hanse chemie

Transcription

hanse chemie

elements35
Quarterly Science Newsletter
Designing with Polymers
Perfectly lubricated
Green power made easy
Catalysis
Metathesis catalysts for oleochemical applications
Biotechnology
Evonik BioTechDay
Issue 2| 2011
02 Content s
08
20
NEWS
04 04 05
06
06
07
07
07
New plant for organic specialty surfactants in China
Catalysts for biodiesel: plant in Argentina planned
Fiscal year 2010: the best result so far in the Chemicals core business
PEEK polymer capacity to be expanded First project house in Taiwan
Plans for isophorone plants in China
Evonik acquires the hanse chemie Group
VESTAKEEP® enhances safety of automotive steering columns
DESIGNING WITH POLYMERS
08 Innovative engine oil additives reduce fuel consumption and
CO2 emissions: perfectly lubricated
CATALYSIS
14 Metathesis catalysts for oleochemical applications: robust and selective
Resource Efficiency
17 Almost 5,000 km across Australia: pioneering trip by the Wind Explorer
NEWS
26
18 19 19
Prize awarded in the 2011 nano+art competition
Study verifies effectiveness of conditioning agent against
hair breakage
Nitrogen oxide reduction: Lines made from VESTAMID® compounds
satisfy requirements
DESIGNING WITH POLYMERS
20 PLEXIGLAS® stands up to glass in photovoltaics systems:
green power made easy
The cover photo shows sugar cane, a vital renewable
raw material for white biotechnology
elements35 Issue 2|2011
BIOTECHNOLOGY
26 Evonik BioTechDay: on a growth course
31 31 31 NEWS
Robust, flexible, and fast drying:
the new clear coating technology from Evonik
PLEXIGLAS® Mineral for extremely weather-resistant structural shells
Credits
Editorial 03
All set for the future
If your car’s transmission and engine oils contain Evonik’s new comb polymers as
viscosity index improvers, your average fuel savings will be 1.5 percent. You’re not
impressed? Car makers see it differently. According to EU guidelines, average CO2
emissions per vehicle and kilometer must be reduced by about 20 grams by 2015—
and our new comb polymers can account for up to 2.5 of those grams.
Comb polymers are just one of about one hundred research projects in the field
of resource efficiency, out of a total of 500 projects currently underway at Evonik. In
2010, we increased spending on R&D by 13 percent to €338 million, having held it
constant at €300 million, despite the economic crisis.
This past financial year shows how high the demand has been for Evonik’s specialty chemicals: compared to most competitors our rebound was faster and stronger. In 2010, we increased sales revenues by 26 percent over the previous year to
€13.3 billion, and even tripled net income to €734 million. We’ve generated the best
result so far in our Chemicals core business—with an EBITDA margin that puts us
at the vanguard of our industry.
This demonstrates that in 2010 Evonik was more profitable than ever before. We
already generate more than 80 percent of our chemical sales—a solid €10 billion—
from significant market positions. We want to build on that in two ways. First, we’ll
invest in high-margin businesses with above-average growth. To this end, we plan
to spend a total of €6 billion by 2015 for projects that include expanding our capacities for isophorone, DL-methionine, precipitated silicas, and chlorosilanes.
Second, through our innovative strength, we plan to tip the scales in our favor.
Our research projects are allowing us to move further and further into the so-called
emerging markets. The latest example is our new Light & Electronics Project House,
which began its work on April 1. Located in Taiwan, this project house will expand
our opportunities as we operate within one of the most important electronics markets in the world. And, as our first project house outside Germany, it enables us to
intensify the global reach of our research activities and close ranks with our customers.
At its core, Evonik is now a specialty chemicals company. To advance our alignment to the future-oriented markets of health and nutrition, resource efficiency,
and globalization of technologies, Evonik has appointed three new members to its
Executive Board: Dr. Yu, Dr. Haeberle, and me. My responsibilities include inno
vation management and international sales—a combination that underscores the vital
connection between research and market proximity.
Patrik Wohlhauser
Member of the Executive Board of
Evonik Industries AG
4 Ne ws
New plant for
organic specialty
surfactants in China
Evonik is building an integrated production
plant for organic specialty surfactants at its
site in Shanghai (China). With an investment
volume in the upper double-digit million
range, the production network± is scheduled
to begin operation in mid 2013. The various
specialty surfactants based on renewable raw
materials will be used primarily for cosmetics
and laundry care products, as well as for industrial applications. Evonik is a leading supplier in these areas.
By building the plant at the Shanghai site,
Evonik benefits from the infrastructure of the
large Shanghai Chemical Industry Park (SCIP)
and close proximity to its customers‘ production facilities. The integrated production network will feature state-of-the-art technology
and meet correspondingly high environment
al standards. Last fall, in its most recent project at SCIP, Evonik commissioned a plant for
the production of plastics and plastics ingredients—a 250-million-euro investment for
the Group.
The Chinese market for cosmetic ingredients is
growing by 10 percent annually
The new integrated production plant will
produce ingredients for cosmetics and laun
dry care products, as well as specialty surfactants for industrial applications. The Chinese
cosmetics industry accounts for the lion‘s
share of production.
„We are already well-positioned in the
market for cosmetic ingredients in Europe
and the United States,“ says Dr. Claus Rettig,
head of the Consumer Specialties Business
Unit. „Now we are following our customers
to Asia, with state-of-the-art technology and
correspondingly high-quality ingredients.
This allows us to supply our customers at the
accustomed high level of quality.“
China is expected to be the biggest market for cosmetics in Asia short-term, leaving
Japan behind to number 2 position. The market in China will account for 25 percent of the
global absolute growth of the upcoming five
years. The Chinese market for cosmetic ingredients, which is mainly driven by multinational corporations, is growing by 10 percent annually. The main reason for this
growth is the developing middle class in
China, whose consumption patterns have
changed in favor of higher quality products.
In Asia, the market for laundry care prod
ucts is driven by a growing environmental
consciousness. Evonik’s products are par
ticularly eco-friendly. For industrial specialty surfactants, the market is growing based
on improved technology standards and
increasing regulatory requirements. With
the construction of the new integrated production plant, Evonik is also increasing its
local capacities in technical service, market
ing and sales.
Catalysts for biodiesel: plant in Argentina planned
Evonik Industries is planning to build a new
facility to produce catalysts for the manufacture of biodiesel in Argentina. Basic engineer
ing for this plant, which will have capacity of
over 60,000 metric tons p.a., has now been
completed and construction work is expected
to start in July 2011. Following completion,
which is scheduled for the end of 2012 at the
latest, the plant will produce ready-to-use
alcoholates for use as catalysts in the production of biodiesel from renewable raw mate
rials. The project is still contingent on the approval of the relevant authorities.
The plant will be located in Puerto
General San Martin, in the Rosario region, at
the heart of Argentina‘s biodiesel industry.
Evonik is planning to build the plant on the
same site as Terminal 6 S.A., which operates
a large biodiesel facility. „Locating the facility at the Terminal 6 site enables us to use the
existing infrastructure and gives us excellent
logistics connections. It could therefore be
erected swiftly, enabling us to supply catalysts competitively to customers in South
America,“ comments Jan Van den Bergh, who
heads the Advanced Intermediates Business
Unit. The new plant will supply especially
Argentina and Brazil.
Evonik has proven expertise in the production of biodiesel catalysts, backed up by
many years of experience. In 2009 it started
up a new production facility in Mobile (USA)
with capacity of 60,000 metric tons p.a. This
plant, which was built in just nine months,
serves the growing North American market
for biodiesel.
Following the success of the new production technology at this US facility, the plan is
to use the same technology for the new facil
ity in Argentina. In the new process, alcohol
ates are produced by reacting alcohol with a
lye.
Evonik is already a global market leader
in biodiesel catalysts—a position it also holds
in South America. „The planned new facility
in Argentina strengthens our commitment to
this region,“ says Van den Bergh. „In the midterm, we are anticipating strong double-digit
growth in the biodiesel market.“ Evonik oper
ates a facility in Niederkassel-Lülsdorf, near
Cologne (Germany) as well as its facility in
the USA.
N e ws 5
Fiscal year 2010: the best result so far in the Chemicals core business
„2010 was an outstanding year for us,“ commented Dr. Klaus Engel, Chairman of the
Executive Board of Evonik Industries AG, at
the financial press conference. The Group‘s
core chemicals business reported by far the
best performance in its history. In order to
realize its focus on specialty chemicals, at the
end of 2010 Evonik agreed to sell a majority
stake in its energy business to a consortium
of municipal utilities in Germany‘s RhineRuhr region. As a result, the Energy Business
Area has been reclassified to discontinued
operations. In addition, further progress was
made in amalgamating the residential real estate companies Evonik Immobilien GmbH and
THS GmbH.
„Our refocusing has almost been complet
ed. In the future, the name Evonik will be
synonymous with global leadership in specialty chemicals,“ said Engel. The focus is on the
most important global megatrends. „We want
to grow and increase our profitability further.
To achieve that, in future the management of
Evonik will be geared to making us faster,
leaner and more flexible, with an even stronger market focus,“ said Engel.
Additional Executive Board
members appointed
for chemicals business
The Executive Board has therefore been increased to six members effective April 1,
2011. Patrik Wohlhauser (46) is the Executive
Board member responsible for the Consumer,
Health & Nutrition segment, Dr. Thomas
Haeberle (54) is responsible for the Resource
Efficiency segment and Dr. Dahai Yu (49) for
the Specialty Materials segment. With an
EBITDA margin of 18.3 percent, Evonik‘s core
chemicals business ranks among the sector
leaders as of 2010. „We want to remain
among the best in class in the future as well,“
said Engel.
The Group has therefore embarked on
key strategic investment projects. It is plann
ing to invest €500 million in a new methionine facility in Singapore, which is scheduled
to start producing feed additives in 2014. In
addition, capacity for precipitated silicas in
Asia and Europe is to be increased by 25
percent by 2014. Further, Evonik is planning
to build a new facility for isophorone chem
icals, preferably in Asia, to come on stream
in 2013. The Group already occupies sig
nificant market positions in all three of
these businesses and now aims to strength
en them selectively in the relevant growth
markets.
