see small concentration technology metals such as lanthanides as a key target for future hybrid recovery metals. The future need for lanthanide recovery is highlighted by the low substitutability of lanthanides in high-tech applications. A good example is neodymium, without which the permanent magnet in the hard drives of computers would not work nearly as efficiently as it does today. Another example is europium, which makes possible the red colour in flat screen televisions and fluorescent lamps. Neither of these elements can readily be substituted; nor are they currently recycled at all. In fact, a long term study conducted by Graedel et.al (2013) reveals that none of the 62 widely used metals or metalloids can be substituted in a way that would fulfil the requirements of their key applications.

The problem is twofold: without a proper recycling system, the supply of raw materials for new high tech products cannot be guaranteed. At the same time, such a recycling system is not feasible without a better product design, collection schemes and process design. The solution to the problem requires systemic eco-innovation along the entire value chain. This includes the development of IPR governance, because leading material combinations are typically heavily protected by companies because of their great value and competitive edge.

The process described in this article is expected to be particularly suitable for the separation of plastics from end-of-life products and

Concentrations (g/l) in prepared artificial chloride hypochlorite leachate Au

Al

Ni

Fe

Pb

Cu

Na

Cl

0,04

0,46

1,0

0,48

0,24

1,0

38

100

Au selectiviness 100% 80% Removal %

form intermediate metal products (like salts) for further treatment in a pyrometallurgical or hydrometallurgical facility. The solution purification and separation of metals from solution, including the selective separation of gold shown in this article, can be applied to different aqueous streams independent of the source. Hydrometallurgical separation methods are increasingly being used in extractive metallurgy. The bioleaching method presented in this paper illustrates the possibilities of continuous reactor leaching systems for treating side streams and wastes still containing rather high residual levels of valuable metals. By utilising biology, there is no need to apply extremely acidic environments with strong oxidizing agents in hydrometallurgy, as the efficient leaching conditions can be achieved by microorganisms from negative-value mineral wastes. As this kind of bioleaching method seems to be very effective for zero-valent metals, it can provide a variety of solutions for treating end-of-life products. n

60% 40% 20% 0%

20

30

40

50

60

Filtrated volume (ml) Gold

figure 3.

Avg. Of other elements

Removal of elements by P. chrysosporium from artificial chloride-hypochlorite leachate

Sources European Commission, 2008: COM 699.

­Recovery. In: Chemical Processes for Sustainable Future.

Graedel, T. E., Harper, E.M., Nassar, N.T. and Reck,

Royal Society of Chemistry. In Press.

B.K. 2013. On the materials basis of modern society.

Sand, W., Gehrke, T., Jozsa, P-G., Schippers, A.,

PNAS: doi: 10.1073/pnas.1312752110

2001. (Bio)chemistry of bacterial leaching – direct vs.

Halinen, A-K., Rahunen, N., Kaksonen, A.H.,

indirect bioleaching. Hydrometallurgy, 59, 159–175

­Puhakka, J.A., 2009. Heap bioleaching of a complex­

UNEP, 2013. Metal Recycling: Opportunities, Limits,

sulfide ore Part I: Effect of pH on metal extraction

Infrastructure. A Report of the Working Group on the

and microbial composition in pH controlled columns.

Global Metal Flows to the International Resource Panel.

­Hydrometallurgy, 98, 92–100

Reuter, M. A.; Hudson, C.; van Schaik, A.; Heiskanen, K.;

Liang, G., Mo, Y., Zhou, Q., 2010. Novel strategies of

Meskers, C.; Hagelüken, C. ISBN: 978-92-807-3267-2 <

­bioleaching metals from printed circuit boards (PCBs)

http://www.unep.org/resourcepanel/Portals/24102/PDFs/

in mixed cultivation of two acidophiles. Enzyme ­Microb.

Metal_Recycling_Full_Report.pdf > (accessed 17.03.14)

Technol. 47, 322-326

Watling, H.R., 2006. The bioleaching of sulphide

Liang, G., Tang, J., Liu, W., Zhou, Q., 2013. Optimizing

­minerals with emphasis on copper sulphides – A review.

mixed culture of two acidophiles to improve copper

Hydrometallurgy 84, 81–108

recovery from printed circuit boards (PCBs). J. Hazard.

Xiang, Y., Wu, P., Zhu, N., Zhang, T., Liu, W., Wu, J., Li,

Mater. 250-251, 238-245

P., 2010. Bioleaching of copper from waste printed circuit

Luda, M.P., 2011. Recycling of Printed Circuit Boards,

boards by bacterial consortium enriched from acid mine

in: Kumar, S. (Eds.), Integrated Waste Management II.

drainage. J. Hazard. Mater. 184, 812–818

ISBN: 978-953-307-447-4. < http://www.intechopen.

Yang, T., Xu, Z., Wen, J., Yang, L., 2009. Factors

com/books/integrated-waste-management-­volume-ii/

influencing bioleaching of copper from waste printed

recycling-of-printed-circuit-boards > (accessed 17.03.14)

circuit boards by Acidithiobacillus ferrooxidans.

Ogunniyi, I. and Vermaak, M. (2009). Investigation of

­Hydrometallurgy, 97, 29–32

froth flotation for beneficiation of printed circuit board

Zhu, N., Xiang, Y., Zhang, T., Wu, P., Dang, Z., Li, P.,

comminution fines. Miner Eng., vol. 22, p. 378–385

Wu, J., 2011. Bioleaching of metal concentrates of waste

Rawlings, D.E., 2002. Heavy Metal Mining Using

printed circuit boards by mixed culture of ­acidophilic

­Microbes. Annu. Rev. Microbiol. 56, 65–91.

bacteria J. Hazard. Mater. 192, 614–619

Salminen, J., Virolainen, S., Kinnunen, P. and Salmi, O. (2014): Sustainable Mining, Metals Processing and

VTT Impulse 39

Robotics – technology with

multifaceted potential

Robotics provides Finnish industry with one of the key technologies of competitivity.

Text Timo Salmi, Marketta Niemelä, Tapio Heikkilä

40 VTT Impulse

M

SCIENCE

any kinds of images are connected saw the introduction of the first robotic appliwith robotics, some of them very cations in the car industry, which continues to fanciful. After all, robots have also play an important role in the application and been the subject of a large num- development­of robotics. In industrial robotics,­ ber of books and films. So-called human- the basic technology became established by the oid robots, walking robots mimicking humans end of the 1980s, and industrial robots became and human activities, have recently been in industrial standard products. In that field, the public spotlight. Major investments have develop­ment has been gradual, involving small been made in humanoid robots, particularly in steps forward on a wide front.

Japan, where local car companies, for instance, Service robotics refers to non-industrial have ­demonstrated their own solutions. They robotics. Service robots include, for example, have been mainly research or demonstration warehousing and distribution robots, milking machines, but in the presented visions, they robots, remotely operated surgeon robots and serve people in their everyday lives. Indeed, robots for difficult conditions such as ocean robotics is seen to have plenty of potential in and space exploration robots. Personal service the future. The robotics applications of every- robots targeted at consumers and special groups day life today and in the near future, however, form their own group, from robot solutions proare robots performing individual routine tasks viding assistance to domestic and toy robots. around the house, such as In the consumer marvacuum cleaners and winket, expectations are great. in the consumer dow cleaners.

IRF (2013), for examTraditionally, a robot market, expectations ple, estimates that 24 million personal household refers to a general-purare great. robots such as robotic pose, computer-controlled­ d e v i c e hand l i ng wor vacuum cleaners and lawn pieces or tools. General purpose refers to the mowers­will be sold during 2014–2017. The programmability of the robot’s motions, and the 2012 and 2013 sales act as a point of comparipossibility of using the same machine for s­ everal son, with sales of around two million robots per different purposes. The robot’s movements are year. usually generated with electric actuators, but Market expansion is slowed down by two they can also be pneumatic or hydraulic. Today, challenges. The robots acquired should be both robots are machines that may have various dif- cost-effective and function reliably in changing­ ferent kinds of physical structures but are pro- and non-organised environments. In industry, grammed to move; they often involve observing the environment is easier to control than the the environment and acting accordingly – there operating environments for service robotics. are various kinds of mobile robots such as auto- However, industrial robots are also developing matically navigating miniature aircraft and cars. in a direction where they work in the same space In robot cars, the car is steered with the help of with human workers. a large number of different actuators, sensors, a In service robotics, robots specialising in a certain, narrow task such as vacuum cleaning, computer and software that utilises all of these.

The word ‘robot’ is also used of software that have reached the highest technical maturity automatically performs certain tasks, for exam- and therefore also commercial success on the ple robotic stock trading or Web robots. These ­consumer market. cases, however, do not involve actual robotics, VTT Technical Research Centre of Finland as the definition of a robot includes a physical- develops not only industrial robotics and spemechanical structure. cial robotics solutions, but also service robotics Robotics combines developments in many solutions for the problems of companies. VTT is different branches of technology: also investigating the possibilities and markets • information technology: processor technology of service robotics as an answer to social chal• computers and software technology lenges such as the ageing population.

• actuators • sensor technology Industrial robotics • mechanics, such as device structures, and The structure of Finnish industry has affected gearboxes. the contents of industrial robotics research in Industry has been the forerunner in the Finland, and thereby also at VTT. A majority application of robotics. The end of the 1960s of the industrial robot markets are controlled VTT Impulse 41

by large, established, international manufacturers. There are no manufacturers of traditional, general-purpose industrial robots in Finland; Finnish manufacturers have concentrated on special applications such as handling heavy objects or abrasive blasting. Other players in the robotic field in Finland mainly include creators of robotic applications, or integrators, and robot salespeople, who also often act as integrators, and those applying robotics. The needs and baselines of the car and electronics industries­ have played a major role in the development of robots. Considering its features, a modern­ robot is a very cost-effective system component into which many kinds of sensors­and control­ systems increasing its intelligence can be connected. The robot itself is, however, only a single­ part of the complete system or functioning application, and its share of the costs of the functioning system has been constantly decreasing.

Indeed, Finnish research has focused on overall solutions and advanced applications instead of the robots themselves.

