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elements32
S c i e n c e n e w S l e t t e r
e v o n i k M e e t S S c i e n c e 2 0 1 0
The Future of Energy
D e S i G n i n G w i t H P o l Y M e r S
Additive Manufacturing:
Digital Layer Construction
c o A t i n G & B o n D i n G t e c H n o l o G i e S
Percarbonate: the Eco-friendly
Bleach for Growth Markets
3 0 3 1 3 3 2 0 1 0

Patrik Wohlhauser
chairman of the Board
of Management of
evonik Degussa GmbH
e D i t o r i A l
Seizing opportunities
Our Functional Films & Surfaces Project House has successfully ended its work and turned all
projects over to the operative units. The team originally planned to work on eleven topics, but it
was soon clear that four of these could not be implemented reasonably. For some projects, more
research was re quired than time allowed, and for some others, the patent rights were problematic
or the investment costs would have been too high. This is why the project house researchers
concentrated on the seven remaining topics, and the results prove they were right to do so: some
developments are already in the commercialization phase, and others stand at the threshold.
The team also owes its success to correctly assessing and exploiting its opportunities—a principle
we have also followed in portfolio management: in chemicals, we intend to invest consistently in
growth areas. We plan to benefit particularly from the megatrends of resource efficiency, health and
nutrition, as well as globalization of technologies. In these industries, we are already a leader in a
number of key markets, and will continue to expand our good positions.
A prime example is our amino acids for animal nutrition. Adding amino acids to animal feed not
only ensures a well-balanced diet for animals but also conserves resources and protects the environment.
This is the finding of a life cycle assessment carried out by Evonik and now certified by Technischer
Überwachungsverein Rheinland, a globally recognized independent auditor. The certificate
proves that we have carefully and impartially evaluated the environmental impact, energy and raw
material consumption of our amino acids over their entire life cycle. And the results allow only one
conclusion: adding our amino acids to animal feed is a highly sustainable form of nourishing animals,
and thus supplying the growing world population with eggs, milk and meat—all with as little environmental
impact as possible. Our amino acids are also an answer to the megatrend of nutrition and
health, and at the same time, driver for positive business development, and an increase in the corporate
value of Evonik.
But portfolio management also means creating the right conditions for the operative units to
fully concentrate on their business activities. To this end, a key point of departure are the infrastructure
service so vital to our Group—their importance is clear from the figures: in Germany and
Antwerp, these services are currently provided by about 7,000 employees, who generate a total
of €1.6 billion in sales. On October 1, we will combine the site services into a single site service unit
that will stand at eye level with the chemical business units. This will allow us to harness the performance
potential of these services more effectively and continue evolving to meet market requirements.
Here, too, we are seizing the opportunity for productivity, sustainable growth, and longterm
job security.
elements32 | 2010 n e w S
contents
4 New manufacturing plant for catalysts
in Shanghai
4 Controlling stake in colloidal silica
maker purchased
5 Catalysis: Evonik expands its presence
in India
5 Heads of agreement on joint venture to
produce superabsorbents in Saudia Arabia
Making a statement with
lighting: the tulip.MGX
light from Materialise
has the kind of delicate
hollow structures that
can only be created by
additive manufacturing
(see also page 18ff)
e vo n i k M e e t S S c i e n c e 2 0 1 0
6 The future of energy
i n n o vAt i o n M A n AG e M e n t
12 Functional Films & Surfaces Project House:
Transferability as a measure of success
n e w S
16 HyaCare® Filler CL – the topical wrinkle smoother
16 PLEXIGLAS RESIST® AAA: new multi-skin
sheets with anti-algae technology
17 nano+art competition –
day and night in nanoworld
D e S i G n i n G w i t H P o lY M e r S
18 Digital layer construction: additive manufacturing
holds untapped potential, particularly for low-volume
production
U n i v e r S i t Y
24 Committed to young talent: twenty-seven Evonik
employees currently teach at German universities
coAt i n G & B i n D i n G t e c H n o lo G i e S
26 Hot Stamping: It‘s a safe bet you‘ll be noticed
28 Percarbonate: the eco-friendly bleach for growth markets
36 e v e n t S A n D c r e D i t S
elements32 evonik science newsletter

+++ Evonik Industries to expand its Asian special polymer capacities
evonik industries that is already one of the leading global providers
of methacrylate chemical products now plans to expand its production
capacities for PMMA molding compounds at its facilities south
of Shanghai (china), and in taichung (taiwan). Fur ther more,
evonik has expanded its methacrylic acid capacities in the Shanghai
MAtcH supercomplex, which began operating just nine months
ago. „we want to grow in particular in places where markets develop
at above­average rates. our polymer business in Asia is showing
remarkable growth rates. that’s why we decided to invest
quickly and consistently in the expansion of our plants,“ explained
Dr. klaus engel, chairman of evonik industries’ ex ec utive Board.
the taichung plant began running in 2007 as part of the joint
venture evonik Forhouse optical Polymers corporation. it produces
some 40,000 metric tons of PleXiGlAS® molding compounds
a year for light guide panels used in flat­screen monitors,
Produced in Shanghai,
PLEXIGLAS® molding
compounds are supplied
to the automotive industry
in Asia, among others.