Group sales and
earnings considerably
higher than last year
Group sales advanced 26 percent to € 13,300
million. Strong demand, high capacity utilization and improved margins lifted earnings
before interest, taxes, depreciation, amortization and the non-operating result (EBITDA)
47 percent to € 2,365 million. The Group‘s
EBITDA margin improved from 15.3 percent
to 17.8 percent. Earnings before interest,
taxes and the non-operating result (EBIT)
surged 89 percent to € 1,639 million; net income tripled to € 734 million in 2010 (2009:
€ 240 million).
In response to the economic crisis, Evonik
introduced the „On Track“ efficiency enhance
ment program at the start of 2009. To bring
a lasting improvement in competitiveness, the
Chemicals Business Area: R&D spending [%]
Group aims to achieve a sustained reduction
in costs of € 500 million p.a. from 2012. All
key cost items were analyzed and structures
and processes were examined with a view to
attaining this goal. By the end of 2010, specific measures had been defined to meet all
target savings and over three quarters of the
savings (almost € 400 million) had already
been achieved.
Chemicals reported a
record performance
The Chemicals Business Area grew sales by
a strong 29 percent to € 12,867 million (2009:
€ 9,978 million). This was driven mainly by
volumes and prices. In most business units
demand was back at or even above the level
seen in the first half of 2008, before the recession. As a result, many production facilities
operated at full capacity.
The effective action to cut costs and raise
efficiency, together with a substantial rise in
volumes, high capacity utilization, and in
creased margins boosted both EBITDA and
EBIT to record levels. Earnings in all business
units were well above the pre-recession level.
EBITDA grew 47 percent year-on-year to
€ 2,357 million while EBIT surged 83 percent
to € 1,702 million.
Spending on
R&D increased
Evonik increased research and development
spending by 13 percent to € 338 million in
2010 (2009: € 300 million). Around 60 percent of this was spent on the development
of new products and new technology platforms.
R&D in the Chemicals Business Area
Development of new products 40
R&D employees
approx. 2,300
Basic research for new key technologies 19
Locations more than 35
Improved production processes for established products 24
Total R&D projects approx. 500
Improved applications for established products 11
R&D projects focusing on resource efficiency approx. 100
Other 6
Cooperation with universities and scientific institutes approx. 300
Number of new patent applications approx. 250
Patents (granted and pending) more than 24,000
Registered trademark (granted and pending)
more than 7,500
6 Ne ws
PEEK polymer capacity to be expanded
Evonik Industries is significantly expanding
its polyether ether ketone (PEEK) capacity in
response to growing global demand. Along
with a number of optimization measures, the
company is modernizing an existing plant.
The project at the Changchun site in China is
scheduled to be completed by 3rd quarter
2011. Evonik has been selling its highly temperature-proof and chemical-resistant PEEK
polymers under the brand name VESTAKEEP®
for a number of years. They are used for man
ufacturing components that must withstand
long-term use under the most severe end-use
environments.
„The capacity expansion not only reflects
the continuous growth in all relevant industries, but is also the result of the successful
commercialization of numerous new projects.
This expansion testifies to the on-going commitment we are making to support our
customer’s continued growth“, says Sanjeev
Taneja, Evonik’s global business VESTAKEEP®
manager. VESTAKEEP® PEEK polymers are
used in demanding applications in medical as
well as in the automotive, aerospace, semiconductor, and entertainment electronics industry and in the oil and natural gas sectors.
Furthermore, thanks to the unique combination of mechanical, thermal and tribological
properties VESTAKEEP® PEEK allows the
replacement of metal in these and several
other applications.
VESTAKEEP® 5000G is the latest PEEK
polymer in addition to Evonik’s product
range. The material offers significantly
higher impact resistance and a better fatigue
profile under dynamic stress as compared to
commercial available grades. It addresses the
unmet needs of the customers. The company
also introduced its VESTAKEEP® M and
VESTAKEEP® I series for applications in med
ical and implant industry two years ago. The
comprehensive product portfolio covers virtually all industrial applications and supports
Evonik’s strategy of serving as a long-term,
reliable partner in the PEEK market.
Evonik´s Changchun
site in China
First project house in Taiwan
Evonik Industries is setting up its first project
house outside Germany. Light & Electronics,
a research and development unit established
on April 1, is located in the Hsinchu Tech
nology Park in Taiwan. The focus of its work
is new products and technologies for the
photovoltaics, display, LED, and lighting industries.
The project house seeks partnerships and
joint developments with Taiwanese institutes,
and above all, with local electronics companies. This is another strategic step in the consolidation of the Group’s global position.
“With the new project house, our goal is to
move closer to one of the most important
electronics markets in the world so that we
can tap into the growth opportunities the
region offers,” explained Patrik Wohlhauser,
the member of Evonik‘s Executive Board responsible for innovation management. “The
new site is a further development of our successful project house concept. With this,
Evonik is intensifying its focus on business
development and customer loyalty and is
adapting its innovation processes for custo-
mers’ innovation cycles, which are becoming
progressively shorter.”
Fast-growing electronics segments include
displays, LEDs, portable communication and
information devices such as navigation devices and tablet PCs, as well as photovoltaics.
The key Asian regions are China, Japan,
Korea, and Taiwan, where a number of important R&D companies in this field have
their headquarters. According to the German
Institute in Taipei, Taiwan stands out among
these countries as the world market leader in
such products as notebooks, scanners, monitors, and LCD monitors. Evonik already maintains partnerships with Taiwanese companies
through the joint ventures Evonik Forhouse
Optical Polymers manufacturing acrylic poly
mers in Taichung for TFT liquid crystal displays, and Evonik Cristal Materials Corpor
ation, which produces glass lenses for the
next generation of LEDs.
Additional contacts will be made and cultivated through the project house. “Electron
ics and lighting are extremely fast, dynamic
markets, whose innovation and product life-
cycles are becoming shorter and shorter,”
says Dr. Michael Cölle, head of the project
house. “The task of this project house is to
acquaint ourselves better with customers’
processes and value chains, and consolidate
our opportunities in these markets through
joint developments.”
In the project houses, Evonik works on
medium-risk research topics involving mul
tiple business units; the emphasis is therefore
on medium- and long-term success. Project
houses run for three years, during which time
roughly 15 to 30 employees typically develop
new products and technologies in collaboration with cooperation partners and universities. As a rule, the new developments of the
project houses are marketed by a business
unit or continued through an internal start-up.
Light & Electronics is the ninth project
house to be set up by Evonik and its strategic
research and development unit Creavis
Technologies & Innovation. The company’s
long-term strategic goal is to make the project house the nucleus of another R&D competence center for the Group in Asia.
N e ws 7
Plans for isophorone plants in China
Evonik Industries plans to construct new isophorone and isophorone diamine plants in
Shanghai (China). Basic engineering at the
Multi User Site China (MUSC), Evonik‘s production site in Shanghai, should be complete
within the next few months, and the worldscale plants are scheduled to go onstream in
2013. With this investment, Evonik is sending
out a clear signal for further growth in isophorone chemicals, and is emphasizing the
high significance of the strategically important Asian region.
Growing global demand from a large
number of user industries is the driving force
behind the decision to construct the new
plants. The planned investment will allow the
company to benefit from the future growth
of the market and in particular to satisfy
increasing demand from customers in the Asia
region. Evonik currently produces isophorone
chemicals in Mobile (Alabama, USA), as well
as in Marl and Herne (Germany).
“Evonik is the only company globally that
produces and markets the entire range of
isophorone chemicals,” says Dr. Ulrich Küst
hardt, head of the Coatings & Additives
Business Unit. “And with the construction of
the new world-scale, state-of-the-art plants,
we plan to strengthen this position and at
the same time extend our global production
network into Asia.” Isophorone, isophorone
diamine, isophorone diisocyanate, and their
derivatives are important components in the
production of industrial flooring, artificial
leather, and paints and coatings, for exam
ple. They are also used in high-performance
composite materials and in chemical synthesis.
Isophorone derivatives
are used in, among
other things, composite
materials for wind
turbines
Evonik acquires the hanse chemie Group
At the end of March 2011 Evonik Industries
closed a purchase agreement to acquire the
hanse chemie Group. By acquiring the Group,
which includes hanse chemie AG and nanoresins AG, Evonik will be able to enter additional markets for specialty applications in sil
icone chemistry. Both parties agreed not to
disclose the purchase price. The sale is still
subject to the approval of the corporate
bodies.
Based in Geesthacht, near Hamburg, the
hanse chemie Group produces high-quality
components and raw materials for the
manufacture

of sealants and adhesives,
molding and casting compounds, for exam
ple. Hanse chemie AG’s products are used
by end-consumers in such markets as the
construction industry, automotive manufacture, dental technology, and in photovoltaic
systems. The silicate-based nanomaterials
and other specialties by nanoresins AG are
used in highly scratch-resistant coatings, ad
hesives, fiber composites, and embedding
materials.
VESTAKEEP® enhances safety of automotive steering columns
The BMW Group has approved spindle nuts
made from VESTAKEEP® PEEK, a polymer
made by Evonik Industries, for use in electrical
steering column adjustment assemblies. The
VESTAKEEP® L4000G-based spindle nuts do
VESTAKEEP® based
spindle nuts passed
the stress tests
not break, even under the most severe conditions. In case of an accident, the spindle
nuts will not break and thus preventing any
plastic pieces from disabling the function of
safety-relevant features such as airbags.
The PEEK polymers that had been used in the
past were unable to meet BMW’s stringent
requirements and failed during stress tests.
Thanks to its improved ductility and impactresistance, VESTAKEEP® PEEK passed the
tests and also met the requirement of high
dimensional stability at different tempera
tures.
VESTAKEEP® spindle nuts are used in the
electrical steering column adjustment assemblies that are manufactured by Solingen,
Germany-based C. Rob. Hammerstein GmbH
& Co. KG. Thanks to their exceptional char
acteristics, they may in the future also be used
in mechanical steering column adjustment assemblies.
Evonik`s PEEK polymers offer particularly
high resistance to temperatures and chem
icals.
8 D ESIGNI N G WITH PO LYM ER S
To ensure the engine
runs smoothly: Engine
oils should work reliably
for about 30,000 kilometers. Gear oils, which
are more complicated to
change, should retain
their lubricating action
for roughly 20 years
Innovative engine oil additives reduce fuel consumption and CO2 emissions
Perfectly lubricated
Lubricants for engines and drives are all-stars: they function as well in heat as in
ice cold, despite mechanical stresses, and remain stable for years. They owe these
advantages mainly to high-performance additives. Specialists at Evonik in
Darmstadt have developed comb polymers, which not only meet all the demands
of advanced drives but also noticeably reduce consumption and emissions.