From the perspective of Finnish industry, the challenges faced by the field of robotics are small manufacturing series and continuously changing products. Considering short-run production, the greatest challenges to the efficient utilisation of robotics are the investments related to an individual product of an entire system, including programming, deployment of a new product, and ability to adapt tochanges in the environment, process or products, that is to say, it is a question of flexibility and adaptability. This subject can be approached from many different directions: from the automation or facilitation of the creation of new software, flexible materials handling and fastening solutions, intelligent utilisation of sensor data, system architecture, etc. Innovative solutions are needed for both the overall system and

safety design becomes more challenging.

42 VTT Impulse

the various subareas, as the weakest link of the overall system determines its practical flexibility. Research has thus been done in the development of flexible system solutions and comprehensive applications.

Furthermore, the research has focused on solving individual obstacles to flexibility by utilising versatile sensor data. Good examples­ of this include the utilisation of force sensors­ in grinding; object picking with the help of machine vision, the most extreme application involving picking completely disorganised objects from drawers; creation of grinding programmes with the help of a measurement profile, and generation of robot programmes with the help of CAD models. There are several examples in industry where short-run production and even one-off production is done at an efficiency almost reaching long-run production levels. There are a lot of possibilities, but awareness of them is regrettably poor.

One research subject that is currently topical internationally is cooperation between humans and robots. The goal is to utilise human flexi­ bility and the robot’s ability to perform repetitive work precisely, or to utilise the robot’s strength.

There are many demanding technical and safety-related challenges. In the case of robots, there are the dangers of collision and crushing.­ Humans and robots have traditionally been ­separated by fences, but with the help of new safety technology,­the fences can be eliminated – while safety design becomes more challenging. Small, light, and slowly moving, so-called safe robots, are a solution for some applications, but in s­ ituations demanding greater strength, speed or precision, more complex solutions are required. VTT’s research has utilised current technology in order to develop solutions that enable human–robot cooperation in many kinds of tasks, such as packaging tasks, handling of heavy objects, or using a robot as a welding jig.

Service robotics Service robots are used non-industrially to perform­various tasks or services for people – hence the name. Service robots are mobile machines that possibly handle objects, operate independently, and interact with people. Service robot applications include agricultural, cleaning, construction and medical (surgery, care, rehabilitation) applications, and space and underwater applications. Service robotics have been

developed­for both professional expert use and for consumers. As the service robots operate in the same room as people, sometimes in a very close interactive relationship, service robot technologies must support ease of use, adaptability, and an ability to function in changing environments – and, in particular, safety.

The safe and easy-to-use interaction of the service robots is largely based on sensors that observe the environment and the robot. The sensors are used to control the robot’s precise functions, such as the motions of its body or arms, and maintain safety, for example, by interrupting the robot’s function when a human is detected too close to the robot or its tool.

Service robotics can also be considered to include the advance functions in the heavy work machines manufactured by the Finnish industry, such as mining machines and equipment.

For instance, intelligent work machines move autonomically in mining tunnels without needing a driver and are steered from control rooms safely and ergonomically.

Care robotics Service robotics are also developed for various care, assistance, and rehabilitation tasks. The purposes vary from simple assistance solutions to social robots that are therapeutic and support interaction. In these applications, the robotic technology is not necessarily very advanced; the challenges lie in designing their interaction and fitness for purpose.

Robotic equipment is available to the elderly and those with disabilities in order to make their everyday life easier, such as a multi-­purpose robotic arm mounted on a wheelchair, or a feeding arm. Robots are being developed to support­ the independent living of the elderly; they monitor­the condition of their owner and can detect falls; they also make an emergency call in the case of an emergency and open a video connection to a doctor or a family member. Service­ robots may be used at rehabilitation clinics,­ where a rehabilitation robot tirelessly assists and guides the patient’s movements, providing suitable resistance for strengthening the patient’s muscular power.

Robotics has also found applications in nonphysical rehabilitation. Humanoids resembling people, such as NAO, and animal-like zoonoids, such as the Paro seal robot, are able to engender positive emotions and activate interaction

a modern robot is very cost-effective.

timo salmi Senior Scientist Timo Salmi has worked at VTT for 26 years, researching the design of production systems, robotics, production automation, and the development of production processes.

Among other things, in the SISU 2010 – Innovative Manufacture research programme, he was the project manager or key researcher in several research projects in the field of robotics.

VTT Impulse 43

accepted because they help people. The closer a robot gets to an area considered to be a human domain – care, for instance, but also a warm, personal, and humorous customer service situation – the more sceptical the expectations. After meeting the robot, however, the experiences have as a rule been positive.

Summary Robot technology is a wide field, where many kinds of know-how are required. Successful applications are achieved by building ­functional overall systems in a practical way. In addition to familiarity with the technology itself, this requires a good knowledge of the application environment. Furthermore, you must master the techno-economic issues in the development of robotics. Even superior technological knowhow is not enough. The applications must suit their target in the techno-economic sense. As a multi-disciplinary institute, VTT has an exceptionally broad technological background in robotics research, and the possibilities of offering support for various robotics challenges with between people. The Paro seal has been found to a balanced approach. reduce the restlessness of those suffering from Attitudes towards robotic technologies are memory disorders, and increase the feeling­ often two-fold. There is a fear that the robots of community at an old-age home. The NAO will eliminate jobs. However, it is well known humanoid has been beneficial to autistic chil- that industry must operate in an atmosphere dren, who find the situations and rules of social of tough international competition; in high-cost interaction difficult to grasp. Interaction with countries, things must be done more efficiently, NAO is easy and unchanging, giving a chance to smarter and better. The productivity of work rehearse the means of human interaction. New must keep up with the competitiveness. In order uses found for NAO include brightening the to achieve this, all the means allowed by technoleveryday life of the elderly: the tiny humanoid ogy should be used, including robot technology. has led exercise sessions and read the Aamulehti Industry is the prime mover of the national newspaper to the elderly. economy, generating funds into the financial The ageing of the population is a megatrend. cycle of the national economy. With the excepRobotics opens up possibilities for both better tion of the very smallest of countries, there care and the reorganisation of care. Robots will are no examples of national economies thrivnot be able to replace nurses – robots do not act ing without industry. It is, therefore, vitally independently, they are tools for the care staff. important by any means necessary to maintain The results of the trials have been positive, but the international competitiveness of industry. the long-term benefits should be systemati- Robotics is justifiably one of the key technolocally studied. There are also ethical questions gies that make the competitiveness of the Finninvolved in the therapeutic use of robots: Can ish industry possible. you become attached to a robot? Does the user There is a great deal of unused potential in the understand that the emotions displayed by the utilisation of new technologies both in industry and outside it. In the future, robotics will robot are not real?

According to an attitude barometer taken in improve the quality of life of the elderly and the European Union’s Member States in 2012, the disabled, making their everyday life easier. people have a positive attitude towards robot- Through research into and the design of interics, Finns more so than Europeans on average. action between humans and robots, VTT can VTT has studied what expectations people have ensure safe, easy-to-use, and ethical robotics of robots in customer service. The robots are applications. n

robotics opens up new possibilities for better care.

44 VTT Impulse

technology Maintenance of fusion reactor successfully performed using remote control the recuirements for the technologies used in the International Thermonuclear Experimental Reactor (ITER) are high, as they are used to control the fusion plasma burning at a temperature of hundred million degrees centigrade. VTT has reached an important objective in the development of ITER fusion reactor remote control, when the divertor cassette collecting impurities was replaced for the first time using remote control in the research facility for remote controlled maintenance. This operation is one of the most demanding measures in the forthcoming ITER fusion reactor, the construction of which is proceeding rapidly in Cadarache, Southern France.

Located in the lower part of the ITER reactor chamber, the 54 cassettes of the reactor component, or the divertor, measuring 3.4 m x 2.3 m x 0.6 m and weighing approximately 10 tonnes each, need to be handled at tolerances of a few millimetres. The divertor cassette is like a giant ashtray, into which the hot ashes and impurities settle.

For the cassette replacement operation, the lights of the Divertor Test Platform, or the DTP2 facility located in a VTT research facility in Tampere were dimmed to correspond with the prevailing conditions in ITER, and the whole operation was performed from a control room with the assistance of virtual models and camera views.

In the ITER reactor maintenance, remote operation and virtual technologies play a key role, and they have extensive opportunities for application in other industrial sectors as well. Similar technologies are being used, for example, on space flights, and in underwater and underground operations.

The system combines robotics, advanced technological tools, powerful computers, and virtual reality platforms.

Miniature-scale measuring devices VTT has developed cost-efficient, hi-tech technology that enables the development of intravenous devices.

The INCITE project is exploring the miniaturisation of an intravenous catheter.

A catheter prototype is being created based on MEMS (Micro Electro Mechanical Systems) technology. This catheter needs to be small enough for insertion into a blood vessel.

54

divertor cassettes were replaced using remote control.

Thin films for food packaging from hybrid materials In his doctoral thesis, Juha Nikkola, Senior Scientist at VTT, developed new hybrid materials that can be used in the manufacturing and shaping of coating layers for thin film composites. This resulted in discovery of new materials suited for, for example, food packaging enhancing preservability of products and biological membranes used for water purification. In the future, similar materials may also be applied to flexible OLED screens and wall and ceiling panels.

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Nano-photonic sensor circuits for mass production the european consortium PHOTOSENS has been developing a

Photos: Noora Salminen

polymer-based nano-photonic sensor circuit with such uses as monitoring of air quality, purity of pharmaceutical processes and food safety. The objective set for the project was to develop a ­disposable, mass-producible sensor chip for generic multi-parameter sensing applications.

By combining nano-photonics, tailored polymer materials and mass manufacturing, the project challenges the traditional analysis technologies, which usually require expensive equipment and a lot of personnel.

In the PHOTOSENS consortium, VTT focused on the manufacturing of polymer-based nano-photonic structures using UV nanoimprinting and integration of multi-parameter sensor.

Read more about the subject on page 48.

