{"690901":{"#nid":"690901","#data":{"type":"news","title":"Turning Pulp Mills Into Next-Generation Biorefineries ","body":[{"value":"\u003Cdiv\u003E\u003Cp\u003EGeorgia\u2019s $41 billion forest products industry needs a transformation, and a Georgia Tech research team is reimagining how pulp mills use energy and what they can make from their byproduct streams.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EFor nearly a decade, \u003Ca href=\u0022https:\/\/www.chbe.gatech.edu\/directory\/person\/sankar-nair\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ESankar Nair\u003C\/a\u003E, professor in the School of Chemical and Biomolecular Engineering and a longtime researcher with the \u003Ca href=\u0022https:\/\/renewablebioproducts.gatech.edu\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ERenewable Bioproducts Institute\u003C\/a\u003E (RBI), has led a collaborative effort to develop technologies that can radically improve the efficiency and profitability of kraft pulp mills.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cWhat began as a project to save energy in pulp production has grown into a much broader vision,\u201d Nair explains. \u201cWe\u2019re not just trying to make mills more efficient. We\u2019re working to turn the kraft pulp mill into a kraft-based biorefinery that produces multiple higher-value products.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Ch3\u003E\u003Cstrong\u003EFrom Energy Savings to High-Value Products\u003C\/strong\u003E\u0026nbsp;\u003C\/h3\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003ENair explains that traditional kraft mills use a highly energy-intensive \u201cchemical recovery loop\u201d to handle black liquor \u2014 the dark, viscous byproduct left after pulp is separated from wood chips. That loop relies on multistage evaporators and massive recovery boilers to remove water, burn the remaining organics for steam and electricity, and recycle inorganic chemicals back into the process.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cThe original desire from our industry partners was to save energy,\u201d Nair says. \u201cInstead of evaporating the water in black liquor, we asked whether membranes could take on most of the dewatering and potentially cut that energy use in half.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EOver time, the team realized the opportunity went well beyond efficiency. \u201cWe use these membranes in such a way that they actually fractionate the black liquor, not just dewater it,\u201d Nair says. \u201cOne stream is rich in lignin; another is rich in organic acids. From those, we can recover and purify components and turn them into entirely new products.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003ELignin is a complex organic polymer and one of the most abundant biological materials on Earth. It acts as nature\u2019s \u201cglue,\u201d providing plants with structural rigidity and resistance to decay.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EFrom lignin-rich fractions, the team has already demonstrated carbon materials that can be tailored for battery anodes and porous adsorbents used in environmental remediation and separations \u2014 today mostly made from fossil-based carbons. These lignin-derived carbons are of particular interest as a domestic alternative to graphite, a critical battery material that is currently dominated by overseas production.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EOn the organic acid side, Nair and \u003Ca href=\u0022https:\/\/www.chbe.gatech.edu\/directory\/person\/christopher-jones\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EChristopher Jones\u003C\/a\u003E, a Georgia Tech\u202fcatalysis and reaction engineering expert, have gone a step further, converting those acids into mixtures of much heavier molecules that could become high-performance industrial lubricants and additives.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cIt\u2019s exciting to do a new cascade of reactions to make products that we haven\u2019t really made before,\u201d says Jones, the John F. Brock III School Chair and professor in the School of Chemical and Biomolecular Engineering.\u0026nbsp; \u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EJones explains that green lubricants derived from non-fossil sources have \u201cboth high demand and high value.\u201d Georgia Tech has not yet compared the performance of these products to conventional lubricants, but the platform is in place to do so in the future.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cThe products we are pursuing from lignin and organic acids have bulk demand and also can command significantly higher prices than traditional pulp-based outputs,\u201d Nair notes. \u201cThat\u2019s essential if the forest products industry is going to be profitable and competitive over the long term.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThe two researchers have collaborated on three papers, with two already published in \u003Ca href=\u0022https:\/\/pubs.acs.org\/doi\/full\/10.1021\/acssuschemeng.4c00212\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003E\u003Cem\u003EACS Sustainable Chemistry \u0026amp; Engineering\u003C\/em\u003E\u003C\/a\u003E (June 2024) and \u003Ca href=\u0022https:\/\/pubs.acs.org\/doi\/10.1021\/acscatal.5c04841\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003E\u003Cem\u003EACS Catalysis\u003C\/em\u003E\u003C\/a\u003E (February 2026).