[ text Boris Eisenberg, Dr. Torsten Stöhr, Dr. Michael Müller ]
D ESIGNIN G WITH POLYMER S 9
No machine, plant, engine would be any use
without lubricant. Wherever moving metal surfaces
come in contact with each other, a lubricant is vital.
They reduce friction, muffle noise, prevent premature wear and tear. Lubricants work best when their
viscosity is aligned to the application: if the oil is too
thick, it prevents the parts from moving. If it is too
thin, the metal surfaces can engage without any protection—machines and engines then break down very
quickly.
The effectiveness of lubricants depends on their
viscosity, and the viscosity, in turn, depends on the
temperature. The colder the temperature, the higher
the viscosity, and the thicker the fluid. At high temperatures, viscosity decreases, and the liquid be
comes thinner and more free-flowing. This is based
on a simple molecular mechanism: particles of thick
liquids are strongly bound to each other by molecular
interactive forces and, therefore, relatively immobile.
This inner friction resembles the movement of two
layers of molecules lying interlocked, one above the
other. Force must be used to overcome the interlocking. When the temperature rises, the interactive
forces weaken, and the molecules glide across each
other easier. The viscosity decreases as a result, and
the liquid becomes thinner.
This principle applies to all fluids—whether honey,
water or oils. The viscosity index (VI) is key to the
evaluation of lubricants. It describes the temperature
dependency of the kinematic viscosity of the oil—the
force necessary to loosen the molecular interlocking
and get the oil to flow. Oils with a low VI change their
viscosity with the temperature more easily than oils
with a high VI. As a rule, engines require oils that
work reliably both summer and winter, which means
oils with a high viscosity index. These kinds of oils
provide adequate lubrication in summer, and are sufficiently free-flowing in winter.
High standards for mineral oils
Pure mineral oils are suitable to only a limited extent
in applications with changing temperature ranges. At
15 degrees Celsius, they are already as thick as butter
and behave less like lubricants and more like brakes
on the moving parts. Today, a conventional engine
oil has to work reliably and efficiently between minus
40 and plus 150 degrees Celsius. This is why existing
engine oils normally consist of a low-viscosity base
oil selectively thickened with additives.
Evonik has long produced polymer-based additives
that increase and optimize the viscosity index. 333
The effect of temperature on polymer solubility.
Because polymers swell with rising temperatures, they ensure that the viscosity
of the solution stays as constant as possible compared to pure oil
Solubility in oil
Good
Poor
Low
Temperature
High
10 D ESIG NIN G WITH POLYM E R S
333 The type of polymers and, above all, their molec
ular mass, is key to the effectiveness of these viscos
ity index improvers (adding 3 to 7 percent corresponds to an additive content of 2.5 percent): the
larger the molecules, the more they swell with rising
temperatures and keep the lubricant sufficiently
thick, even at high operating temperatures.
Large molecules do have one weak point, how
ever: mechanical stress in the thin lubrication gap
can easily tear the polymer chain. For this reason, the
second key parameter for the suitability of a lubrication oil is the shear stability of the polymers used.
High shear stability means that the molecular chains
are split slowly, even with heavy mechanical loading,
so the polymer breaks down only after several years
of service. Gear oils are expected to retain their lubricating effect for about 20 years, while engine oils
are supposed to work reliably for approximately
30,000 kilometers.
VI improvers ensure the viscosity
stays as constant as possible
Evonik has supplied VI improvers based on poly
alkyl(meth)acrylate (PAMA) for decades under the
VISCOPLEX® trademark. The molecules consist of a
long polymethacrylate chain with alkyl side chains
that ensure solubility in the base oil. In solution, the
PAMA chains form a ball, which wells up with in
creasing temperature. When this happens, the balls
expand, thereby increasing the viscosity of the oil. To
be more exact, VISCOPLEX® ensures that the viscos
ity of the solution remains as similar as possible compared to that of the pure base oil without additive.
What the chemists are doing, then, is thwarting
physics: The effect is contrary to the natural behav
Measuring kinematic
viscosity, which indicates
how much force is
required to get a liquid
to flow
At low temperatures, the comb polymers reduce the kinematic viscosity
of the oil compared to PAMA by about one third. At high temperatures,
they achieve the same good values as PAMA polymers. Bottom line: comb
polymers reduce the temperature dependency of viscosity
Expanded
PAMA
Log log (KV [cst+0.8])
Contracted
PAMA
Expanded
comb
Collapsed
comb
Oil-insoluble
PAMA backbone
oil-soluble
polyolefin arms
Base oil
Log T [K]
ior of a liquid, which always becomes thinner when
the temperature rises. The additives reduce the loss
in viscosity and expand the temperature window in
which the oil displays optimal lubrication.
In principle, the thinner the oil, the easier it is for
an engine to run, and the less fuel it consumes. The
art lies in keeping an oil‘s viscosity as stable as possible within the highest possible temperature range.
Today’s engines and transmissions are becoming
increasingly compact and powerful. This means
increasing standards for lubricants. For this reason,
the chemists at Evonik have searched for molecular
structures that hold the flow properties of the lubricant nearly constant without becoming too thick in
cold temperatures and thin in hot temperatures.
Resource Efficiency Even more powerful: comb polymers
The specialists from Darmstadt have developed a
completely new architecture for the molecules of the
polymers. The backbone consists of extremely long,
polar molecule chains that carry non-polar polyolefins as side chains at regular intervals.
Chemists refer to these as “comb polymers” because their structure resembles a comb. The building
blocks of the long backbone consist of short-chained
methacrylates, and other co-monomers. By varying
the percentages of the monomer mixture, the polarity of the chain and the number of side chains can
be selectively controlled during polymerization.
About 100 monomers have an average of 0.8 to 1.6
molecular teeth, each with some 400 carbon atoms.
The modified structure results in completely new
properties. The long side chains ensure extremely
good solubility in the base oil over a broad temperature range. The stiffness of the backbone is designed
in such a way that the large molecules „collapse“ at
low temperatures by forming very small units, so that
the lubricant remains adequately free-flowing. If the
temperature rises, the long side chains push apart and
the comb polymer wells up, which results in the desired thickening effect.
Comb polymers have proven their outstanding
properties as lubricant additives on a number of engine test stands. Compared to conventional PAMA ad
ditives, they show significantly better values for all key
parameters. The shear stability of the molecules is
many times higher, and the flow properties of the oil
are optimized during cold start. The kinematic viscos
ity, measured at 40 degrees Celsius, is about one third
lower. This means that the lubricant is easy to pump
at relatively low operating temperatures, and the
movement of the engine parts and gear wheels in the
transmission slows only a little—an effect that has a
direct and positive impact on fuel consumption.
Lubricants must be precisely coordinated to oper
ating conditions. Because thermal stress on the poly
mers is particularly high in the engine, comb polymers for engine oils contain fewer side chains than
those for gear oils. Shear stability is the most 333
Politicians demand
economical vehicles with
low CO2 emissions
Today, engine developers and car manufacturers not only focus
their attention on the design and performance of their products but
on fuel consumption and emissions. The pressure is coming primar
ily from the political arena: Over the next few years, the EU will be
reducing the permissible fuel consumption of new vehicles in several
stages. By 2015, manufacturers will have to reduce fuel consump
tion to the point that exhaust emissions are, on average, below 130
grams of CO2 per kilometer. In 2010, the average CO2 value of
newly registered cars in Germany was 151 g/km. Car manufacturers
and importers who do not comply with EU limits in the future will
have to shoulder millions of euros in fines.
Engineers use an array of methods to reduce fuel consumption:
lower vehicle weight, improved aerodynamics, more efficient en
gines and drive trains. Most of these methods are technical in nature.
But the more sophisticated the component, the more expensive and
time-consuming it is to increase its efficiency and performance even
more. In addition to technical optimization, selecting a high-performance lubricant can also reduce a vehicle‘s fuel consumption and
emissions. Thanks to their modified chemical structure, the new
additives from Evonik each show optimal viscosity over a broad temperature range, and guarantee highly efficient operation of engines
and transmissions. Test-stand results have shown that additives based
on comb polymers achieve fuel savings of about 1.5 percent. The
benefit corresponds more or less to that obtained through high-effi
ciency wheel bearings or an electronic start-and-stop system for
the engine. For engine developers and car manufacturers, then, this
margin is a giant leap.
12 D ESIG NIN G WITH POLYM E R S
Additives are supposed to keep
the viscosity of lubricating oils
constantly within an optimal
range over the widest possible
range of temperatures. The
viscosity index (VI) plays a
decisive role. Changing temper
atures have a greater impact
on the viscosity of oils with a
low VI than on the viscosity of
oils with a high VI
333 important factor in transmissions—in a fast turning
transmission, extremely small toothed gear flanks are
subject to strong forces and significantly higher pressures than in the engine. Consequently, comb polymers have to stand up to high shear forces while
retaining optimal viscosity values over a wide range
of temperatures.
Fuel consumption reduced once again
After many years of development work, chemists at
Evonik have developed four comb-polymer-based
high-performance additives that meet all the demands
of today’s engines and transmissions. Most importantly, these developments also help reduce fuel consumption and emissions. In a comparison with a standardized reference oil (RL 191), conventional PAMA
additives have been shown to reduce fuel consumption by 3.5 percent—comb polymers in the engine oil,
on the other hand, lower fuel consumption by 4.4
percent. In combination with gear oils, which also
contain comb polymers, the savings increases to a
total of about 1.5 percent.
At first glance, a 1.5 percent reduction in fuel consumption does not seem particularly high. Comparison in absolute figures reveals the actual weight of
this relatively small percentage: the International
Energy Agency (IEA) estimates that, worldwide, road
traffic emits about five billion metric tons of carbon
dioxide per year. Of this figure, 1.5 percent corresponds to a savings of 75 million metric tons. Accord
ing to EU standards, average CO2 emissions per
vehicle and per kilometer must be reduced by about
Influence of the engine oil on gas consumption. The measurement was taken on the engine test stand in Darmstadt, and a
standardized reference oil (RL 191) was used for comparison.