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key terms Cyber security, information security, Cyber War Room, KYBER-TEO key persons Reijo Savola, Pasi Ahonen, Veikko Rouhiainen key message VTT is engaged in research and development related to strategic cyber and information security with companies and organisations.

VTT contact Reijo Savola, Pasi Ahonen, Veikko Rouhiainen more information www.vtt.fi

on several fronts Advancing cyber security

VTT is conducting extensive and versatile research and development related to cyber and information security.

The KYBER-TEO project entity serves specifically industrial needs.

Text Matti Välimäki Photos iStockphoto

48 VTT Impulse

Strategic research and assignments The distinction between cyber and information security is becoming obscure, and today these two terms are largely used as synonyms.

In principle, though, cyber security is a sub-area of information security, aiming at ensuring the security of critical functions for society. The terminology is changing rapidly, however, and no unambiguous definitions have been established.

VTT collaborates with companies and various organisations in research and development related to cyber and information security – and also performs different assignments related to these matters.

Reijo Savola, Principal Scientist, cyber security, says that typical assignments include different information security analyses, assessments and testing. VTT also performs, for example, risk analyses and, on the basis of these, assesses system architectures and their implementation.

VTT is internationally known for its research related to information security indicators.

– The basic idea of information security indicators is the establishment of as good a situation awareness image of information security as possible, which helps decision-making at all organisational levels. The information needed by the strategic, operative and technical levels is provided in exactly the same language they use.

The indicators make it possible to report, for instance, to the company’s management group the information security data needed by it in an easy-to-understand visual format. The key matters that have emerged in the risk analysis can be described, for example, by using a traffic light style visualisation.

– The idea is also that the necessary data is passed along throughout the various phases of risk analyses and the product and service develop­ment linked with it.

Adaptive information security is another spearhead area of VTT operations that is partly related to these indicators.

– If, for example, a certain monitoring system is used both in a hospital environment and at home, it is rational that the identification needed to access the system adapts according to the situation. In practice, this means that in a closed hospital environment or, for example, an ambulance, access to the system is easier, but elsewhere the access control is stricter. It is not sensible to require too much information, if it is not really needed.

Savola points out that adaptive features make the system lighter and easier to use.

– The role of this type of adaptive systems is also becoming more and more emphasised all the time, as IoT, the Internet of Things, becomes more common. Various types of devices we use in our everyday lives are constantly linked with each other, exchange information with each other, and travel from place to place.

The whole arsenal in use in the Cyber War Room Reijo Savola is especially proud of VTT’s new Cyber War Room – a miniature-scale internet, isolated from the rest of the world, where different kinds of test attacks can be made. He estimates that, in the future, attack competence VTT Impulse 49

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he same basic principle applies to cyber and information security as security in general, points out Veikko Rouhianen, Research Professor at VTT, where his area of speciality is risk management and security.

– One can get quite far simply by using common sense, understanding the risks, and behaving accordingly. No system will help you, if you do not use it. Information security is not the responsibility of a company’s ICT personnel only, but everyone has to observe it in their daily activities.

On construction sites, it is already a normal practice that everyone wears a helmet. Similarly, it should be totally clear that security-sensitive information is not sent by e-mail, for example.

– A minimum requirement is an encrypted e-mail connection. The good old paper is also a surprisingly good alternative.

In addition, people should be aware of, for example, which information is security-sensitive and which is not.

What makes the situation more complicated is the fact that when innocent-looking pieces of data are brought together, the final outcome may reveal too much.

– In such matters, we should revise our attitudes. For instance, in social media, people disclose matters they would better leave untold.

– When basic thinking related to information security is in order, it is a good point to start developing the systems in other respects as well, underscores Rouhiainen.

“Various types of devices we use in our everyday lives are constantly linked with each other.” will be an important skill for cyber security professionals, to ensure the best possible expertise for defence against criminals.

– The legislation alone prohibits making this kind of cyber attacks in the open Internet, where different malware can spread. In the Cyber War Room, we do not need to rely on simulation, but we can freely use the entire attack arsenal available to us, and test the defence capabilities of different systems. This will serve both our customer companies and our strategic research.

VTT also operates in the Finnish Information Security Cluster (FISC, www.fisc.fi), involving companies that specialise in information security solutions.

– At the moment, even the big Finnish information actors are small in global scale. Still, we have a lot of expertise in this sector in Finland. In the FISC network, the idea is to enhance co-operation and to collectively gain access to larger projects and challenges, and to consider development trends at a strategic level.

And, as we are discussing cyber and information security, the work is never done. Technology and the threats related to that evolve all the time.

Someone is always developing new methods of hacking into systems.

– This combat is somewhat disproportionate.

We have to be prepared for any kind of threat scenarios all the time, to be relatively good at everything. Criminals, on the other hand, can focus on developing only one cyber weapon of their choice at a time; they do not need to prepare themselves across the whole front, says Savola describing the situation.

Development of industrial cyber security VTT has been working several years for the development of industrial cyber security in several projects.

Senior Scientist Pasi Ahonen mentions as one example of the achievements among the projects targeted at the industry the common requirements for vendors, which supports the management of automation system vendors’ information security. By applying it, an industrial company 50 VTT Impulse

will have its various system suppliers, devices and solutions function in accordance with its own information security concept.

VTT has also produced, for example, information security instructions for factory environment, in other words, basic rules on what every employee, from plant cleaner to automation engineer, needs to know about information security.

At the moment, Ahonen heads a three-year KYBER-TEO project entity (2014–2016), with an aim to develop cyber security services and practical implementation of information security solutions and practices in the industrial sector. The main sponsor of the project entity is the National Emergency Supply Agency.

– The idea is to develop and test cyber security services in the participating companies with a view to ensuring production and continuity. In bilateral cases, the confidential results are naturally revealed only to the organisation involved. At the same time, however, general information is also generated, which can be shared for everyone to use, also outside the projects. n

Sharing experience The kyber-teo consists of three work

packages:­cyber protection practices and mappings, practical implementation of cyber security in domestic production, and monitoring services of production automation network.

– We also provide a forum for exchange of information and peer support. Companies can, for example, compare what functions well and what doesn’t.

One of the problems in the development of cyber security is that very little information about production stoppages caused by, for example, viruses is made public.

– It is important to develop a more closed sharing of information system on the subject, so that people are aware of, for example, any active attacks. This will also make preparation for fending off such threats easier.

In addition to the National Emergency Supply Agency, the other customers involved in the KYBER-TEO project includes Metso Automation, Neste Oil, Outotec, Turun seudun puhdistamo, and, from the service sector, Nixu, nSense, Prosys and Nordic LAN & WAN Communication Oy. – There is room for new companies, as we are only going through the first year of the project, hints Pasi Ahonen.

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key terms Photosens, printed intelligence, mass production key persons Pentti Karioja, Jussi Hiltunen key message The market opportunities for printed intelligence are just starting to open up.

VTT contact pentti.karioja@vtt.fi, jussi.hiltunen@vtt.fi more information www.vtt.fi

In the picture, gold-plated and non-gold-plated sensor chips in various formats, produced using roll-to-roll technique.

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tomorrow Printed intelligence encompasses a vast amount of potential applications and market opportunities.

Text Riitta Niskanen Photos Noora Salminen

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nder VTT leadership, an inter­ national Photosens research project­ developed a sensor solution, in which sensors printed on a polymer­ platform measure concentrations of one or multiple substances. The application opportunities for this new technology are huge and the markets for applications based on it are only beginning to open.

Coordinator of the project at VTT, Research Professor Pentti Karioja, shows a roll of sturdy polymer film with small squares. The roll contains nanophotonic sensor circuits printed on a polymer platform.

– In the development, we focused specifically on mass production techniques, by which large amount of sensors can be made. We wanted an easy-to-handle sensor solution that is cheap for both the manufacturer and the consumers, he explains.

In other words, the sensor platform is ready, but it does not suffice on its own. Jussi Hiltunen, who acts as researcher at VTT Oulu, shows a small metallic reader, which is a prototype.

He places a sensor inside the reader and the camera­technology incorporated into the device deciphers­the information collected by it.

– The long-term goal is to develop a device for consumer use, he points out.

Easy-to-use mass product The three-year Photosens research project, directed by VTT and financed by the EU, ended last January.

– VTT coordinated the project, ­compiled an international consortium around it, and showed the direction in which the research should go, specifies Pentti Karioja.

– We have established a view of what kind of additional pieces would be needed nationally and at the European level, Jussi Hiltunen continues.

The objective set for the project was to develop a disposable, mass-producible sensor chip for generic multi-parameter sensing applications.

A key requirement was that the sensor chip is capable of performing screening tests without ­specialized equipment or special expertise.

VTT’s contribution to the project was the transfer of nanophotonic structures into polymer structures by the use of UV nanoimprinting and the integration of a multi-parameter sensor.

– Our role was to produce printed intelligence spiced up with optical sensing technology, says Pentti Karioja, summarising the project.

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Sensor of

One or multiple substances to be detected The operating principle of the sensor solution is simple. The sensor platform measures the concentrations of various chemicals in the environment or in industrial process control. When foreign bodies attach on the surface, these can be detected and analysed.

The project used a few examples to demonstrate the functionality of the sensor platform.

– One of them was a pharmaceutical process, in which we measured drug residues. The other was related to the milk scandal in China. The sensor structure developed by us was sensitised to detect melamine, explains Hiltunen.

– A key part of the innovation was the possibility to individualise the substance which the sensor surface would react to, i.e., we can purposely seek for specific agents. In more general terms: we can seek for practically anything. There are millions of possibilities, so we usually carefully define a certain chemical the presence or non-presence of which the sensor will reveal, he continues.

Furthermore, the sensor can identify several agents, not just one. The measures and data of all agents can be collected easily from the same sample.

The sample may also originate from various sources, but the structure of the sensor identifying it is always the same.

“first professional use and only then consumers.”

Both SERS (Surface Enhanced Roman Scattering) method and photonic crystals are used in the sensor.

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First to professional use, then to consumers The application opportunities for printed intelligence are huge. It facilitates monitoring of, for example, air quality, cleanness of pharmaceutical industry processes and food safety.