\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Ch3\u003E\u003Cstrong\u003EScaling Up: Continuous Manufacturing and Field Trials\u003C\/strong\u003E\u0026nbsp;\u003C\/h3\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EA key hurdle in moving from lab concept to mill reality is scalable manufacturing of the membranes themselves. That\u2019s where collaboration with Georgia Tech\u2019s advanced manufacturing community comes in.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cIn recent years, we\u2019ve really focused on how we can manufacture these membranes at low cost and in a continuous, scalable way,\u201d Nair says. \u201cThat\u2019s involved close collaboration with colleagues in materials science, mechanical engineering, and Georgia Tech\u2019s manufacturing institutes.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EAnother Georgia Tech collaborator, \u003Ca href=\u0022https:\/\/me.gatech.edu\/faculty\/harris\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ETequila Harris\u003C\/a\u003E, a professor in the George W. Woodruff School of Mechanical Engineering, is leading the effort to move the current small-scale batch process into a continuous, industry-ready, roll-to-roll system that can produce long sheets of reduced graphene oxide membranes.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EA key enabling step to shift from batch-mode production, says Harris, was integrating vacuum pressure into the manufacturing system to support high-throughput continuous production without the use of any volatile organic solvents that are commonly used in membrane production. Harris envisions \u201chigh-quality output at production speeds above 60 meters per minute,\u201d which will \u201cdramatically increase production volume while reducing solvent usage and waste, such as water,\u201d says Harris.\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThe technology is now mature enough for field testing. The team is preparing to deploy membrane modules at a major pulp and paper mill near Savannah operated by Rayonier Advanced Materials (RYAM).\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cWe\u2019re assembling full membrane modules and installing them in a test skid that will run on real kraft black liquor from the mill,\u201d Nair says. \u201cWe\u2019ll collect long-term performance and reliability data that feeds into detailed models of how best to deploy these membranes in a working kraft mill.\u201d\u0026nbsp;\u003C\/p\u003E\u003Cp\u003ERYAM leaders, including \u003Ca href=\u0022https:\/\/www.linkedin.com\/in\/larissafenn\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ELarissa Fenn\u003C\/a\u003E, Director of New Products and Chair of the External Advisory Board for Georgia Tech\u2019s \u003Ca href=\u0022https:\/\/renewablebioproducts.gatech.edu\/research\/center-for-renewables-based-economy-from-wood\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ECenter for a Renewables-Based Economy From Wood\u003C\/a\u003E (ReWOOD), help ensure that cutting-edge research remains connected to real-world industry challenges and opportunities.\u003C\/p\u003E\u003Cp\u003E\u201cMuch of our internal research is focused on supporting current operations, customers, and product lines,\u201d Fenn says. \u201cPartnerships with universities allow us to look five to ten years ahead and engage in transformational research that can create entirely new opportunities for our business and the broader forest products industry.\u201d\u003C\/p\u003E\u003Cp\u003E\u201cThe transition to more sustainable materials, chemicals, and fuels represents one of the greatest opportunities our industry has seen in decades,\u201d she adds. \u201cContinued innovation is essential not only for maintaining competitiveness, but also for creating new markets for renewable, wood-based resources and strengthening the long-term sustainability of the forestry sector.\u201d\u003C\/p\u003E\u003Cp\u003EFenn emphasized that the impact extends well beyond individual companies.\u003C\/p\u003E\u003Cp\u003E\u201cThe forestry economy is the backbone of many rural communities across Georgia and throughout the Southeast,\u201d she says. \u201cAdvancing technologies that create new value from renewable resources helps support landowners, manufacturers, and the communities that depend on this industry.\u201d\u003C\/p\u003E\u003Cp\u003EFenn works at RYAM\u2019s Jesup, Georgia facility, which employs more than 800 people and is the largest employer in the local community.\u003C\/p\u003E\u003Cp\u003E\u201cFacilities like ours are deeply connected to the communities we serve,\u201d Fenn says. \u201cWhen we invest in innovation, we are investing in the future of manufacturing, forestry, and economic opportunity in rural America.