Compared to PAMA, oils with comb polymers can reduce
gas consumption by another 0.9 percent
Comb
PAMA:
Comb:
20 °C;
20 °C;
44 °C; efficiency = 95.2%
44 °C; efficiency = 95.7%
PAMA
Advantage vs. RL191 [%]
5.0
4.5
Influence of the gear oil on gas consumption, measured as torque
loss on the drive shaft. Here, too, comb polymers can help reduce
gas consumption by another 0.5 percent compared to PAMA
Torque loss [Nm]
5
4.4
●
4.0
3.5
3.5
4
●
3.0
2.5
3
●
●
●
2.0
●
1.5
1.0
2
●
●
0.5
0
1
0
25
50
75
100
125
150
Applied torque [Nm]
20 grams by the year 2015—and the new comb polymers can eliminate up to 2.5 of those grams.
This shows how the chemists at the Oil Addit ives
Business Line are translating the ideas and wishes of
engine developers and lubricant manufacturers into
a chemical structure of the required additives. They
act as mediator between the growing technical challenges of engines and drive trains, and the practical
experience of lubricant manufacturers. This requires
close cooperation with formulators in setting the very
specific properties of the lubricant and a continuous
exchange with customers and suppliers.
Every engine in the world is the same in this way:
They all have to run, and run as long and as troublefree as possible. But this alone is not enough anymore.
Traffic is increasing dramatically worldwide, and is
considered the problem child of climate policy because, thus far, it has been unable to noticeably curb
traffic-related greenhouse gas emissions.
This is why future vehicles will also be assessed
based on whether engineers and suppliers have
exhausted all potential for the lowest possible fuel
consumption and low emissions. Against this backdrop, chemically custom-designed additives can help
ensure that advanced engines not only function
optimally but also consume as little fuel as possible.
Doing so is not only in the interest of the driver but
also car manufacturers, engine developers, and the
oil industry—all of whom must ensure that, in the
future, vehicles offer substantially lower emission
levels and greater environmental compatibility. Only
then will traditional drive technologies continue to
be relevant. 777
Boris Eisenberg joined Evonik‘s Oil Additives
Business Line in 1995, and currently works in product
development in the Innovation Management unit.
Since 2008, he has been responsible for product devel
opment with a focus on defined polymer architecture.
Eisenberg holds a degree in chemical engineering from
the University of Darmstadt (Germany) and is author
of more than 20 patents and scientific publications.
+49 6151 18-3028, boris.eisenberg@evonik.com
Dr. Torsten Stöhr studied chemistry with a focus on
polymer science at Johannes-Gutenberg University
Mainz (Germany) and the University of Massachusetts
at Amherst (United States). He earned his PhD at the
Max Planck Institute for Polymer Research in Mainz, at
IBM Almaden Research Center in San Jose (California,
USA), and at Stanford University in Palo Alto (Califor
nia). He joined Evonik Industries in 2000, and came to
the Oil Additives Business Line in 2002, where he
worked on defined polymer architectures. Since 2008,
he has been in charge of global product development
of all viscosity index improvers and pour point depressants of the business line.
+49 6151 18-4743, torsten.stoehr@evonik.com
Dr. Michael Müller is responsible for strategic marketing in the Oil Additives Business Line. After studying chemistry at the University of Freiburg and earning
his doctorate there at the Institute for Macromolecular
Chemistry in the working group of Prof. Gerhard
Wegner, Müller started his career in 1984 at Evonik
Röhm GmbH. He held different positions in research,
application engineering and technical service in the
Acrylic Polymers and Oil Additives Business Lines, including most recently Global Business Manager Engine
Oil and Driveline for Oil Additives, before moving to
his current position.
+49 6151 18-4573, michael.mueller.mm@evonik.com
14 C ATALYS I S
Robust and selective:
metathesis catalysts for
oleochemical applications
Metathesis plays a key role in oleochemistry to make renewable resources
usable for the chemical industry. The metathesis catalysts used for this
purpose must be robust and highly active to convert the raw material
qualities, which are subject to frequent fluctuations and occasional contam
ination. The Evonik portfolio features two catalysts, catMETium® RF2
and catMETium® RF3, that can solve this difficult task.
[ text Dr. Renat Kadyrov ]
Metathesis is a chemical reaction in which four
atoms receive new bonding affiliates in a single step.
Depending on the substrate combination, it is distinguished between ring-closing metathesis (RCM),
cross-metathesis (CM) and ring-opening metathesis
polymerization (ROMP). The development of well
defined catalytic systems for metathesis reactions
won the Nobel Prize in Chemistry in 2005.
Today, metathesis is a highly significant method
of the chemical industry, for instance in the development and production of modern plastics or of active
pharmaceutical ingedients (fig. 1). Ring-closing meta
thesis is an elegant method for construction of macro
cyclic ring systems and therefore is an indispensable
reaction step in the synthesis of modern active pharmaceutical ingredients for the treatment of hepatitis
C or cancer. Ring-opening metathesis polymerization
is an effective method to produce specialty polymers
for large, complex and corrosion-resistant com
ponents for automotive applications or chemical containers. In oleochemistry, metathesis reactions are
used for functionalizing unsaturated fatty acid deriv
atives.
Evonik markets metathesis catalysts under the
name of catMETium® RF (fig. 2). All catalysts are
based on unsaturated N-heterocyclic carbene Ru
complexes (Ru-NHC). The catalysts all share the
characteristics of high temperature stability, high
turn-over numbers (TON), and high selectivity.
The metathesis of olefins plays a particularly important role in oleochemistry, since this technology
allows for direct access to renewable resources and
for their efficient use without creating any by-prod
ucts. For example, metathesis turns triglycerides and
unsaturated fatty acid derivatives (from palm, soy,
canola or sunflower oil) into fine chemicals, function
alized monomers, polymers, biodegradable lubricants
and specialty chemicals such as cosmetics.
Cross metathesis of unsaturated fatty acids and
acid esters with functionalized olefins, allow for accessing a diversity of double-functionalized olefins.
These represent interesting raw materials for creat
ing macrocyclical compounds, polyesters, poly
amides, lubricants or surfactants for example. On the
other hand, the non-functional olefins that are gener
ated in the same process can be further converted to
α-olefins, oil field chemicals, lubricant additives and
waxes.
Highly prized robustness and stability
at high temperatures
Metathesis catalysts for oleochemistry applications
must have special properties for operating economically. catMETium® RF2 and catMETium® RF3 meet
these requirements. They stand out for high tolerance
for a variety of raw material qualities, fulfilling an
essential prerequisite for the use of renewable resources in oleochemistry.
The thermal stability of catMETium® RF catalysts
represents another advantage, which is especially important in equilibrium-limited cross-metathesis 333
K ATALYSE 15
Figure 1
Ring-closing metathesis
Cross metathesis
Application areas of
olefin metathesis
A
A
+
+
+
Y
Y
Ring-opening metathesis
Pharma
n
Oleochemistry
n
Antiviral active ingredients
Dosing of active
ingredients
Bulk and
special polymers
Polymer
Dental materials
Functionalized oligomers
Coatings
Figure 2
Evonik´s catMETium® RF
product family
Me
Mes
Cl
Cl
N
N Mes
Mes
Ph
Ru
PCy3
catMETium® RF1
Cl
Cl
N
N Mes
Mes
Cl
Ru
S
Cl
Ph
Me
N
N Mes
Cl
Ru
S
N
Ph N
Cl
N Ph
Ru
S
PCy3
PCy3
PCy3
catMETium® RF2
catMETium® RF3
catMETium® RF4
16 C ATALYSI S
333 or homo-metathesis. The high thermal stability of
Figure 3
the catalysts allows for combining the catalytic meta
thesis step with thermal separation and to return
non-converted starting materials to the process.
The high thermal stability of RF catalysts is evident in the homo metathesis of methyl oleate, in
which octadec-9-ene and dimethyl-9-octadec-9-ene-1,
18-dioate are obtained in an equilibrium reaction (fig. 3).
While saturated Ru-NHC complexes quickly degrade at temperatures just above 70 °C and therefore
produce a wide range of by-products, the catalysts of
the catMETium® RF technology show unparalleled
thermal stability and robustness, even at tempera
tures above 100 °C.
As a result, reaction speed and productivity significantly increase at high temperature (fig. 4). Even
at high reaction temperatures, the catMETium® RF2
catalyst achieves a turnover number of > 200,000
with a selectivity of > 98 percent. With an integrated
thermal separation of the products, the reaction equilibrium can be shifted toward higher volumes and
yields without the risk of destroying the catalyst by
thermal stress.
Homo metathesis of methyl oleate
O
O
O
O O
+
O
Figure 4
Comparison of yield in C18 diester and C18 olefin
in the homo metathesis of methyl oleate
(catalyst loading 3 ppm, reaction time 2h)
Theoretical conversion in case of thermodynamic
equilibrium of homo metathesis
Yield in by-products/isomers
Yield in C18 diester and C18 olefin
Simple business model
Saturated Ru-NHC complex
Yield [%]
60
50
●
●
●
40
30
●
●
20
10
●
0
●
0
10
20
●
30
40
50
60
70
100
80
90
Temperature [°C]
In addition to the excellent activity, selectivity, and
robustness of the catMETium® RF technology in var
ious application areas, Evonik offers further added
value with a clear, independent IP position that is also
reflected in the business model. Evonik uses a simple
proven business model to market the catMETium® RF
catalysts that makes license agreements superfluous
and allows for transparency. The total kilogram price
for the catalysts includes all license fees for the use
of intellectual property; customers have no further
obligations.
This business model is also reflected in the name,
since the acronym RF stands for Royalty Free. This
allows customers to make use of the new catalysts
without any restrictions. 777
catMETium® RF2
Yield [%]
60
50
●
●
●
40
●
30
20
10
0
0
10
20
●
●
30
40
50
●
60
70
●
100
80
90
Temperature [°C]
Dr. Renat Kadyrov deals with synthesis, up-scaling and production of homogeneous catalysts at Evonik´s Catalysts
Business Line. He received his PhD from
Kazan Sate University in 1984 under
direction of Professor Boris A. Arbuzov.
Over the next ten years he worked at
the University of Kazan. He was as post
doctoral fellow at the University Halle/
Saale (West Germany, 1986/87) and
in the Max-Planck-Group at Rostock
University (1993/94). From 1994 he
worked at the University of Greifswald
and at the Institute of Catalysis at Ros
tock University before in 1999 he joined
Aventis R&T. Since 2001 he has been
an employee of Evonik.