– My dream is that, when I’m old, I would have a machine next to my microwave, by which I could make sure that everything is in order. In other words, in the future, this kind of measuring would be available to anyone. They are applicable to monitoring our operations and decision-­ making concerning, for example, medication and vital functions, Karioja elaborates.

As concerns foodstuffs, they can be used to ensure that they do not contain any additional, harmful agents.

By waving the sensor around in indoor air, we can check whether suspicions of the existence of mould spores turn out to be true or not.

In health monitoring, the daily samples can be taken easily and cost-effectively, transmitted to a physician with a computer, and thus monitor in which direction the indicators telling about our personal health are shifting.

These are just a few examples of the potential applications of the innovation. However, the starting shot has now been fired.

– In the future the chain will go like this: first professional use and only then consumers. The first users can include, for example, local shops and restaurants, because the price of the reader depends on how many of them are needed. The ordinary consumers come only after that, says Pentti Karioja, envisioning the future.

The sensor platform is ready. The measuring methods are ready. The reader developed for analysing the samples is almost ready, only awaiting the final touches.

– We have the functional technology. Now we need to find the companies in the world that are ready to exploit the results of the research and use them in their own operations, summarises Karioja.

Nanocomp involved as a research partner The company that has made the most advances in the commercialisation of the new innovation is the Joensuu-based Nanocomp Oy, operating in the area of nano-optic manufacturing.

The company participated in the Photosens research project as VTT’s partner and played a vital role in the development of mass manufacturing techniques for sensors.

– Our role was to study the roll-to-roll technology, i.e. how to perform large-volume nanophotonic roll-to-roll manufacturing, says Samuli Siitonen, Chief Technology Officer at Nanocomp Ltd.

The sensor is capable of identifying several substances at the same time. In the picture, a single 2x7 chip.

In principle, there are three levels in the mass production technology of nanophotonics. Sensors have been produced using traditional lithographic methods for a long time. VTT studied sheet-level technology in particular. Nanocomp focused on the roll-to-roll production level.

– We aim at finding a cost-effective and rapid method for producing sensor chips based on nanophotonics, as well as related techniques and equipment. Our goal is to reach the disposable functioning mode in the component prices, which is what the sensitive measuring method of this sensor structure is all about, says Siitonen.

In a disposable method suited for Everyman, the user of the sample and sensor surfaces would not need to take any complex measures. After use, the sensor could be recycled with plastics or burned.

– In the research project, however, we are discussing very challenging detector types. Ease of use is a future challenge that we keep in mind all the time, says Siitonen.

Any printing press is not suited for printing of sensor chips based on nanophotonics.

– Nanocomp has been working with mass manufacturing of nano-class surface structures for years. Therefore our starting points for developing printing methods of sensor surfaces have been good. We have the equipment for printing optical printed components, or photonic components, and also equipment for their further processing, says Samuli Siitonen.

Market launch within the next few years Even though Nanocomp Ltd has advanced far in its Photosens technology, the sensor structures are not yet in actual production in the company.

– This is largely research aimed at future products. It requires long-term development cycles, specifies Samuli Siitonen.

The technology leader, however, considers the field very inspiring, and the expectations are high.

– Sensor technology production using roll-toroll method is a very up-and-coming and interesting area of operation. We have been given the opportunity to delve into matters in the forefront.

We will be ready the day all support functions for market entry are mature enough, he rejoices.

For example, according to Siitonen, an affordable and easy-to-use reader must be on the market before anyone is interested in buying sensors.

Chemical functionalities, which facilitate screening of specific agents, must also be ready.

– This project is not about the launch of a single technology, but a sum of many. Market entry will take place when all the branches are ready.

We already have the readiness to make certain types of sensors, but we do not have any off-theshelf products yet.

Samuli Siitonen believes that concrete steps towards utilising the new innovation will be taken within about five years. Many matters going on right now give strong support for this estimate. n VTT Impulse 55

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key terms Australia, Finnish companies, commercial relationships, international cooperation key person Gerald Thomson key message Presence in Australia can provide a solid base for Nordic companies to build commercial relationships in Asia.

VTT contact john.kettle@vtt.fi more information www.vtt.fi

What’s going on

in Australia?

The rapid transformation occurring in Asia offers opportunities for Finnish companies and research organisations that have a base in Australia, says Gerald Thomson.

Text Paula Bergqvist Photos Esa Tanskanen and iStockphoto

H

.E. Ambassador Gerald Thomson, based at the Australian Embassy in Stockholm, visited VTT in August 2014. The Ambassador represents his country also in Finland, Estonia and Latvia. He sees many opportunities for increasing business and R&D collaboration between Australia and Finland.

There are about 50 Finnish companies which have branch offices in Australia, and also others that have a presence through their sales agencies.

– These companies include Konecranes, Fiskars and Marimekko. He pinpoints particularly two companies, Metso and Outotec which are among the biggest suppliers of mining equipment in Australia. It is estimated that 60 percent of mining equipment in Australia is provided by six overseas companies and two of them are Finnish.

– The Australian economy is the world’s 12th largest.­It is experiencing its 23rd year of uninterrupted growth and is forecast to have average annual real GDP growth of 2.8 per cent between 2013 to 2019.

Australia is increasingly tied to fast-growing economies in Asia, says the Ambassador.

Base close to North Asia According to Ambassador Thomson, having a presence in Australia can provide a solid base for Nordic companies to build commercial relationships in Asia.

It is predicted that Asia will account for 50% of global GDP by 2025.

– The business opportunities look very positive because of the large transformation that is occurring in

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Asia. This growth has been generated by a mining boom that has been driven by developments in China and other parts of Asia. The Australian Government is quite optimistic about the continuing growth in this sector.

It has been estimated that by 2030 two thirds of the world’s middle class will live in Asia. This will generate opportunities in the education, health services and agribusiness sectors.

Priority targets The Australian government has identified priority areas into which it is particularly interested in attracting foreign companies not only for investment purposes, but also for research and development. Those sectors include, resources and energy, infrastructure development, the digital economy, materials science and technology and medical science and technologies.

– Committed investment in the resources and energy sector totals about 268 billion Australian dollars. That is an amount roughly the size of the Finnish economy. The timing of some projects is uncertain, but it gives you an indication of the continuing growth that is to be expected in this sector over the medium term.

– There is a big push in the mining sector to achieve productivity gains. This opens opportunities for international companies, including companies in the ­Nordic region, to help Australian companies improve efficiencies across entire supply chains.

In the health sector, the Australian government has created a 20 billion dollar health-research fund, that can be leveraged by foreign companies. Australia has a proven track record on innovation in the medical sector.­ Australia is a country that is highly connected, has adopted quickly new digital technologies and is installing a new nationwide broadband network. Australia’s hunt for new and efficient IT solutions is generating good opportunities for creative foreign firms.

Renewable energy will be a focus for Australia over the medium term, including due to the Government’s commitment to reducing CO2 emissions by 2020.

There are a lot of opportunities also in the field of advanced manufacturing, including in defence technologies.

– Bioenergy or the bioeconomy in Australia is not as well-developed as in the Nordic region. However, the interest in this area in Australia is growing, assures Ambassador Thomson, who points out that there is a lot of available biomass in the country.

Gerald Thomson

The buzz in Melbourne and Sydney There is a lot happening in terms of infrastructure and urban development at the State government and city administration levels in Australia – creating opportunities in niche areas.

– For example, Melbourne has projects on the go where sustainable-city technologies developed in Finland are relevant. In Sydney there are projects where scope exists for Finnish companies to find collaboration in the field of energy efficient buildings, tells Ambassador Thomson. n

23 years of uninterrupted annual growth

The Australian economy is: • the world’s 12th largest • in its 23rd year of uninterrupted annual growth • rated triple ‘A’ by all three global rating agencies • forecast to have average annual real GDP growth of 2.8 per cent between 2013 to 2019 • increasingly tied to fast-growing economies in Asia Source: Australian Trade Commission, Austrade

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jyri häkämies:

We must maintain Finland as an

attractive target for investment The Manifesto of Growth published by the Confederation of Finnish Industries this autumn lays out challenges facing Finnish companies.

Text Antti J. Lagus, Hanna Rusila Photos Vesa Tyni 58 VTT Impulse

key persons Jyri Häkämies, Erkki KM Leppävuori, Anne-Christine Ritschkoff key message Finnish industry must be capable of reforming itself VTT contacts Erkki KM Leppävuori, Anne-Christine Ritschkoff more information www.vtt.fi

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ndustrial operations have been draining out of Finland and Europe into other continents. The United States attracts entrepreneurs with its cheap energy. The share of industry of the Finnish gross domestic product has dropped from 23 per cent to 15 per cent.

However, Jyri Häkämies, CEO of Confederation of Finnish Industries (EK), sees also opportunities for Finland, related to innovativeness and technology. In Häkämies’ opinion, here in Finland, we should not settle with the basic notion that we are losing­production, but we have to take care of educational system, energy and logistics, and the flexibility of the labour system. We have to ensure that Finland maintains its attractive­ness for the industrial sector.

According to Häkämies, in certain cases it may be advisable to take the production elsewhere due to, for example, market proximity.

In such cases, however, it is extremely important to keep the corporate headquarters and product development here.

– We can manage by two routes. The industrial sector needs to streamline its competitiveness, and our competencies have to be among the best in the world, as has been the case, says Häkämies.

The exile of industry is by no means inevi­ table, Häkämies argues. There are examples of production returning to Finland from

Malesia, for example, due to application of Lean Management practices.

Speed and agility – It is often said that Finns are eager to adopt new matters. In my opinion, Pekka Ala-Pietilä, chairman of the board at Solidium, has summarised this very well: Finland has two strengths, speed and agility. I, however, feel that these are not being exploited well enough. The labour market is inflexible and decision-making is slow.

According to Häkämies, we should be fast to react and willing to test new things, so that we would be the first in the world to do something.

– Forest industry is an excellent example of how a sector can reform itself. They have been hit hard, for example, in the paper sector, but now they are discussing such matters as biofuels and wood-based construction.