\u201d\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Ch3\u003E\u003Cstrong\u003EModular Pathways to a Bio-Based Future\u003C\/strong\u003E\u0026nbsp;\u003C\/h3\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003ETransforming an operating mill into a full biorefinery isn\u2019t something that happens overnight, and Nair\u2019s group is designing with that reality in mind.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cAll of these technologies are modular and designed to be fully integrated with the kraft process,\u201d he says. \u201cYou don\u2019t have to spend billions of dollars up front to build an entirely new plant. You can gradually integrate membrane-based fractionation and stream upgrading technologies for new product streams into the existing kraft process, and each mill can follow its own transition path.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThat modular design also provides flexibility in how mills manage energy. Diverting black liquor into higher-value products means less organic material available as fuel for the recovery boiler. Still, the energy-efficiency gains from membrane dewatering reduce overall consumption, and mills can draw on grid electricity to make up the difference.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cThe goal is not to save energy for its own sake,\u201d Nair emphasizes. \u201cIt\u2019s to use that energy more productively to create value-added outputs that support jobs, rural communities, and a more innovative and resilient bio-based economy in Georgia.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThe urgency of this work is underscored by the pressures facing the industry: Georgia\u2019s forestry sector has seen paper mill closures since the 1990s, due to digitization and shifts in demand, with three major mill closures in 2025. The Georgia Forestry Commission estimates that mill closures erased the market for 8.3 million tons of timber, and reduced lumber usage, import tariffs, and labor shortages compounded the crisis, according to the \u003Ca href=\u0022https:\/\/fieldreport.caes.uga.edu\/publications\/AP130-4-13\/2026-timber-forecast\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003E2026 Georgia AG Forecast\u003C\/a\u003E. New revenue streams and efficiency gains may be essential for mills\u2019 survival.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EBeyond kraft mills, Georgia Tech researchers are already extending the membrane platform to agricultural biomass and municipal waste streams in collaboration with partners like the University of Tennessee, Knoxville, and Texas Tech University. They are also tapping into national initiatives, including the NSF \u003Ca href=\u0022https:\/\/www.casfer.us\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ECenter for Advancing Sustainable and Distributed Fertilizer Production (CASFER)\u003C\/a\u003Eand the \u003Ca href=\u0022https:\/\/www.bridgesengine.org\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EBiobased Rural Innovation for Domestic Growth and Economic Security (BRIDGES)\u003C\/a\u003E.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u003Cstrong\u003ELignin-Derived Materials for the Battery Supply Chain\u003C\/strong\u003E\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u003Ca href=\u0022https:\/\/www.mse.gatech.edu\/people\/matthew-mcdowell\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EMatthew McDowell\u003C\/a\u003E, co-director of the Georgia Tech Advanced Battery Center, sees many cross-sector applications for lignin-derived carbon materials, including batteries, which are increasingly foundational to strategic sectors such as mobility, the power grid, and defense.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003ELignin-derived carbons can serve as a domestic replacement for graphite in lithium-ion batteries \u2014 a critical material not widely produced in the U.S.\u0026nbsp;\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cConventional synthetic graphite is derived from crude oil and requires very high temperatures, making it energy-intensive and polluting,\u201d McDowell said, noting that their goal is to convert lignin and cellulose \u201cto high-value battery materials that could enable the growth of a new battery supply chain here in the United States.\u201d He envisions the work one day transitioning to the Advanced Battery Center, which is planning a new facility scheduled to open at the end of 2027 that will enable companies and academic researchers to \u201cbuild and test full-scale battery cells for translational R\u0026amp;D.\u201d\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003ELife-cycle analysis carried out by the team has shown benefits in both lower costs and more efficient energy use when making these carbons from biomass sources.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EToday,\u202fChina leads the world in battery production, with\u202fKorea and Japan\u202falso long-established leaders. The U.S. is building more domestic capability for national security and economic reasons.