+49 6181 59-8710
renat.kadyrov@evonik.com
Re sou rc e e ff ici en cy 17
Almost 5,000 km across Australia
Pioneering trip by the Wind Explorer
The Wind Explorer pilot vehicle is a two-seated
electromobile that weighs just 200 kilograms and
with a range of 400 kilometers per battery charge.
The bodywork consists mainly of a carbon fiber
composite with ROHACELL® structural foam from
Evonik. Its lithium-ion batteries, based on yet
another Evonik technology, are charged by a mobile
wind turbine or—in exceptional cases—in the
conventional way from the power grid
„We’re incredibly proud. A dream has come true,“ com
mented German extreme sportsmen Dirk Gion and Stefan Simmerer at the end of their two-and-a-half week pioneering trip
across Australia. The two piloted the Wind Explorer, a lightweight electric vehicle, from Albany on the Indian Ocean to Cor
poration in 17 days and set three new records during their roughly
4,900 km trip: The first time a continent had been crossed by a
vehicle powered by wind and lithium-ion batteries, the longest
overall distance covered by an exclusively wind-powered land
vehicle, and the longest distance covered in 36 hours. „What‘s
more it was resource-efficient and had virtually no impact on
the climate,“ said Simmerer. The Wind Explorer was powered
by lithium-ion batteries, recharged by a portable wind turbine
whenever wind conditions permitted. The 200 kg vehicle therefore only notched up electricity costs of around €10 for the almost 5,000 km trip.
Gion and Simmerer came up with the idea for this recordbreaking trip last summer. Just weeks later they found the
necessary partners in German industry, led by Evonik Industries
AG. Evonik provided the materials for the lightweight bodywork
and the high-performance lithium-ion batteries. The battery
pack with power of 8 kWh enabled the Wind Explorer to run
for about 400 km in demanding temperatures of 60 °C. Dr. Klaus
Engel, Chairman of Evonik‘s Executive Board, congratulated the
team: „This was a tremendous achievement by Dirk Gion and
Stefan Simmerer. It shows what pioneering spirit and German
high-technology are capable of.“
The special feature of the Wind Explorer is that it is an electric vehicle with its own mobile power supply. When the battery
is empty, the pilots can recharge them via a portable wind turbine, if wind conditions allow, or via the conventional power network. It takes half an hour to erect the turbine and six-meter high
telescopic mast made of bamboo. In addition to wind power, the
Wind Explorer can be driven by kites. In this way, the lightweight
vehicle reached speeds of around 80 kph as it crossed the states
of Western and South Australia, Victoria and New South Wales.
The pilots started in Perth. Having carried out various tests
during the first 500 km, the real trip began in Albany. For the
first 800 km to Nullarbor Plain the Wind Explorer was driven
entirely by electric power. Strong winds then enabled the pilots
to use the kites. Finally the Wind Explorer achieved its best performance within 36 hours at the south coast, covering 493 km.
„It‘s great to see how lightweight construction and lithium-ion
technology can provide a response to the problem of global warm
ing,“ said Simmerer.
The record trip from Albany to Sydney was not the first feat
by Gion and Simmerer. Gion made headlines in 2004/2005 with
the „Earthflyer“ kiteboard project in Australia and in 2006 as a
water-skier towed by the “MS-Deutschland” cruise liner. In 1997
Simmerer was the first person to cross Chang Tang, the Tibetan
high plateau, and climb Zangser Kangri (6,551 meters). He has
since led expeditions in South America, Africa and Kamchatka.
Pioneering projects like the Wind Explorer are a good opportunity for German industrial companies to test their technol
ogy under extreme conditions and extend their technical edge.
Competition is particularly tough in the automotive sector, which
is increasingly turning its attention to electric and hybrid vehi-
cles. New lightweight materials such as ROHACELL®, which was
used in the Wind Explorer, and smart tire technologies that reduce rolling resistance are in great demand. However, the race
for tomorrow‘s technology to power electric vehicles will be
won principally by expertise in batteries. „Through our subsidiary Li-Tec we aim to become the European market leader in
battery cells,“ said Engel. 777
18 Ne ws
Prize awarded in the 2011 nano+art competition
What happens when art and science enter a dialogue, when space is
given to the tensions and synergies between both disciplines? This
year’s presentation of the prizes for the nano+art competition pro
vided at least a visually impressive answer to these questions. In his
speech at the presentation ceremony, Dr. Harald Schmidt, head of
the strategic R&D unit Creavis Technologies & Innovation, stressed
the importance of nanotechnology for Evonik and highlighted the
great potential for development of new products and improved processes.
The competition invited entries from female students, graduates and
young scientists working in the field of nanotechnology at universities, research institutes and other organizations in Germany and
Europe. Entrants were asked to submit images from their research
work on the themes of „Woman“ and „Man,“ with the ultimate goal
of raising awareness of nanotechnology among the broader public
and making it more understandable. This is why the Employer
Branding unit of Evonik Industries has organized the event for the
last six years.
1
With her entry “Opera Ball” (left), Julia Lambrecht
from Kassel was the grand prize winner of this
year’s nano+art competition, and grateful recipient
of the €1,000 prize money. The winning image shows a
photomicrograph of a crystallized organic semiconductor material. Some of the crystals formed on the surface
of the substrate during preparation of an organic transistor. In this process, the development of the visible
crystallites is an undesired side effect of the intended
generation of organic semiconductor nanowires.
2
Second place and a check for €500 went to Aruna Ivaturi
from the Nanoscience Centre of Cambridge University
for her „Floral Bouquet“ (top right): „The multi-colored
‘dandelions’ in this floral bouquet represent women all over the
world—various shades of personality, character and identity,“
explains Ivaturi. Her Floral Bouquet is a scanning electron micrograph of tin oxide nanorods grown by a hydrothermal method.
The dominance of the homogeneous nucleus formation during
growth leads to the formation of dandelions. The stunningly
unusual architecture of these „flowers“ makes them promising
candidates for electrode material in such products as low-cost
batteries and solar cells for the energy storage and conversion
markets.
3
Third prize, which carried an award of
€250, went to Claudia Mattheis for
her “Dancer” (bottom right), a digital
micrograph of electrospun polymer com
posite nanofibers. The thickened parts, and
their interplay with the fibers, were interpreted as a passionate dancer, whose spirited
movements can vibrate the surrounding
area. This image addresses the theme of
„Woman.“
N e ws 19
Study verifies effectiveness of conditioning agent against hair breakage
Shampoos and conditioners that contain the
new silicone conditioning agent ABIL® T Quat
60 from Evonik significantly reduce hair fiber
breakage. This is the result of a joint study by
Evonik‘s Care Specialties Business Line and
TRI/Princeton of Princeton (New Jersey,
USA), a leading independent research institute largely devoted to the study of human
hair. ABIL® T Quat 60 also provides outstand
ing conditioning features, such as easy comb
ing and a superior feel in both wet and dry
states. The conditioning agent is universally
suitable for all shampoos and conditioners.
Broken hair fibers are brittle, fray, and
lead to the formation of unsightly split ends.
As a result, they reduce the perception of hair
smoothness, lower shine, and hinder a fluid,
flowing motion. Because consumers rely on
hair care products to solve this problem, improving the anti-hair breakage functionality
of shampoos and conditioners is an important
issue for the manufacturers of these products.
Hair breakage, as revealed by a
scanning electron microscope
Evonik always substantiates its hair product
solutions through many hair performance
tests. As the experts from Evonik and TRI/
Princeton have proven, ABIL® T Quat 60
reduces hair breakage in both shampoos and
conditioners. Their joint study examined the
breakage of hair that was treated with a
shampoo and a conditioner containing ABIL®
T Quat 60. The treated hair underwent de
fined tests that are often used to make claims
regarding anti-breakage, strengthening, or
smoothness. All testing was performed on
hair damaged in the standard way, and in
volved repeated combing with a custom-built
automated grooming device, followed by
counting the number of broken fibers. To ensure statistical relevance, the experts evaluat
ed eight tresses per treatment. The results of
the experiment show that the shampoo and
conditioner formulations containing the new
conditioning ingredient ABIL® T Quat 60 provide a dramatic anti-breakage benefit by 60%
for shampoo and 88% for conditioner.
The extreme effectiveness of ABIL® T
Quat 60 against hair breakage is a result of
its excellent substantivity to hair keratin. This
silicone conditioning agent also provides
impressive heat protection properties, longlasting color protection, and a clean, silky skin
feel. It is highly suitable for use in condition
ing shampoos, dandruff shampoos and conditioners, and even leave-in formulations and
body washes.
Nitrogen oxide reduction: Lines made from
VESTAMID® compounds satisfy requirements
Illustration of catalytic reduction of nitrogen oxides
Evonik offers a variety of VESTAMID® polyamide 12 compounds that help automobile
manufacturers develop systems for reducing
nitrogen oxide in diesel vehicles. All the grades offered by Evonik have performed excellently in tests, and some are already in use.
A 32.5-percent aqueous solution of urea
serves as the reducing agent in systems developed today by car makers for the selective
catalytic reduction (SCR) of nitrogen oxides
from diesel engines. The VDA (German
Association of the Automotive Industry) has
registered this solution under the brand
AdBlue®.
At temperatures above 60 °C, water decomposes AdBlue®, yielding carbon dioxide
and ammonia; the latter in turn reacts with
nitrogen oxides, forming water and nitrogen
and thus reducing the emission of nitrogen
oxides by about 90 percent.
AdBlue® places heavy demands on lines in
SCR systems. They must be resistant to urea
and ammonia as well as any gas mixture flowing back from the catalyst. Because the urea
solution is heated to up to 60 °C, but freezes
with expansion at –11 °C, good hydrolytic
resistance and bursting strength at higher
temperatures are essential, along with high
impact resistance and elasticity at low tem
peratures.
Various VESTAMID® polyamide 12 compounds satisfy all these requirements. Evonik
helps car makers develop their individual systems by offering them a variety of products.
All VESTAMID® compounds have been subjected to a recirculation test with AdBlue® at
60 °C and 80 °C (with external air temper
atures of 40 °C and 50 °C respectively) over
a period of 5,000 hours, to check for any
changes in their mechanical properties. All of
the grades tested have excellent values for
strain at break, bursting strength, and, in particular, low-temperature impact strength at
–40 °C.
Of all the grades tested, VESTAMID®
LX9008 best satisfied all the requirements;
VESTAMID® L2140 and X7293 are already
being used in SCR systems.