Technology must rest on a solid theoretical basis According to new research results, 60 per cent of the existing professions will disappear.

Robots and machinery will replace human labour. Häkämies says that instead of decelerating, we should press the gas pedal even harder, and embrace robotics and techno­ logical solutions. In other words, in his opinion, we should not think that new tech-

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key words Competitiveness, economic growth, business operations, industry

“TEchnology needs to be commercial.”

nologies are eating away our work, because that kind of thinking will prevent any chances of success.

Häkämies notes that technology needs to be commercial in order to sell at all. This is also visible in VTT’s operations, one third of which consists of basic research, one third of enterprise­ -driven research and one third of commercialisation of technologies. According to Häkämies, this is also one of the eternal questions of innovation policy: what is the ratio between theoretical­ and applied research? Häkämies is convinced that innovations cannot rest on applied foundations only, since without more solid foundations they soon lose their momentum.

Häkämies points out that, when making techno­ logy investments, industry must consider their payback period. The rules applied vary from one sector to another. For example, energy investments are made for several decades, whereas games industry, for instance, is much more fast-paced.

Companies value predictability Häkämies is of the opinion that low corporate tax system is better than a complicated system of deductions.

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– The clearer and simpler the tax system for corporate actors, the more predictable the business environment. When making investment decisions, companies value predictability, so that they can be sure, for example, that a tax decision made this year is not totally reversed the next.

The Confederation of Finnish Industries’ recent industrial manifesto points out that drawing the line between industry and services has become more difficult than before. The limits are now drawn partly within the companies. Many traditional technology companies are earning a larger and larger share of their turnover from services.

Häkämies believes that the Internet of Things will further promote this development, when products around the world can be supervised from central control rooms located in Finland.

Häkämies summarises the message of enterprises as follows: the public business subsidy machinery must be highly customer-driven.

SMEs in particular may not have a separate product development unit, but the same entrepreneur considers also these aspects of the operations alongside other business activities. n

More turnover, new products Companies sometimes consider money invested in research and develop­ ment as an unproductive expense item. The impact study published­by VTT in June tells another story.

Almost 80 per cent of VTT’s customer companies estimated that ­collaboration with VTT had generated new products, services­or processes.­About 73 per cent of them estimated that their competitiveness­ had improved. Totally new technology was introduced as a result of the project by 57 per cent of the customers.

VTT’s share of Finland’s investments in R&D is about four per cent. With that money, VTT has been involved in the development of 36 per cent of Finnish innovations. This can definitely be called impact, says Erkki KM Leppä­vuori, President & CEO of VTT. – In difficult times, we should make even higher investments in ­reforming and developing trade and industry, he says.

When distributing funds, the CEO would place the emphasis on applied research, which brings direct benefits to companies.

– In my opinion, in Finland, the situation is somewhat skewed in the direction­of basic research. It would be advisable to shift the focus, he says.

The statistical data of the impact study derived from the extensive SFINNO innovation database and the data collected by Statistics Finland.

– This makes the results reliable. Of course, there are several other ­factors affecting the success of companies than investments in research, but the direction is clear: research and development is of great importance,­ says Anne-Christine Ritschkoff, Executive Vice President of Strategic ­Research at VTT.

“BIOeconomy is a rising sector.”

The background support of bioeconomy

ERKKI km LEPPÄVUORI Photo: Antonin Halas

The impact on the customer companies’ turnover, product range, and ­competitiveness was reviewed on several sectors. VTT contribution boosted the company turnover the most in the bioeconomy sector. There the growth was as high as 73 per cent after innovations where VTT had played a major role.

Bioeconomy touches especially the forestry sector and the chemical industry that account for almost 45 per cent of the Finnish exports.

– Forest biomasses and the added value products derived from it naturally play a key role in the Finnish bioeconomy strategy. Bioeconomy is a rising sector,­and on a sector like that it is a must to invest in research and development to have the business take off and soar, underscores Leppävuori.

Promising prospects lie also in cleantech and digital technologies.

– And this does not necessarily mean the same sector on which Nokia operated. For example, social media shows how much potential is hidden in digital services.

Consumers do not necessarily recognise the role of research investments­in the products and services. Within the industrial sector, on the other hand, the benefits are well acknowledged.

– Most of our operations are B-to-B. We do major contribution to, for example, nuclear security. Thanks to our testing services, construction industry products are granted their CE markings and boat models their ­approvals, says Ritschkoff, continuing the list.

VTT has two perspectives in its operations: Firstly, research gives companies­”technology impulses”, which facilitate development of products and services. Secondly, technology is used in the efforts to solve any encountered problems.

Anne-christine Ritschkoff VTT Impulse 61

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key terms Bioeconomy, forestry, wood biomass, cellulose, new consumer solutions Key persons Kristiina Kruus, Anna Suurnäkki key message VTT develops new solutions from wood biomass.

VTT contact kristiina.kruus@vtt.fi, anna.suurnakki@vtt.fi more information www.vtt.fi

I

n Finland, wood grows at a faster rate than it is used. The annual growth is more than 100 million cubic metres, of which the industry uses only approximately 50 million. It would be possible to use some 70 million cubic metres of wood annually and still remain on a sustainable level.

– As regards the use of wood, we clearly pass the criteria of sustainable development. Regardless of this, exploitation of forestry resources could be more efficient and economical, says Anne-Christine Ritschkoff, VTT’s Executive Vice President, Strategic Research.

– The new products need to be affordable and as good as plastic – or even better. We have to establish business value chains in Finland to launch new business operations.

VTT advances public bioeconomy projects and assignments by contributing 600 man-years for the purpose. 24 per cent of VTT’s turnover is associated with bioeconomy. In addition to biotechnology and chemistry, in these R&D activities VTT uses, for example, process technology and business know-how.

Wood is a versatile material Researchers can adapt wood biomass to nano­ cellulose, chemicals, drugs, food products and feed with varying characteristics. By affecting the cell metabolism, it is possible to produce special chemicals from sugars, including isoprene, carotenoides, fragrances and substitutes for rubber.

The pulp cooking process is currently under development for the purpose of produc-

Towards bioeconomy with the power of wood Finland’s rich wood resources are transformed into an increasing array of materials, of which VTT has a multitude of examples to show.

Text Paula Bergqvist Photos Antonin Halas ja iStockphoto

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ing textiles. In Finland, it would be possible to achieve production rates of regenerated cellulosic fibres with a value of EUR 8–10 billion. The VTT ­laboratory in Jyväskylä is already spinning ­cellulosic yarn. The development is conducted in ­collaboration with Aalto University and Tampere University of Technology. The common vision is to create future design products from Finnish wood.

The least exploited component of wood is lignin, 50 million tonnes of which is annually g­ enerated in industrial processes worldwide. As fuel, lignin is worth EUR 50–100 per tonne. H ­ owever, more valuable uses for lignin could also be found.

There are already products in the markets containing a small amount of lignin, but VTT aims to raise its share on a new level.

– The claim that anything else can be made of lignin but money is no longer true, says VTT Research Professor Kristiina Kruus.

Wood material or wood-based raw material­ not suited for production of fibre-based products­ can be ‘blown up’, thus opening its structure to be used as original material for the production of sugars, and further, chemicals and fuels. VTT has developed methods by which plant cell walls are dissolved and further broken down to sugars, to be used in production of ethanol. St1 Biofuels and VTT have made an agreement on research aiming at optimisation of the wood-based production process.

A die-cast cup with almost 80% of woodbased materials, fibres and lignin. VTT has developed the manufacturing method in the FIBIC’s FuBio programme.

The plant cell walls are dissolved.

VTT Impulse 63

Anna Suurnäkki and Kristiina Kruus presenting the newest biomaterials developed at VTT.

New material solutions of wood In recent years, the Finnish forestry industry has shown interest in every valuable components found in wood biomass, and achieved visible results: new tall oil-based biodiesel and nanocellulose products have entered the market.

Anna Suurnäkki, Principal Research Scientist at VTT presents products of tomorrow developed at VTT. One of them is a bag suited for dry foodstuffs, such as peanuts, consisting of three bio-based layers – each with a special task for protecting the product. One of the layers is a nanocellulose film that can be used for other applications as well, such as a printing platform for electronics.

– We have developed the properties of fibrebased packages to make them more mouldable and lighter.

By foaming materials it is possible to make protective packaging, insulants and other porous materials with good thermal insulation, or shock or sound absorption properties. They could 64 VTT Impulse

replace, for example, currently used packaging materials for refrigerated products, or function as composites that can be burned after use.

In the field of celluloce-based textile fibres, VTT has developed new dissolution methods suited for viscose and lyocell processes, and methods by which continuous fibre yarn can be spun from cellulose without the dissolution of the cellulosic fibre. By using foam, fibres of different lengths have also been run on a paper machine into non-woven fabric.

– In the future, recycling of textile ­products containing cellulosic fibres will become more important, when legislation concerning dumping­of organic waste in landfills becomes stricter. Therefore, from the very early stages of development, we consider how cellulose could be recovered after use and employed, for example, in the manufacture of new textiles, says Suurnäkki. n

Metsä Fibre is designing a bio-product plant in Äänekoski The existing Äänekoski pulp mill is almost 30 years old.

Metsä Fibre, part of Metsä Group, decided to design a larger plant with more versatile uses to replace the pulp mill nearing the end of its life cycle. The decision was affected by the good availability of wood in Finland, and the increasing global demand for softwood pulp.

– The project is still pending final investment decision. It requires an environmental permit and completion of pre-engineering. If everything goes well, the new bioproduct mill will enter production in autumn 2017, says Niklas von Weymarn, Vice President, ­Research, at Metsä Fibre.

At first, the new plant will not differ much from the old one.

– We have envisioned that alongside pulp production, we would have totally new product lines running in addition to the current side products. Whether they will be ready in the first phase of production – that is still difficult to say. The goal is that the plant would eventually evolve into a modern multiproduct entity.

Significant business out of side products

Polyurethane, the cheap and light packaging material also known as expanded polystyre, is an environmental problem. VTT has been developing both fibre foam technologies and foam forming techniques for biopolymers that could be used for producing, for example, bio-based materials to replace polyurethane.