PLEXIGLAS® CoolTouch®
specialty compounds,
for example, with their
heat-reflective effect,
are suitable for roof
applications
+++ New production plant for active pharmaceutical ingredients in China
evonik industries has started up a production plant for active
pharmaceutical ingredients in china. it will supply the chinese
market, among others, and has a capacity of 70 cubic meters that
can be doubled if required. the plant, in the city of nanning in
Guangxi province, has been set up in collaboration with a european
pharmaceutical company for which evonik will produce various
active ingredients under a multi­year supply contract and in
compliance with cGMP (current Good Manufacturing Practices),
the pharmaceutical industry‘s chief quality assurance guidelines.
the plant was erected in just 15 months. „that would not have
been possible without the excellent support of the administration
of the autonomous province of Guangxi, the city of nanning, and
wuming district,“ said Dr. Hans­Josef ritzert, head of evonik‘s
ex clusive Synthesis & Amino Acids Business line, at the official
opening ceremony, attended by customers from all over the world
elements32 evonik science newsletter
news
and demand for these flat­screen monitors has risen significantly,
particularly in Asia. the expanded taichung plant, with capacities
to produce another 20,000 metric tons a year, is scheduled to become
operational in the second quarter of 2011.
Since november 2008, in its first expansion stage, the Shanghai
PMMA plant had been producing some 18,000 metric tons a
year. the products are supplied as a comprehensive line of
PleXiGlAS® molding compounds to various industries in Asia, including
the automotive, lighting, and electronics industries. the
de mand for PleXiGlAS® molding compounds also has increased
considerably in these market segments, prompting the company
to accelerate the construction of a second expansion stage with
capacities of another 18,000 metric tons a year. the expanded
pro duction capacities will become operational in the second half
of 2011.
Beyond that, evonik has expanded its
production capacity of methacrylic acid at
the MAtcH supercomplex in Shang hai to
25,000 metric tons. Pro duc tion at the expanded
capacity has begun this May.
these steps are the continuation of a
series of Asian investments for evonik indu
stries: nine months ago, in november
2009, the Group finished building the
MAtcH supercomplex for producing polymers,
polymer precursors, and coating systems
in Shanghai and began operating the
€ 250 million plant. the plant is the Group’s
largest investment in china.
as well as chinese political figures. evonik has been active in nanning
since 2001, initially as a partner in a joint venture and since
2005 as the sole owner of this company. now operating as evonik
rexim (nanning) Pharmaceuticals co. ltd., the company produces
cGMP­compliant amino acids and amino acid derivatives by
biotechnological processes. with the new active­ingredient production
plant evonik now has another strong foothold in nanning.
„the new plant is an expression of our horizontal integration
strategy,“ said ritzert. the term „horizontal integration“ stands
for a network of western (europe, nAFtA) and Asian production
sites from which evonik offers customers tailored and exclusive
solutions along the entire value chain of active pharmaceutical
ingredients. „with this plant we will further consolidate our position
as a high performing partner for exclusive synthesis,“ added
ritzert.
3

+++ New manufacturing plant for catalysts in Shanghai
evonik industries officially commissioned in June, 2010, a new
manufacturing plant for precious metal powder catalysts in
Shang hai (china). the pharmaceuticals, fine­chemicals, and industrial­chemicals
sectors use the catalysts made there to manufacture
products such as vitamins, pharmaceutical agents, and intermediate
products for polyurethane used, among other things, in
car­seat foams and refrigerator insulation. Several customers, government
agency representatives, and evonik employees attended
the inauguration of the plant. evonik is the worldwide leader in
precious metal powder catalysts. in addition to the Shanghai plant,
the Group operates similar production sites in Hanau (Ger many);
tsukuba (Japan); Americana (Brazil); and calvert city (kentucky,
USA).
“the new facility now allows us to supply the chinese market
straight from a local source,” says Dr. wilfried eul, head of
evonik’s catalysts Business line. the Shanghai site is ideal, given
its proximity to the Jiangsu and Zhejiang Provinces, which are
home to a host of pharmaceuticals and fine­chemicals companies.
Proximity to chinese customers means that products and services
can be optimally geared to the needs of that industry. “this enables
us to participate even more intensely in the booming chinese
pharmaceuticals and fine­chemicals markets and to augment
our market position,” adds eul.
with this move, evonik has now maximized its china services,
which include everything from sampling to technical service,
cat alyst production, and precious metal management. “what this
means,” explains tim Busse, Director Asia, catalysts Business line,
+++ Controlling stake in colloidal silica maker purchased
evonik Degussa corporation has purchased a controlling interest
in Harris & Ford Silco, llc of Portland, oregon, from indianapolisbased
Harris & Ford, llc. the company has been renamed evonik
Silco Materials, llc and will become part of one of the world’s
leading specialty chemicals companies. „this is an important, strategic
addition to evonik’s inorganic Materials Business Unit and
further positions evonik as a key supplier of specialized chemicals
in high tech growth industries such as the semiconductor sector,“
said Jack l. clem, Senior vice President & General Manager of
evonik’s inorganic Materials Business Unit and head of the Busi­
Colloidal silica and ultra-high purity silica are a key
component of the chemical mechanical polishing (CMP)
process in the semiconductor manufacturing industry
Inauguration ceremony for the new
manufacturing plant for catalysts in Shanghai
“is that we’re able to act much faster in supplying the types of
catalysts our customers need to meet their specific demands.”