20 D ESIG NIN G WITH POLYM ER S
PLEXIGLAS® stands up to glass in photovoltaics systems
Green power made easy
PLEXIGLAS® is transparent and formable, UV- and weather-resistant—an
ideal material for manufacturing ultra-lightweight solar modules in shapes
and colors that are in tune with design. Experts from Evonik and Sunovation
are working together on lightweight-module solutions that open up completely new avenues to climate-friendly power generation in architecture,
vehicle construction and city planning.
[ text Peter Battenhausen, Markus Krall, Uwe Löffler, Andreas Wöll ]
It is slated for mass-production this year: the SUNOVATION
ECO TECHNICS carport. Developed by Sunovation and
partners, the carport combines design with functionality. Its
8-square-meter photovoltaics surface can generate about one
kWp of electricity and cover the consumption needs of an
electric urban vehicle driving about 40 kilometers a day.
The power generated is fed into the network, and withdrawn
again, when needed, via the integrated power plug. Specially
fabricated for Evonik, the prototype shown in the photo has been
installed in May 2011 on the premises of the Darmstadt site. To
meet the design standards of this upscale carport, developers
used PLEXIGLAS® materials in both the cover and carrier sheets
Plastic or glass? This is the question that
countless car manufacturers, architects, packaging
designers, and city planners have racked their brains
over. Often, the answer is pretty simple: Plastic wins
out whenever weight or formability is a pivotal factor. Or put another way, plastic is the first choice if
the focus is on fulfilling and implementing the design plans of the architect or designer.
Interestingly enough, however, this question has
played a minor role in photovoltaics (PV). The glasson-glass modules currently in use consist of a carrier
sheet and a cover sheet made of glass. Depending on
the structural specifications for the glass strength,
these standard systems have one grave drawback:
Each square meter of glass module weighs at least
20 kilograms. In comparison, PV modules based on
PLEXIGLAS® weigh half as much. Indeed, this is why
many construction projects fail to exploit the potential of photovoltaics. A case in point is renovating
existing buildings to make them more energy-effi
cient. The existing substructure is unable to bear the
additional static loads of the glass modules.
Lightweight construction: an
attractive niche in photovoltaics
Conventional glass modules are, therefore, of limited
use on account of their weight. Obviously, then, the
glass has to be replaced with a transparent, resistant,
but above all lightweight material. This is where Elsen
feld, Germany-based Sunovation GmbH began its
work. The company has been devoting itself to lightweight construction modules for over 15 years and
has been successful at carving a niche for itself 333
The Alstersonne, a solar
catamaran that has sailed
the Alster since the year
2000. Sunovation has
installed its modules on a
total of four of these
catamarans, which are
operated in Heidelberg,
Hannover, and on Lake
Constance, in addition
to Hamburg. The
PLEXIGLAS® solar
modules form a curved,
partially transparent roof
on the catamarans.
Their low-weight, high
weather resistance,
and formability make
them especially useful for
overhead applications
22 D ESIG NIN G WITH PO LYME R S
333 in the photovoltaics market. Currently, Sunovation
is the only company that produces lightweight solar
modules from plastic, keeps advancing their development, and has gained a wealth of experience in the
field worldwide. A host of applications—bus stops,
golf carts, and solar portholes for boats, the solar cat
amaran Alstersonne in Hamburg, the solar butterfly
in Freiburg, which supplies energy to a radio tower,
and the largest lightweight solar module in the world,
measuring 1.5 meters by 4 meters—testify to the
company‘s success.
The best possible material for the lightweight
modules is poly methyl methacrylate (PMMA), which
Evonik Industries has sold for over 75 years under the
PLEXIGLAS® trademark. PLEXIGLAS® stands out
from other plastics by virtue of its longevity, high
UV- and weather resistance, high light transmission,
and its outstanding surface hardness. As a thermoplast, it can be handled and processed by all shaping
methods and is completely recyclable.
PMMA for freedom of design
The world‘s largest lightweight solar module with a cover sheet made of
PLEXIGLAS®. The module measures 1.58 meters by 4 meters and has a maximum
power of about 880 Wp. The true record, however, is its low weight. The
SUNOVATION® module weighs only 80 kilograms, which makes it over 60
percent lighter than a glass-glass module of this size for overhead use. In addition,
with a U-value less than 1 W/m²K, the module boasts excellent heat-insulation
properties. The module exhibits outstanding structural properties, can withstand
high mechanically applied loads, and excels with its durable, highly transparent
and scratch-resistant surface
In addition to its low weight, PMMA has another key
property that makes it superior to glass as a carrier
sheet for solar cells. The modules can be produced in
any shape desired. They can be easily bent into a roof
over a bus stop or into a gently arching roof con
struction on solar boats, and they can be used in noise
barrier constructions over express train and subway
tracks, individually shaped for high-tech, powergenerating façades. The lightweight modules are installed either cold-formed, in which the module is
clamped into an existing space, or following treatment in a heating furnace, in which it is shaped into
its final three-dimensional form with the help of
forming tools.
With its lightweight modules, Sunovation has
opened up new areas of application in photovoltaics.
Schematic structure of a SUNOVATION® module
Base sheet
Transparent
plastic
Cell-connector
technology
Solar cells
(crystalline or
thin-film
technologies)
Permanently
elastic multicomponent gel
Cover sheet
Transparent
plastic
●
4 mm
SS: 2 – 30 mm
MWS: 6 – 32 mm
●
^ Solid sheet
SS =
^ Multi-wall sheet
MWS =
Graphic: sunovation
approx. 3 mm
The façade of the Photovoltaics Information
Center (PIZ) in Gelsenkirchen. The vertical
shading “gills” are made of holographic mirrors that focus the sunlight onto the interior
SUNOVATION® modules. Another unique
feature is that the gills can be adjusted to the
sun’s position and aligned accordingly. This
allows regulation of shade for the interior
spaces behind them
The substructures of buildings can be designed to
weigh less and use fewer materials. When existing
buildings are modernized, a relatively weak sub
structure is no longer a problem. Vehicles can be de
signed with curved roofs or interior constructions
that supply power to the on-board system or battery
and add no weight to the vehicle.
Advanced technology from Sunovation
Sunovation modules basically consist of three layers.
The upper cover sheet and the lower carrier sheet
are both made of transparent plastic, but the carrier
sheet can be a solid or a multi-wall sheet. Between
these layers is a special permanently elastic multicomponent silicone-based gel in which the photo
active solar cells are embedded. The solar cells float,
as it were, in the gel and are decoupled from the
carrier sheet and cover sheet. 333
Strengthening Sales
Plastic modules for the
international market
Photovoltaics is a global business. This is why small, innovative
companies do well to look for internationally active partners to
strengthen their marketing position. Sunovation has therefore
established a joint venture with MAGE AG to market polymerbased lightweight modules more effectively in other countries
with great potential for photovoltaics. A subsidiary of MAGE
AG, MAGE Solar GmbH, headquartered in Regensburg, special
izes in marketing OEM-produced mono- and polycrystalline
standard modules. Another subsidiary of MAGE AG produces
for the systemic completion of solar panels on the substructures
and installation systems designed for PV modules. The company
is active throughout Germany and eleven other countries, in
cluding France, the United Kingdom, Italy, Slovakia, and the
United States, the key market of the future.
24 D ESIGNI N G WITH PO LYME R S
333 The gel not only holds the solar cells in place but
Built by the Venturi
company in 2007, the
car with integrated
solar roof made of
SUNOVATION®
modules can be
marveled at in Monaco.
The monocrystalline
solar cells supply
maximum power of
150 Wp
plays a central role in the forces that occur during
forming. It consists of several components, and can
be adapted to the shearing forces that occur during
forming through formula modification—depending on
how strong the sheets should be and whether the carrier is designed to be solid or hollow. The forces are
evenly distributed over the gel, which transfers the
mechanical load to the cells. Both crystalline and
amorphous silicon is used for the solar cells, but thinfilm and dye cells are also possible.
The first PLEXIGLAS® roofs with integrated solar
cells by Sunovation were installed more than thirteen
years ago. But back then, photovoltaics was still not
a generally accepted form of renewable power gener
ation. The only people interested in using PV modules
were committed environmentalists and a few trail
blazers.
Since then, the times have changed dramatically.
An increasing number of architects and developers
have now gone in for “green building”—the idea of
building private and public buildings as sustainably
and ecologically as possible. A vital component of
green building is recyclable modern construction materials and environmentally and climate-friendly
energy supply. This also applies to energy-efficient
renovation and modernization of existing buildings,
which plays an important role in the energy concept
of the German federal government.
In green building, lightweight modules not only
generate energy, but play additional roles: they pro-
The latest version of PLEXIGLAS® Solar (0Z023) is even better
adapted to the absorption spectrum of solar cells. It blocks
sunlight below 350 nanometers, which damages the solar cells
and cannot be converted into electricity anyway. At a wavelength
of 350 to 400 nanometers, however, it allows more high-energy
photons to pass through than other transparent plastics, thereby
increasing the electricity yield of the solar module
vide roofing, thermal insulation and sound insulation,
and create shade. To put it another way, why produce
expensive roofs or façades that you have to equip with
modules and thermal protection systems when all of
your key requirements can be met with multi-functional solar modules?
High potential in
the automotive industry
A revolution similar to that in the construction industry can be observed right now in the automotive
industry. The vehicles of the future are no longer
being developed and marketed based solely on technical and aesthetic criteria. To reduce traffic emis
sions and allow the industry to meet its climate obligations, the fleet of the future will have to consist of
ultra-light and eco-friendly (electric) vehicles. A
higher plastic content and regenerative energy supply will be key features.
Because the components have to meet the high
standards of safety, durability, and quality exacted by
mobile applications, the use of photovoltaics in vehicles poses a special challenge. Several renowned
automakers are currently experimenting with solaractive roofs. Integrative plastic-based PV solutions
have already been realized multiple times in concept
cars.
But electromobility covers far more than just the
vehicle alone. Eco-friendly driving also goes handin-hand with today’s charging stations. Together with
PLEXIGLAS® Solar 0Z023/PLEXIGLAS® Solar IM20—3 mm
UV blocking standard PMMA grade—3mm
III-V cell spectral response
Transmission [%]
100
90
80
70
60
50
40
30
20
10
0
250
300
350
400
450
500
Wavelength [nm]
its partners, Sunovation has developed the SUNOVATION ECO TECHNICS carport, a carport with integrated LED lighting that generates emissions-free
electricity, thanks to curved PLEXIGLAS® modules
that are a part of the roof. With a total surface measur
ing approximately eight square meters, the modules
have maximum power of over 1 kWp. Compared to
glass-glass modules, PLEXIGLAS® leads to weight
savings of over 60 percent and allows delicate, aes
thetically pleasing construction. A prototype of the
carport has begun operation in May 2011 on the
grounds of Evonik in Darmstadt.