Metsä Fibre’s current side products of pulp production include turpentine, tall oil, electricity, steam, district heat, bark and wood chip screenings. In 2013, the company turnover was approximately EUR 1.3 billion, of which the abovementioned side products already accounted for more than 10 per cent.

The biggest side streams that the plant could use in novel ways include bark, wood chip screenings, and lignin. They are currently utilised for energy production. Von Weymarn believes that, in the future, much more valuable uses will be found for lignin.

VTT acts as trailblazer

More efficient combustion In spite of everything , some of

the wood material still ends up as raw material for energy. For energy production purposes VTT develops also thermal processes – gasification and pyrolysis – to make them more efficient. Within the next few months, such research will transfer to new research facilities at Kivenlahti, ­Espoo. VTT’s Bioruukki will become a place where companies can test the functionality of their ideas.

– VTT has an important role to play as a trailblazer and creator of competence platforms required for new business activity. FIBIC’s FuBio programme, under which companies have been promoting their best ideas in collaboration with VTT, serves as a good example of this.

According to Niklas von Weymarn, VTT acts as a trailblazer in bioeconomy research worldwide.

Research conducted by VTT is also used at the Äänekoski bioproduct plant.

VTT Impulse 65

business Test+ combines business and design approaches

Innovation actors support reform in companies The finnish economy is undergoing a deep structural change. Therefore,

the development of growth companies and business areas requires close co-operation between companies and public administration. This year Tekes, Finnvera, Sitra, Finpro, the Academy of Finland and VTT have all worked together on joint direction work.

Joint direction work helps create new business models intended to speed up the development of business areas favourable to Finland. A joint direction helps all parties involved work together to achieve common goals in ways suitable to their respective roles. This helps to ensure that public resources can be exploited to their highest potential for the Finnish economy.

– The primary goal of this work is to support the renewal of Finnish business, stresses Pekka Soini, Director General of Tekes.

The joint direction partnership covers five themes that are used to create and develop a new business model aimed at the promotion of globally competitive business ecosystems.

VTT’s Test project offers SMEs in particular an opportunity to start testing their own product ideas in a safe and cost-efficient manner.

The project gives the participating companies an opportunity to rapidly and effectively test the technical implementability and commercial profitability of new components, and the design and functionality opportunities offered by new materials. One of the objectives is also to develop the Test operating model to better meet the development needs of the future bioeconomy sector.

50

A 170-year old beer treasure found at the depth of 50 metres is making its commercial entry.

Historical beer launched Five beer bottles were discovered in a wrecked ship found in the Åland Islands in 2010. Two of them found their way to VTT. VTT analysed their physiochemical composition, and Belgian University of Leuven reconstructed the recipe of the beer. The reborn beer from the 1840s made its market entry when the Stallhagen brewery from the Ålands began new production of the beer.

New taste variations can be brought to beer by cultivating yeast strains and by taking advantage of yeasts and bacteria found in the nature. One of VTT’s most recently introduced research fields relates to the development of new hybrid yeast strains that have new kinds of taste profiles or a better ability to turn sugar into alcohol than natural lager yeast.

66 VTT Impulse

Photo: Henry Kestilä

Depth camera piloted A surveillance system based on depth cameras developed by VTT was piloted during the summer and autumn of 2014 at the Rinteenkulma shopping centre in Rovaniemi, for example. Depth cameras allow collection of valuable information of how people behave in a shop: where do they spend their time, what draws their interest, or where they intend to go next. Read more about the subject on page 72.

VTT Impulseâ&#x20AC;&#x201A; 67

Finland ranks among the leading nations of the world in many international comparisons. For example, the economic competitiveness, and the education and innovation systems have been widely acclaimed.

Text Salla Peltonen Photos iStockphoto

Finland

is good

investment 68â&#x20AC;&#x201A; VTT Impulse

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International investments growing According to Invest in Finland, operating as part of Finpro, in 2013, a total of 213 foreign direct investments (FDI) were made in Finland. The year before, the figure had been 153. Most of the investments were made in consumer trade, business services, the health care and well-being sector, and the ICT sector. The most important investor countries were Sweden, the United Kingdom, Germany and the United States.

According to a preliminary estimate of the United Nations Conference on Trade and Development (UNCTAD), the foreign direct investments rose from the previous year by 11%, to USD 1,460 billion. The amount of investments made in developing economies continued to grow (share was 52% of total flow), whereas investments in developed countries remained historically low for a second time (39% of total flow), even though international investments in EU countries increased.

Top-class competitiveness According to the World Economic Forum (WEF)’s ”The Global Competitiveness Report 2014–2015” comparison Finland ranked fourth among the most competitive countries of the world. In the comparison of 144 countries, Finland was preceded by Switzerland, Singapore and the United States.

Finland’s strengths include the health care system, basic and higher education, functionality of the economy and societal institutions, and innovations. The weaknesses, on the other hand, are the small size of the market area, and ineffectiveness of the labour market.

Finland reached the top position also in the Europe 2020 Competitiveness Index comparison produced by WEF. According to the report, Finland’s ranking reflects the state’s large focus on education and training, which has provided

business

table economy, efficient infrastructure, enterprise-friendly business environment and highly educated labour force with good language skills provide many opportunities for companies and investors interested in Finland. Finland also serves as an ideal route to the markets of Russia and Northern Europe.

Gateway to the east Finland provides a well-functioning gateway to Russia, and it also holds a central position with a view to the Northern European markets of 80 million consumers.

Finland has a long experience of trade with Northern Europe, and strong historical and cultural ties with its neighbouring countries, which provides the country with valuable information and understanding of the region. Finland’s modern logistics and communications networks contribute to smoothly running and safe traffic. Finnish and Russian railways have the same rail width, so the carriages do not need to be adjusted or reloaded when crossing the border. Consequently, most of the transit trade from EU to Russia already passes through Finland.

VTT Impulse 69

finland has the wold’s best offering of research scientist and engineers.

the workforce with the skills needed to adapt rapidly to a changing environment, and has laid the groundwork for high levels of technological adoption and innovation.

Finland also improved its economic competitiveness ranking in the annual survey assessing the competitiveness of various countries conducted by the Swiss Institute for Management Development (IMD). Among the 60 countries studied, Finland ranked 18th, climbing up two positions from last year.

According to IMD, Finland has improved its competitiveness as regards, for example, international trade and financing. Finland’s positions were further enhanced by alleviations in the corporate tax, stronger confidence in the opportunities of the Finnish cleantech industry, and the increase of foreign direct investments in Finland and from Finland to other countries.

According to Prof. Arturo Bris, Director of IMD World Competitiveness Centre, Finland’s prospects look good. In a Taloussanomat interview,

Uncomplicated business environment The Finnish business environment promotes generation of business activities.

There is not much bureaucracy, financing­ is available for investments, and also foreign-owned companies can benefit from various investment incentives, research and development subsidies, and research data, which is produced in extensive collaboration with Finnish universities and private sector actors. According to Transparency International, a non-governmental organisation monitoring corruption, Finland is one of the least corrupt nations in the world.

70 VTT Impulse

Prof. Bris said that Finland belongs among those European fringe-area economies that has clearly improved its competitiveness in spite of unemployment and the challenging situation of public finances.

Skilled labour force Finland has skilled and highly educated labour force with good language skills. Exchange of information between universities and the business world is one of the key factors behind Finland’s recognised innovation competence and economic success. Finland has particularly strong competence in the ICT and mobile technology sectors, and in generation of renewable energies.

The Finnish education system has repeatedly reached excellent results. For example, in the PISA benchmarking study conducted in OECD member states every three years, measuring the skills of 15-year-olds in mathematics, sciences, and literacy, Finland has held top positions from year to year. In spite of a drop in the results, the skills of Finnish young people still rank among the best in the OECD area. In the latest study, conducted in 2012, Finland came sixth in mathematics, third in literacy, and second in sciences.

About one third of the Finnish labour force has a degree or a higher qualification. According to WEF report, Finland has the world’s best offering of research scientists and engineers, and they have been educated in one of the world’s best educational systems. Labour costs, on the other hand, are lower than in other Nordic Countries.

English is the universal language of Finland’s highly international business community. More than 90% of under 30-year-old Finns speak English. Swedish is one of the two national languages of Finland and many Finns also speak Russian.

Robust innovation system Finland is known as a strong innovator, and it has focused on, for example, seeking creative

solutions to global problems. The sum used on research and development per capita is one of the highest in the world. Finnish companies and consumers adopt new technologies rapidly, which makes Finland an ideal test platform for new solutions and technologies.

The foreign direct investments in Finland are also often related to knowledge and expertise.

Finland has several high technology clusters, and technology companies with top competences in the areas related to, for example, wireless and mobile solutions, cleantech, health care and wellbeing, and new materials and processes.

Stable society Finland is one of the very few countries that still holds the highest possible AAA credit rating according to two biggest credit rating agencies Fitch Ratings and Moody’s. According to Standard & Poor’s, Finland’s credit rating is AA+.

According to Fitch estimate, published at the end of September 2014, Finland’s economic and political foundations and the financing of the pension system still rest on a firm foundation.

In the WEF comparison, Finland was ranked at the European top for its strong social inclu-

sion. The inequality in the country is low, the state provides social services, and the citizens have the opportunity to improve their economic status independent of their socio-economic background. In terms of sustainable development, Finland came second, which demonstrates that its economic prowess does not come at the expense of environmentally sustainable practices and outcomes.

