Surfactant-Free Multiphase Forming of Fiber Composite Products for Significant Reduction in Energy and CO2 Emission

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OPEN 2021
Atlanta, Georgia
Project Term:
08/24/2022 - 08/23/2025

Technology Description:

The technology proposed by the Georgia Institute of Technology avoids surfactant use to generate a stable foam by instead relying on hydrodynamic means to generate an unstable high-density foam to disperse the fiber into. The fiber mat is formed in a fast dynamic process before loss of integrity of the multi-phase fiber-air bubble mixture. The team will develop a next-generation paper manufacturing system that includes a novel microbubble generator integrated with a next generation headbox that can scale up for commercial production. The proposed approach should reduce the energy consumption and carbon dioxide (CO2) emissions associated with the production of paper, as well as other fiber composites (e.g., tissue, cardboard, nonwovens, and new fiber-based products).

Potential Impact:

The goal of the proposed technology is to replace the current method of manufacturing paper, tissue, and other fiber composite materials with a new process that will significantly reduce associated energy consumption and CO2 emissions.


The proposed system offers energy security benefits by lowering energy requirements for evaporative drying, including reducing water usage and being more resourceful in the use of the raw material (fiber).


Broad commercial implementation will result in more than 30% reduction in energy consumption in the dryer section, directly reducing the fossil fuel demand and reducing CO2 emissions by 25%.


The new process will improve product quality at a lower production cost.


ARPA-E Program Director:
Dr. Ken Pulido
Project Contact:
Prof. Cyrus Aidun
Press and General Inquiries Email:
Project Contact Email:


AstenJohnson Inc.
Kimberely-Clark Corporation

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