With Solar Carport, Sunovation and its roughly
20 employees are planning to take the plunge into
mass-production. There is every reason to believe
the carport will be a success. Its modular construction makes it easily expandable for large-scale applications, and installing it is incredibly simple. It can be
set up on any even, stable substrate without a foundation and without a construction permit. Sunovation
will even take back used solar modules and recycle
them.
As these examples show, efficient products and
systems tailored to a specific application are possible
only through close cooperation between customers
and material manufacturers. Evonik and Sunovation
are currently studying the effect of various plastics
on the performance of solar cells. For this purpose,
nine modules are being measured and compared for
their endurance on a test bench under real outdoor
weathering conditions. The plastics used in the pan
els include conventional PLEXIGLAS®, polycarbonate,
and PLEXIGLAS® Solar, which is optimized for modules. The latter is a newly developed PMMA that
shows improved transmission in the short-wave UV
range. It allows high-energy radiation of between 350
and 380 nanometers to pass through far better than
other plastics. Consequently, more high-energy photons reach the solar cells and can be converted into
electricity.
Low weight, optimal transmission, and high UVand weather resistance are the main reasons why
PLEXIGLAS® Solar was used as the cover sheet for
the world‘s largest lightweight design module, which
Evonik presented at the K trade fair for plastics in the
fall of 2010. The module is 1.58 meters wide, four meters long, and weighs only 80 kilograms.
In the future, renewable power generation could
become as commonplace as today‘s coal- and gas-fired
power plants. Cars would be refueled with climatefriendly green electricity, buildings would be de
signed with power- and heat-generating façades and
roofs, and in cities, emissions-free public transport
would be the norm. But visions of this kind can become a reality only if high-tech and design are intelligently combined, that is, when material and function
interact closely with one another.
For this to happen, materials manufacturers, developers and customers along the entire value-added
chain must cooperate and promote innovations to-
gether. Freely formable PLEXIGLAS® based solar mod
ules are opening up a highly promising but challeng
ing new field of application. The modules have to do
more than just generate power efficiently and reliably.
They must also fulfill the aesthetic expectations of
architects, developers and customers, and as hightech products, withstand the influences of wind and
weather over many years. The partnership between
Evonik and Sunovation is one example of how to leverage the potential of advanced materials both economically and ecologically, while simultaneously
meeting the demands of aesthetics, performance and
sustainability. 777
Peter Battenhausen,
business development manager
for the Acrylic Polymers
Business Line, works primarily
with solar applications for
PLEXIGLAS®.
+49 6151 18-4519
peter.battenhausen@
evonik.com
Markus Krall
is founder and shareholder
of Sunovation GmbH. In 1997,
Krall developed the current
SUNOVATION® module in
cooperation with Evonik Röhm
GmbH based on a feasibility
study.
+49 60 22 70 99-13
mk@sunovation.de
Uwe Löffler
is responsible for the Inter
national Market Segment Solar
in Evonik’s Acrylic Polymers
Business Line.
+49 6151 18-3010
uwe.loeffler@evonik.com
Andreas Wöll
is general manager of
Sunovation GmbH and has
extensive experience in photovoltaics and solar thermal
technology. He is primarily re
sponsible for the rebuilding
of the company, further devel
opment of Sunovation tech
nology, and the development of
a more efficient and powerful
production process.
+49 6151 18-3010
aw@sunovation.de
26 BI OTE C H NO LO GY
Evonik BioTechDay
On a growth course
White biotechnology has become an indispensable part of the chemical industry.
But experts agree: the field is still in its infancy. High double-digit growth rates
and key strategic decisions show that industrial biotechnology will replace even
more conventional petrochemical processes. At Evonik’s BioTechDay in March,
some 200 participants discussed the opportunities this will create.
[ text Dr. Thomas Haas, Dr. Jan Pfeffer ]
Biofuel, cosmetics or
biopolymers: The desire
to replace fossil raw
materials has dramatically
increased demand for
renewable carbon sources
BI OTE C H NO LO GY 27
For years, it was impossible to imagine how a chemical industry could get along without oil. But because of finite deposits,
political uncertainties, and technological advancement, the industry has given more and more thought to new approaches, and
for some applications, has already developed competitive or even
better alternatives to petrochemical products. Thanks to microorganisms and enzymes, biotechnological processes increasingly
enable the development of products such as biofuels, polymers
and solvents based on renewable raw materials.
“About ten percent of the world market for chemical products
is now produced with the help of biotechnologically produced
substances,” said Patrik Wohlhauser, the member of the Board
of Evonik Industries AG with responsibility for innovation man
agement, at the opening of BioTechDay, which was held March
9–10 in Marl. “Evonik now generates about eight percent of its
sales from white biotechnology, with high growth rates.”
Nearly 200 participants at the event learned about the potential of biotechnology for the chemical industry. There was also
a Product Marketplace, featuring classical biobased products,
such as amino acids and cosmetic active ingredients, as well as
new developments from Evonik, which are already established
in this market. The Group has special expertise in developing
strains, fermentation, and in processing bioproducts.
With its Biotechnology Science-to-Business Center (S2B Bio),
Creavis strategic research and development unit for basic
research activities, and its Biotechnology Area of Competence,
in which Evonik bundles its cross-business-unit biotechnological
know-how, the Group has positioned itself well in these areas.
“The dream of creating a product in a single cell is impossible in
classical chemistry. But thanks to biotechnology, it is becoming
a reality,” said Dr. Thomas Haas, head of the S2B Bio and organizer of the convention.
With biotechnology Evonik has expanded its technology portfolio to foster the growth fields of resource efficiency, nutrition
and health, as well as the globalization of technologies. “Our innovation projects are allowing us to move further and further
into the so-called emerging markets,” said Dr. Peter Nagler, head
of Innovation Management Chemicals & Creavis at Evonik.
Biotechnology requires patience
It took longer for biotechnology to get where it is now than
consultants predicted ten to 15 years ago, when a 25 or even 40
percent share of the world market in 2010 seemed possible. Technological hurdles, radically altered industrial value-added chains
that called for new partnerships, and market mechanisms for
raw materials meant that companies had to design highly tar
geted and flexible biotechnology strategies.
“Theoretically, hundreds of chemicals and plastics can be
manufactured from renewable raw materials, but up to now,
only a small number actually have,“ added Dr. Hanns Martin
Kaiser, consultant at McKinsey & Company. He described the
reasons for this, and the situation in industrial biotechnology in
his presentation. In the past, bio-related sales were generated
The Product Marketplace at the Evonik BioTechDay
provided material for discussion
mainly in biofuels, plant extracts and natural rubber. “Bio-based
chemicals may be relevant to a broad spectrum of market partic
ipants,“ says Kaiser. “But right now, virtually no manufacturer
can cover the value chain alone. This means that partnerships
are essential.“ Kaiser cited five forces driving continued growth
in this sector: cost competitiveness, flexible use of raw materials, consumer demand, technological innovations, and pressure
from public authorities.
Trend in raw material prices means
substantial planning uncertainty
The costs for biotechnologically manufactured products are increasingly competitive with those of classical petrochemistry.
“Until now, the prices of crude oil and raw sugar, for example,
haven’t had much to do with each other,” said Kaiser. But this
also means that it is hard to predict when a biotechnological
process will be cheaper than a petrochemical process, 333
28 BI OTE C H NO LOGY
According to estimates, the chemical industry generates about 7 percent of its sales revenues
in biotechnology. Major segments are biofuels, plant extracts, and natural rubber
Sales chemical industry 2008
Bio-dependent sales 2008
Share in biotechnology
sales in € billions
€ billions
1,745
(100 %)
1,619
(93 %)
Product class
Examples
Biofuels
Ethanol
Biodiesel
Plant extracts1
Hydrocolloids (gums, industrial starches, etc.)
Essential oils
Flavors and fragrances
Natural rubber
Rubber (isoprene, etc.)
Food/feed ingredients
Organic acids (citric acid, lactic acid, etc.)
Amino acids
Vitamins
Pharmaceutical ingredients
Enzymatic APIs
Biologics
5
Oleochemicals
Natural fatty acids
Fatty alcohol
Surfactants
4
Polyols
Sorbitol, mannitol, xylitol
Glycerol
3
Enzymes
Detergent enzymes
Grain processing enzymes
2
Bioplastics
PLA, PHA
Starch based plastics, etc.
1
Others
Other specialties
R&D services
40
37
18
9
GraPHIC: McKinsey & Company
7
126
(7 %)
1 In 2008 only selected regions of world markets available; updated based on 2010 split
Source: SRI, F.O. Licht, Frost & Sullivan, Press search
‘The Pull’ of the U.S. Renewable Fuels Standard
‘The pull’ has advanced worldwide technology innovation that continues to evolve and improve through
government funding and led to increase venture capital and public and private company funding
Renewable fuels1 (unclassified) – 1st generation
Advanced biofuels2 – 3rd & 4th generation
Biomass-based biodiesel3
Cellulosic biofuels4 – 2nd generation
Mrd. Liter
140
120
100
80
60
GraPHic: cargill
40
20
0
2006
1
2
3
4
2007
2008
2009
2010
2011
2012
Includes all types of biofuel
Biofuels other than corn-based ethanol with GHG savings >50%
Biodiesel with GHG savings >50%
Lignocellulosic biofuel with GHG savings >60%
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
Quelle: U.S. Renewable Fuels Standard
BI OTE C H NO LOGY 29
The technology demon
stration facility of Buta
max, a joint venture of
BP and DuPont, with a
specified nominal capac
ity of 37,000 liters
biobutanol per year
333 particularly since the situation could change several times
over the course of the years, depending on the trend in raw
mater ial prices. Moreover, biotechnologically produced chemicals are not necessarily superior when it comes to reducing CO2
emissions. It depends on the method of production.