In 2010, the U.S. Newsweek magazine compared the living conditions of citizens in one hundred countries. Finland came out as the best country in the world. The categories included in the comparison were the national educational and health care services, quality of life, economic competitiveness, and the political environment.n

Sources: IMD World Competitiveness Yearbook 2014: imd.org/wcc/news-wcy-ranking/ The Europe 2020 Competitiveness Report 2014: reports.weforum.org/europe-2020-competitiveness-report-2014/ The Global Competitiveness Report 2014 – 2015: weforum.org/issues/global-competitive-

Read more

ness emaileri.fi/g/l/102331/0/0/148/51/9 finland.org/public/default.aspx? contentid=198513

• Promotion of Finland’s external economic relations, the internationalisation of Finnish enterprises, investments in Finland and the country brand: team.finland.fi • Statistics about international companies in Finland, tailored services from the beginning to the end of investment process: investinfinland.fi • News about investments in Finland: goodnewsfinland.fi

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VTT Impulse 71

how to become a leading country in

flexible energy production systems Text Antti J. Lagus Photos Jarmo Katila and iStockphoto

The Neo-Carbon Energy research project explores the inner workings of a new energy system.

T

he EU has set strict goals for carbon dioxide emissions reductions. What these goals mean in practice is that energy systems must be completely emissions-free by 2050.

In order to have any hope of attaining these goals, changes must be well under way by 2030. The traditional solution is a two-path model, one path being nuclear power and the other being the continued use of fossil fuels with carbon capture and storage (CCS).

VTT partners with the Lappeenranta University of Technology (LUT) and the Finland Futures Research Centre at the University of Turku in the Tekes-funded Neo-Carbon Energy research project, which is exploring the functional principles of the energy system of the future. Solar and wind energy are expected to play a major role – if not in Finland, then in most of the rest of the world.

– The cost of solar energy is decreasing, and solar energy can now be deployed on a large scale, but only with a suitable energy storage system. The cost of solar energy is now half of what it was in 2008. Germany pioneered large-scale production, but this is now starting in other countries too. In Finland, the cost of producing solar energy is now EUR 120 per MWh, and estimates show that by 2030 the cost will be halved again, says the project coordinator, Principal Scientist Pasi Vainikka from VTT and Adjunct Professor at LUT. When the cost reaches EUR 60 per MWh, solar energy will be cheaper than many of the technologies 72 VTT Impulse

Expertise in storage systems There must be extensive capacity for energy storage and a delivery system for transport as well industrial use. Basic industry, however, requires a steady energy supply such as can be provided by old, reliable energy sources – coal, natural gas and nuclear power. Solar and wind energy involve a significant intermittency problem that must be resolved.

In technology terms, this project is about developing an infrastructure for energy storage.

Vainikka points out that even if Finland never becomes a world leader in the manufacture of wind turbines or solar panels, Finland would do well with even a small slice of the ecosystem that will arise around storage systems and their control.

– Energy may be stored in the form of hydrocarbons generated when carbon dioxide from various sources and hydrogen produced with electricity are made to react with each other.

Finland is already building a network of storage facilities for liquefied natural gas, and there is a gas pipeline linking us to central Europe. Methane is thus one of the most attractive options, says Vainikka.

According to Vainikka, the technological solutions for implementing hydrocarbon storage facilities already exist. The costs of energy ­storage are expected to drop by 50% by 2020.

business

used for electricity generation today. Finland gets about 900 hours of full sunlight per year.

In sunnier parts of the world, the figure is two or three times higher. To put it another way, in the Mediterranean solar energy will only cost EUR 30 per MWh by 2030. Vainikka notes that at such a cost level solar energy would provide the cheapest electricity available.

Vainikka asks whether Finland should not take this trend seriously and what will happen if we do. That is what the Neo-Carbon Energy project is all about. Production capacity tends to shift to the cheapest production method, and this may generate a self-sustaining trend.

Piloting creates markets – Essentially, it all boils down to the pricing of the storage technology. Investors must be able to recoup their capital outlay. We need to launch pilots to learn more about the technology and to create markets, says Vainikka.

Vainikka compares today’s energy storage development efforts to the creation of frequency converters in the 1970s: they were originally developed for the Helsinki metro. The world’s first GSM mobile phone network was also a humble effort, delivered by Nokia to Radiolinja in Finland in 1991. Vainikka notes that it is now important to launch the first pilot projects in energy storage.

The steering group of the project has representatives from more than a dozen industry leaders in Finland. VTT is in charge of the project, which has an overall budget of EUR 14.2 million. About half of this is covered by VTT, about EUR 6 million by the Lappeenranta University of Technology and about EUR 1 million by the Finland Futures Research Centre at the University of Turku.

Outlining the power plant of the future In addition to futures research, the project includes component modules such as the study and modelling of energy system structure, business chains, technical process modelling and experiments to demonstrate what the power plant of the future might look like.

Storage capacity can be modelled The project also involves considerable investment in the dynamic modelling of the energy system. Professor for Solar Economy Christian Breyer from the LUT is working with VTT scientists to create an hour-by-hour model of how much solar and wind energy production on the one hand and other energy production on the other there is around the world at any given time, how these can balance each other and when storage and transmission are required.

When the model is modified to include industry as well as transport, it indicates how much of various functions are required and what the new energy system will look like.

VTT Impulse 73

Pasi Vainikka has a vision of closed circulation in energy production.

Lots of room on the energy storage market Jouni Keronen, Executive Director of the Climate

“Methane would be sufficient to power Finland’s entire transport system.”

– The power plant of the future will not just generate energy: it will also be able to retrieve power from the grid, store it and feed it back in when required. In the Neo-Carbon Energy system, energy production would work pretty much in closed circulation, leveraging carbon dioxide emissions, Vainikka outlines the project vision.

Carbon dioxide can be used not only to generate­power but also to manufacture products such as synthetic materials.

Finland’s pulp mills could convert their carbon dioxide emissions into hydrocarbons with renewable electrical power. The fuel thus obtained, such as methane, would be amply sufficient for powering Finland’s entire transport system, which has an annual energy consumption of about 55 TWh. The current vehicle stock could be converted to use gas as fuel with a relatively simple installation kit, which would mean that they would then be indirectly running on renewable electricity. Finland could also export methane to central Europe. n 74 VTT Impulse

Leadership Council, says that in order to balance the effects of climate, we need demand flexibility or energy storage. Energy storage is currently the bottleneck on the energy market, and it is this problem that the NeoCarbon Energy project is addressing.

The Climate Leadership Council is an association established by the Finnish Innovation Fund Sitra and several Finnish enterprises this year. Its purpose is to challenge Finland to take more rapid action to combat climate change.

– We need smart power grids to implement flexibility. We need to have facilities to enable the rapid storage and retrieval of energy, and smart power grids will help with this too, says Keronen.

The Neo-Carbon Energy project is creating opportunities for Finnish enterprises, from small service providers to major players in the energy sector. Keronen believes that there is a huge need for future solutions and that the number of participating enterprises will multiply.

– The energy storage market is as yet undeveloped, and there is lots of room there for businesses to stake a claim, says Keronen.

Working closely with academia Professor Christian Breyer from the Lappeenranta University of Technology notes that the Neo-Carbon Energy project covers the entire value chain, exploring not only future energy systems and energy production but also the end-user perspective. The period under study extends to the middle of the century, as any energy system introduced will remain in use for decades.

– Our university is working closely with VTT in the component modules of the project. We are looking for energy solutions consistent with sustainable development, taking into account cost-effectiveness, diversity of energy sources and the increasing of energy security. This is a project important for Finland, especially if Finnish enterprises can commercialise the technology that we are researching, says Breyer.

The project is looking at energy storage in the form of methane. Breyer says that methane is also an interesting option as a transport fuel. Being a renewable energy source, it is more sustainable than petrol, a fossil fuel. Also, although battery technology is improving, batteries will remain an impractical power source for shipping or long-distance transports.

The Rinteenkulma shopping centre in Rovaniemi is one the first pilot sites.

Pekka Rinne, Director of the shopping centre, has high expectations.

Tracking people 76â&#x20AC;&#x201A; VTT Impulse

business The piloting of a tracking system using depth camera technology in shops and senior apartments has shown that the information gathered with the system can benefit several stakeholders. Text Riitta Niskanen Photos Henry Kestilä

T

he new people tracking system, developed by VTT, aims to distinguish people from other moving objects and track their movements.

– The depth camera we have developed is based on a similar solution as the one used in the first Microsoft Xbox Kinect cameras for gesture recognition. It allows three-dimensional modelling of space and the tracking of moving objects, says Senior Scientist Sari Järvinen from VTT. For example, human figures moving in a shop can be recognised and tracked.

– The purpose is not to identify people individually.

The information analysed from depth data is provided as coordinates, not as video image, Järvinen says.

The main parts of the tracking system are a depth camera (infrared laser, a light-sensitive cell, and 3D image processor), software for processing depth information and a service analysing behavioural information.

When the light from a depth camera hits a person – or even a large amount of people – the camera produces a dot pattern of each person. In the camera cell, the pattern changes as the person moves. The software incorporated in the equipment deduces where the person is located and what is he or she doing.

– The system can be used in many different fields.

I believe that it will first be applied in the commercial sector, where we are closest to having a finished product, Järvinen estimates.

Still, a lot remains to be done before we have a finished commercial product in our hands.

– The basic tracking system is now completed. The services to be built upon it are still under development for various areas of application, specifies Järvinen.

Assistance for operational optimisation The functionality of depth camera technology has been tested at the Rinteenkulma shopping centre in Rovaniemi since last may.

– An installation of seven sensors is placed in the shopping centre passageway with a lot of traffic and most of the people passing by at good speed. Now the technology used in the basic tracking system is ready to tackle such an environment. Next, we will develop an analysis tool for store needs, Sari Järvinen points out.

In autumn 2013, VTT piloted the system at the women’s clothing section at Anttila department store in Oulu. In the pilot project, the real-time data produced by the system had been connected to intelligent lightning control.

– We tested whether it was possible to affect customer behaviour by use of light. We tracked people’s behaviour in static lighting, dynamic white lighting, and dynamic colour lighting. The third alternative, dynamic colour lighting, seemed to be able to attract the most people.

VTT Impulse 77

Sensors monitor the flow of people in the shopping centre.

When considering the matter from a wider perspective, according to Järvinen, the trade sector could benefit from people tracking system in many ways and thus optimise its operations.