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EResearchers at Georgia Tech on the front lines of this work also include Jones, who also collaborated on the lubricants research; \u003Ca href=\u0022https:\/\/www.isye.gatech.edu\/users\/valerie-thomas\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EValerie Thomas\u003C\/a\u003E, Anderson Interface Chair of Natural Systems and professor in the H. Milton Stewart School of Industrial and Systems Engineering and the Jimmy and Rosalynn Carter School of Public Policy; and \u003Ca href=\u0022https:\/\/www.mse.gatech.edu\/people\/meisha-shofner\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EMeisha Shofner\u003C\/a\u003E, professor in the School of Materials Science and Engineering.\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThomas is leading research on life-cycle and economic analyses of converting lignin to produce \u201ccarbonized lignin\u201d anodes that can replace petroleum\u2011based synthetic graphite in batteries. She says that lignin\u2011based graphite can displace petroleum\u2011derived synthetic graphite, delivering 84% lower energy use, 92% lower greenhouse gas emissions, and lower emissions of other pollutants.\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cThis work establishes a supply chain for making batteries, which has really broader impacts throughout Georgia,\u201d says Thomas, who believes lignin-based battery materials will lead to a stronger forest products economy and a more resilient battery supply chain in Georgia.\u0026nbsp;\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EMcDowell agrees. \u201cMarrying the forest products industry and the battery industry makes a lot of sense for Georgia, because both of those industries are really big,\u201d he says, and both are \u201ckey employers in the state.\u201d In his view, innovations could benefit both simultaneously.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u003Ca href=\u0022https:\/\/research.gatech.edu\/people\/scott-sinquefield\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EScott Sinquefield\u003C\/a\u003E, senior research engineer in RBI, sees the graphene-oxide membrane work as squarely within its charge to modernize the forest products sector that anchors Georgia\u2019s rural economy.\u0026nbsp; \u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cPart of our mission is to support this industry and advance it. This falls right under our umbrella,\u201d he said, noting that RBI has been providing scientific support to mills for nearly a century, dating back to its origins as the Institute of Paper Chemistry in 1929.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThe Georgia Tech team\u2019s vision is clear, as Nair explains: \u201cIf we can do this right, kraft mills don\u2019t just survive. They become hubs of advanced biomanufacturing that anchor a more resilient and sustainable forest-based economy for the state.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E","summary":"","format":"limited_html"}],"field_subtitle":"","field_summary":[{"value":"\u003Cp\u003EGeorgia Tech infuses innovation into the forest products industry, converting waste streams into high-value products, from high-performance automotive lubricants to batteries.\u0026nbsp;\u003C\/p\u003E","format":"limited_html"}],"field_summary_sentence":[{"value":"Georgia Tech infuses innovation into the forest products industry, converting waste streams into high-value products, from high-performance automotive lubricants to batteries. "}],"uid":"36757","created_gmt":"2026-06-24 17:10:56","changed_gmt":"2026-06-26 14:41:42","author":"ychernet3","boilerplate_text":"","field_publication":"","field_article_url":"","location":"Atlanta, GA","dateline":{"date":"2026-06-24T00:00:00-04:00","iso_date":"2026-06-24T00:00:00-04:00","tz":"America\/New_York"},"extras":[],"hg_media":{"680506":{"id":"680506","type":"image","title":"sankar--1-.JPG","body":null,"created":"1782321076","gmt_created":"2026-06-24 17:11:16","changed":"1782321076","gmt_changed":"2026-06-24 17:11:16","alt":"Headshot of Sankar Nair ","file":{"fid":"264779","name":"sankar--1-.JPG","image_path":"\/sites\/default\/files\/2026\/06\/24\/sankar--1-.JPG","image_full_path":"http:\/\/hg.gatech.edu\/\/sites\/default\/files\/2026\/06\/24\/sankar--1-.JPG","mime":"image\/jpeg","size":20230,"path_740":"http:\/\/hg.gatech.edu\/sites\/default\/files\/styles\/740xx_scale\/public\/2026\/06\/24\/sankar--1-.JPG?itok=8DC9uqPB"}}},"media_ids":["680506"],"groups":[{"id":"1214","name":"News Room"},{"id":"1188","name":"Research Horizons"}],"categories":[],"keywords":[{"id":"187915","name":"go-researchnews"}],"core_research_areas":[{"id":"39491","name":"Renewable Bioproducts"}],"news_room_topics":[],"event_categories":[],"invited_audience":[],"affiliations":[],"classification":[],"areas_of_expertise":[],"news_and_recent_appearances":[],"phone":[],"contact":[{"value":"\u003Cdiv\u003ENews Contact\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u003Cstrong\u003EWriter:\u003C\/strong\u003E Anne Wainscott-Sargent\u0026nbsp;\u003Cbr\u003E\u003Cstrong\u003EMedia Contact:\u003C\/strong\u003E Jennifer Martin | \u003Ca href=\u0022mailto:jennifer.martin@research.gatech.edu\u0022\u003E\u003Cstrong\u003Ejennifer.martin@research.gatech.edu\u003C\/strong\u003E\u003C\/a\u003E\u003C\/p\u003E\u003C\/div\u003E","format":"limited_html"}],"email":[],"slides":[],"orientation":[],"userdata":""}}}