On the other hand, the legislation enacted in recent years and
government subsidies have unquestionably favored advancement
of biotechnology. “Because of these measures, there is a good
chance that the scope of industrial production will double in the
next few years,“ said Kaiser. Nevertheless, this should not give
people false hope. Aside from the high investment required, the
long time-to-market, and society’s skepticism regarding sustain
ability, so far very few products based on biotechnology that
enable new functionalities have successfully been placed on the
market.
Martin Todd, managing director of LMC International, illustrated just how complex the decision for or against a certain raw
material for a biotechnological process can be. The British company is a consultant to companies in agribusiness all over the
world. “The demand for renewable carbon sources is increasing
rapidly, thanks to fast economic growth and the desire to replace
fossil sources.” As a result, raw material prices have climbed because arable land has had to be expanded to create „more expensive areas,“ the rising cost of crude oil has increased the production costs of farmers, and because of the widespread use of
biofuels, whose prices directly correlate with rising crude oil
prices.
“This is why the prices for renewable carbon sources will
follow those of fossil carbon sources,” said Todd. The dynamics
vary, however, for reasons that include energy content (when
compared to crude oil, vegetable oils have a 1 to 1 content, while
ethanol is 0.7 to 1 in the same comparison), the pricing politics
of the Brazilian government, which mean that fuel prices in that
country can differ greatly from world prices, and economically
attractive byproducts (such as glycerin) that occur in the production of biofuels. “Because of their high energy content,
vegetable oils are likely to be more expensive than carbohy
drates, especially because they are many times more land intensive and their potential crop areas are geographically limited,”
said Todd. “When it comes to carbohydrates, a resource like sugar cane is a less obvious topic for the ‚Food vs. Fuel‘ debate, but
it also requires arable land, obviously.”
Simplified production processes,
thanks to biocatalysts
Jack Staloch does not believe that there is a food shortage currently, but does believe that “food is lacking in the right places.”
Staloch is a vice president of the agricultural multinational Cargill, and worldwide head of the Biotechnology Development
Center. For the last four years, there has been a law in the United
States that stipulates a threefold increase in the use of biofuels
as a share of fuel consumption by 2022. Fifty billion liters were
produced in the United States last year—half of the world‘s production, and more biofuel than ever before.
Owing to its biotechnological expertise, Cargill is also active
in this segment, though it is far from its only field of activity.
“Biotechnology accounts for about four percent of our sales,”
said Staloch. The company has core competencies in fermen
tation, enzymes, separation and engineering. “Thanks to biotechnology, we can develop new products and processes, or
lower production costs,” said Staloch.
A good example is the production of lactic acid. To extract
lactic acid following bacterial production, lime and sulfuric acid
had to be added to the fermentation broth. But with Cargill’s
newly developed yeast bacteria, sugar can now be fermented to
lactic acid without the same amount of additional chemicals—and
at the same production rates and yields. To find the right bio
catalyst, Cargill researchers tested about 1,200 yeast strains.
They then modified the best candidates before ultimately transferring the fermentation to the production level. “We also rec
ognized, however, that this yeast strain makes a good fermentation platform for other applications,” said Staloch, “such as
organic acids for plastics and synthetic fibers.”
Ray W. Miller, Global Business Development Manager in the
Applied Bio Sciences Division at DuPont, stressed that chemical
companies operating in the field of biotechnology have to have
a lot of patience. A pioneer in industrial biotechnology, 333
30 BI OTE C H NO LO GY
Butamax‘ de novo pathway to produce biobutanol
with a modified yeast strain
Sugar
2 NAD+
OH
2
O
ALS
OH
O
Pyruvate
CO2
O
O
O
KARI
2 e–, 2 H+
OH
OH
O
DHAD
OH
ADH
2 e–, 2 H+
KivD
OH
H2O
O
HO
Acetolactate
O
α-Ketoisovalerate
CO2
H
O
Isobutanal
OH
Biobutanol
OH
2 NADH
2 NAD+
O
HO
2 NADH
X
Dihydroxyisovalerate
2 Ethanol + 2 CO2
Biomass
© ButamaxTM Advanced Biofuels LLC
333 Miller made no secret of the fact that it took some time before
the decision-makers of his own company were ready to commit
to biotechnology. “Today, even the American consumer is
demanding green products,” said Miller with a touch of selfderision.
Technology platforms expand
the fields of application
Citing the example of 1,3-propandiol, a glycol produced biotechnologically from glucose, he explained that sales remained low
from 2000 to 2006 but then rose dramatically in 2007. “Our annual growth rates now average 50 percent,“ said Miller. More
over, DuPont is building its Sorona® polymer platform on biopropandiol—a business that used to be the domain of petro
chemistry. These kinds of polymers enable highly dimensionally
stable clothing, durable car seat covers, as well as plastic resins
that protect against moisture and odors. DuPont supplies other
biotechnologically produced materials in such indust ries as
cosmetics, packaging, polymers and biofuels. Together with
the energy company BP, DuPont has established the joint venture Butamax, which is now developing a second-generation
biofuel.
Dr. Elke Hofmann, Commercial Director Europe at Butamax
Advanced Biofuels, stressed the importance of such biofuels,
which have a higher energy content than bioethanol. “One of
the biggest weaknesses of bioethanol is its 30 to 40 percent
lower energy content compared to conventional fuels,” said Hofmann. “The energy content of biobutanol, on the other hand, is
closer to the values of conventional fuels.” So Butamax embarked
on a quest for the right butanol molecule. After intensive
research, isobutanol was selected in 2004. “We tested hundreds
of different molecules,” said Hofmann. Butamax produces the
butanol with a modified yeast strain. Biobutanol shows advantages along the entire value-added chain including the ability to
be more easily blended than ethanol at the refinery.
In 2007, butanol successfully passed a fleet test that included
vehicles from model years as early as the 1990s. So in 2009, the
company began construction on a pilot plant in Hull (England),
with a specified nominal capacity of 37,000 liters per year. The
plant is currently in the start-up phase. “We plan to start
marketing the biobutanol in the United States in 2013 with plans
to expand to Europe,“ announced Hofmann. 777
Dr. Thomas Haas
heads Evonik´s Biotechnology
Science-to-Business Center
which is under the direction of
Creavis Technologies &
Innovation.
+49 2365 49-2004
thomas.haas@evonik.com
Dr. Jan Pfeffer
works as Project Manager
Research and Development
in the Biotechnology Scienceto-Business Center.
+49 2365 49-5457
jan.pfeffer@evonik.com
N e ws 31
Robust, flexible, and
fast drying: the
new clear coating
technology from Evonik
Two-component (2K) PUR coatings were formerly
regarded as the global benchmark for high-grade
coatings. They are particularly weather and chemical
resistant, and the hardness-to-elasticity ratio is right.
Another advantage is that they cure at room temper
ature. In certain applications, however, the abrasion
resistance of the coating films leaves much to be de
sired. The new polysilane system developed by Evonik
offers many of the advantages of 2K PUR coatings,
and it is at the same time especially tough.
With this development, Evonik has solved a problem that persisted for a long time. In the past, many
silane-based coatings lacked the desired flexibility,
due to their high crosslinking density and high SiO2
content. Evonik‘s new coatings show none of the
unwanted brittleness. This result was achieved by
developing a resin concept based on oligomeric silane
resins in combination with acrylate polyols with a
balanced ratio of organic and inorganic components.
An important feature is that, because of the high
reactivity of polysilanes toward water and polyols,
these coatings are processed as two-component
systems.
Evonik has also developed a novel catalyst concept
for its new coatings. Thanks to this development, the
polysilane coatings cure rapidly even at room temper
ature. The new coatings thus provide a genuine alternative to the current standard.
Credits
Publisher
Evonik Degussa GmbH
Innovation Management
Chemicals & Creavis
Rellinghauser Straße 1–11
45128 Essen
Germany
Scientific Advisory Board
Dr. Norbert Finke
Evonik Degussa GmbH
Innovation Management
Chemicals & Creavis
norbert.finke@evonik.com
Editor in Chief
Dr. Karin Aßmann
Evonik Services GmbH
Konzernredaktion
karin.assmann@evonik.com
Contribution Editors
Christa Friedl
Michael Vogel
Demanding façade
design with
PLEXIGLAS® Mineral
PLEXIGLAS® Mineral for extremely
weather-resistant structural shells
Individual façade design depends on the interplay of touch, shape and light.
PLEXIGLAS® Mineral provides new options for this purpose. This mineralfilled acrylic is homogeneously colored, can be thermoformed in two or three
dimensions and shows unique reflection behavior.
„PLEXIGLAS® Mineral makes it possible to achieve story-high, formed,
individually routed or printed façade elements,“ says Ralf Nettner, Product
Manager for PLEXIGLAS® Mineral at the Acrylic Polymers Business Line of
Evonik Industries. „Our material paves the way for creative ideas.“
But PLEXIGLAS® Mineral not only has a stylish look, it is also exceptionally
tough and defies all winds and weathers. The façade material offers high impact strength and UV stability. It can be fastened to all conventional supporting
structures. It combines a velvety reflective surface with high brilliance and
durable color stability. PLEXIGLAS® Mineral is available in many standard
colors as well as individual shades.
PLEXIGLAS® Mineral is extremely flame-retardant and emits very little
smoke. Its combustion gases are neither corrosive nor toxic. The material is
rated Class D, s2, d0 to EN 13501-1. PLEXIGLAS® Mineral NF is rated in Class
C, s1, d0.
Design
Michael Stahl, Munich (Germany)
Photos
Evonik Industries
Karsten Bootmann
Dieter Debo
Tim Wegner
Stefan Wildhirt
Sunovation (p. 21, 23, 24)
Butamax (p. 29)
Stuwil/Fotolia (title)
Pinnacle Pictures/Getty Images
(p. 4 top)
Stefan Richter/Fotolia (p. 8)
Nazira/Fotolia (p.11)
slobo/iStockphoto (p.12 bottom)
Mauritius Images/Phototake (p.19)
Printed by
Laupenmühlen Druck
GmbH & Co.KG
Bochum (Germany)
Reproduction only with permission
of the editorial office
Evonik Industries is a worldwide
manufacturer of PMMA products sold
under the PLEXIGLAS® trademark
on the European, Asian, African, and
Australian continents and under the
ACRYLITE® trademark in the America
Forget about gloss that fades.
Create your world of wow.
Visit us at www.plexiglas.net and www.plexiglas-polymers.com and
find out more about PLEXIGLAS® and its high-gloss surfaces that last.

hanse chemie

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