– For the management level of a chain of shops, it could offer a lot of information about human behaviour at various levels. If two shops in a chain have very different amounts of customers but about the same sales volume, one could consider whether some alterations would be needed in the way goods are displayed. In a marketing campaign held in a shop, it is possible to follow whether traffic around the campaigned products increases.

More effective use of facilities Trade sector is not the only business area that could use depth camera technology.

– Investments in business premises are usually a major cost for enterprises. With the help of the system, it is possible to monitor how the premises are used, Järvinen explains.

Companies have many facilities intended for common use, for example big conference rooms.

Using the “people tracker”, it is possible to monitor the occupancy rate of such premises.

– There may be a lot of reservations for the conference room and it seems to be in constant use. Tracking may reveal, however, that not all reservations are used. Or it reveals that 78 VTT Impulse

the premises are mainly being used for telephone conferences of one or two people, when they could accommodate 20 people. In such a case, one could consider whether the conference room could be changed in some way.

In a company, where there are different types of work stations in common use, one could monitor what types of work stations are really used and which are not.

Safety for senior citizens The depth camera technology also facilitates safety services for the elderly living alone. They would benefit the elderly people themselves, their family and home care services.

– An elderly person can be tracked for a longer period of time to establish his or her typical behavioural models. This is done to ensure that the person can manage on his or her own.

Memory disorders are easy to hide during short visits, and family members may not detect them.

Our objective is to investigate how the behavioural information gathered by the system could be used for such purposes, says Järvinen.

The people tracker has already been piloted in a senior apartment.

– The system facilitates spotting changes in an elderly person’s behavioural routines and thus detecting if there are any potential problems. If one morning, out of the usual, coffee has

High expectations at Rinteenkulma

piloting of the people tracker at the Rinteenkulma shop-

not been made by ten o’clock and nobody has entered the kitchen, one can assume that something has happened, says the researcher.

The objective is that if changes are spotted in the elderly person’s routines, information about this is rapidly put forward and measures taken to check if he or she needs help.

The people tracker does not disturb the senior citizen’s life in any way. He or she does not need to carry any kind of safety device with him or her or carry out any measures. An unnoticeable camera monitors his or her normal daily life, in other words, the normal events, for example, in the living room and kitchen only.

The home care can easily monitor how the elderly person is managing at home by contacting the system using a web browser. If there has not been the normal amount of movement around the house, the system can also alert the home care to make an inspection visit.

– The development of the people tracker has been very interesting. The pilot projects have produced different opinions and valuable practical data on how the system should be developed further, says Sari Järvinen, summing up the experiences so far. n

ping centre in Rovaniemi has continued for approximately six months. The testing has focused on the technology only, and the system has not yet produced any actual data.

However,­ Pekka Rinne, Director of the shopping centre, has high expectations.

The system pilot station has been placed in a shopping centre passegeway. The depth camera recognises the movements of people along the passage, registers how they move forward, and what seems to be attracting their interest.

This way, a lot of valuable information can be gathered, and Pekka Rinne is very enthusiastic about its potential uses.

– When we arrange a campaign or take a new measure in the shopping centre, we will be able to see whether it interests people and whether they, for example, stop to look at an add. Usually we only monitor the sales, in other words, how money flows are affected. It does not necessarily tell how well we have succeeded. A successful campaign may produce sales later, he points out.

In an individual shop, the system reveals whether people stop to look at the campaign product. Or if the shelf order is changed in a shop, the retailer receives information on whether the new organisation has attracted attention and turned out successful.

– Particularly in grocery, clothing and sports shops the order of things can be changed on a daily basis to test what would work the best, says Rinne.

The director of Rinteenkulma is certain that the system will interest the shops operating in the centre.

– For example, in a service-oriented sports shop it is certainly interesting to know how the customer moves in the shop and when he or she needs service. Usually a salesperson has to sense when a customer wants service and when he or she wants to continue browsing. The system may indicate when a customer is interested in getting more information about a product and needs service.

As a shopping centre director, Pekka Rinne is also interested in the data collected by the system on which shops truly attract customers.

– We are constantly considering what kind of shops we have and where they are located, whether we would still need some other types of shops, and whether we have too much of something.

Each year, the Rinteenkulma shopping centre, located in the centre of Rovaniemi, records 3.7 million visitors. They make 2.1 million purchases amounting to EUR 47 million.

VTT Impulse 79

A smart spectral sensor has been miniaturised into a very small size.

Light wavelengths reveal the contents

Miniaturising devices

to fit on your palm Jarkko Antila is the CEO of Spectral Engines, manufacturer of smart spectrometers. His journey began with space technology studies at Otaniemi.

Text Milka Lahnalammi-Vesivalo Illustration iStockphoto

80â&#x20AC;&#x201A; VTT Impulse

A thousand times smaller and a hundred times cheaper Spectral sensors can be used, for example, for the study of the composition of foodstuffs, paper or air-fuel mixture during the manufacturing process. The advantages of the device include the cost-effective price and small size.

– For example, in food industry, an entire product line could be equipped with our devices at the same price you usually pay for a single traditional device, Antila points out.

According to Antila, as the production ­volumes increase, the sensor price will even-

business

S

pectral Engines, manufacturer of smart spectral sensors, detached itself as a VTT spin-off company in summer 2014.

– All materials have a spectral fingerprint by which they can be identified. Using our technology, the massive laboratory equipment needed to measure them can be miniaturised to hand-held size, says Jarkko Antila, CEO of the company.

The identification of the spectral fingerprint of materials is based on the identification of the light wavelengths the material reflects. In Spectral­Engines’ devices, a small IR range filter­ and a detector replace the traditional spectro­ meter. This combination allows implementation of a smart spectral sensor, where a specific setting­can be used to select a certain wavelength of light from all light introduced through a filter.

– The wavelengths to be measured are selected according to the material under examination by using a software attached to the device. In other words, the user of the device does not need to be familiar with spectrometry, explains Antila.

tually be about a hundred times lower and the size about a thousand times smaller compared to laboratory equipment. The secret is that due to an adjustable filter, light can be steered at a single point, which facilitates the use of a costeffective single-point IR detector, and therefore the device does not need complex cooling or optics increasing its size. In addition, it is easier to make the device sturdy and durable.

At the moment, the production volumes are still rather small, but the goal is to attract clients who would order thousands of devices a year.

Accordingly, from the very beginning, all production has been made easy to scale upwards.

Aiming at growth Spectral Engines orders the parts for the device from subcontractors and focuses itself on the development, manufacturing, and software.

From the very beginning, the small company has had the idea of concentrating its forces on the aspects of production where its strengths lie, and buying the rest from subcontractors.

– We aim at a turnover counted in tens of millions. We are in the process of building a global company.

Currently, there are four founding members operating at Spectral Engines with a VTT background, and one application engineer hired from outside VTT. Jarkko Antila is responsible for the company operations in general as the CEO, Janne Suhonen is responsible for marketing, sales and business development, Uula Kantojärvi for technological development and Jussi Mäkynen for systems engineering.

The first hired employee Matti Tammi started this autumn as applications developer at ­c ustomer interface and, in addition, Joachim

“The user does not need to be familiar with spectrometry.”

VTT Impulse 81

Photo: Kari Likonen

Jarkko Antila

Mannhardt­ acts as applications and business

developer in Germany. As the production volumes increase, the company also aims to hire new personnel for production.

From space technology to the Åland Islands Jarkko Antila used to study space technology at Helsinki University of Technology at Otaniemi just because it sounded interesting to him. At the end of the ’90s he saw a notice on the institution’s notice board, announcing that a space technology group at VTT was seeking a summer employee, but the application period had already ended. Antila decided to send an e-mail concerning the position anyway, and ended up at VTT. – After that work started to steer my studies.

Eventually, I worked at VTT as research scientist for three years and developed sensor solutions.

In one of the projects, a client approached Antila and asked him to become a product development manager at INFICON in the Åland Islands. Jarkko spent a total of three years on this job, after which he returned to VTT for four years as team leader, until he began to focus on giving rise to Spectral Engines only.

82 VTT Impulse

Pocket size device is born VTT developed its spectrometry know-how already at the turn of the 21st century with Vaisala’s air quality sensors, and assignments made for the European Space Agency (ESA). In 2008, VTT started to develop fuel sensors for Continental, and, at the same time, new inventions related to microelectromechanical systems, or MEMS chip structures, were made. This opened up new development opportunities.

– We worked in close collaboration with chip developers. We saw that fair departments always had huge demo gadgets on display, and we, on the other hand, decided to make an easy-to-use pocket-size device that can be hooked up to a computer by USB, Antila says.

This philosophy has turned out hugely successful at VTT, since it has been easy for other people than experts alone to slip the demo device in their pocket and demonstrate it to customers at fairs and meetings.

The first Spectral Engines products were also developed on the same basis.

From a VTT invention to a product Because VTT was unable to take the well-begun R&D any further and proceed to applications, and, on the other hand, because the invention was not sufficiently ready for companies, the idea of the establishment of Spectral Engines came about. At the end of 2012, VTT applied for Tekes TUTL funding for the purpose of ­commercialising the technology.

– We were granted a significant amount of funding and we were thus able to use sufficient­ amount of time for market research alongside technology development. We were able to establish­a company concept and a product prototype to be piloted with clients.

When Spectral Engines started its operation in June, it already had clients who had tested the device and given feedback on it.

Next, Spectral Engines is aiming at the ­G erman and US markets. In Finland, Antila hopes to have more co-operation with other actors within the field.

– Different companies and business sectors have different operating methods. For example, joint projects managed by VTT help to build up co-operation, Antila says. n

VTT

VTT Technical Research Centre of Finland is the biggest multitechnological applied research organisation in Northern Europe.

VTT provides high-end technology solutions and innovation services. From its wide knowledge base, VTT combines different technologies, creates new innovations and a substantial range of world class technologies and applied research services thus improving its clients’ competitiveness and competence. Through its international scientific and technology network, VTT can ensure the efficient transfer and utilisation of information and technology.

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VTT Impulse is VTT’s publication on science, technology and business.

Published twice a year in Finnish and in English.

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Editor-in-chief: Olli Ernvall, tel. +358 20 722 6747.

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