Precious­metal recycling is another of the key services provided in
addition to technical service support for customers who employ
catalysts. the recycling service, which evonik provides in close
co operation with Heraeus (www.heraeus.com) in Shanghai,
entails recovering precious metal from within china and thereby
establishing a closed domestic cycle for precious metals. that
cre ates a clear cost benefit for customers. “the market has appreci
ated evonik’s catalysts and their powerful uses, coupled with
the comprehensive service we offer,” says Busse. this attitude
was reflected by the many participants who attended the recently
held seminars for customers from the regional pharmaceuticals,
color ants, and vitamins industries and the fine­chemicals and
agrochem icals sectors.
ness Unit’s north American activities. „with this transaction, evonik
will be able to provide our customers with high­quality and customized
silica manufactured in an ultra clean environment.“
evonik Silco Materials manufactures colloidal silica and ultrahigh
purity silica, a key component of the chemical mechanical
polishing (cMP) process in the semiconductor manufacturing industry.
evonik Silco Materials’ proximity to the major semiconductor
manufacturers on the west coast and proprietary technology
combined with evonik’s world­class research and Develop ment,
complimentary product portfolio, and close relationships with
global corporations create a unique platform that strengthens the
inorganic Materials Business Unit and creates long­term growth
through turnkey solutions for the cMP market.
evonik Silco Materials is a leader in the development of colloidal
silica and is a leading source of standard and custom, highquality,
low metals and ultra pure silica sols. in addition, each sol
may be customized for particle size, stabilizing ion, pH, sodium
content, particle size distribution, and concentration. the com ­
p any will remain in Portland. „this acquisition is good news for
evonik’s customers and customers of the newly­named evonik
Silco Materials, llc,“ said clem. “colloidal silica is a growth market
and evonik is a growth­oriented company.”
4 elements32 evonik science newsletter

+++ Catalysis: Evonik expands its presence in India
evonik has acquired the precious metal powder catalysts business
of ravindra Heraeus Pvt. limited, Udaipur (rajasthan, india). As
stipulated in the agreement, all know­how, technology, and business
relationships with catalyst customers will pass from ravindra
Heraeus to evonik, while the production equipment will remain
with the indian company. Both partners have also concluded longterm
agreements concerning contract manufacturing and precious
metal recycling. Based on these agreements, ravindra Heraeus
will continue to produce precious metal catalysts for the indian
market and recycle used catalysts at its site in Udaipur on behalf
of evonik. the catalysts for evonik‘s existing indian customers are
currently imported from Germany. in the future, these products
will also be manufactured by ravindra Heraeus in india.
Precious metal powder catalysts are used in the pharmaceuticals,
fine chemicals and industrial chemicals industries for such
purposes as selective and cost­effective chemical synthesis of
pharmaceutical or agricultural active ingredients. the pharmaceuticals
and fine chemicals markets in india have posted above­average
growth for several years, owing in part to the outsourcing
strategies of pharmaceutical and agricultural companies, which no
elements32 evonik science newsletter
news
longer produce the active ingredients themselves. “with Heraeus
as a strong, capable partner, we can now supply our high­quality
precious metal powder catalysts to customers in india from local
production and offer them the complete package of services for
precious metal management,“ said Dr. wilfried eul, head of
evonik’s catalysts Business line.
For the customer, this means a short processing time and integration
into the local precious metal loop to avoid import duties
and lengthy importation processes. “this will allow us to step up
our participation in india’s above­average growth in pharmaceuticals
and fine chemicals, and expand our leading position in precious
metal powder catalysts,” says eul. currently, evonik produces
precious metal powder catalysts at its sites in Hanau
(Germany); tsukuba (Japan); Americana (Brazil); calvert city
(kentucky, USA); and lately also in Shanghai (china).
ravindra Heraeus, a precious metal company, is a joint venture
between the worldwide leading precious metal and technology
company Heraeus located in Hanau (Germany) and the family
enterprise ravindra choksi (india). each partner holds a 50 percent
stake in the joint venture.
+++ Heads of agreement on joint venture to produce superabsorbents in Saudia Arabia
Superabsorbents are a key base material for the manufacture
of hygienic products such as diapers. The photo shows
an applied-technology laboratory at Evonik’s Krefeld site
evonik industries, national industrialization company (tasnee)
and Sahara Petrochemicals are planning to set up a joint venture
to produce super absorbent polymers. their intention is to build a
state­of­the­art world­scale facility with capacity of 80,000 metric
tons p.a. at Jubail in Saudi­Arabia. Start­up would be in the first
quarter of 2013. Dr. klaus engel, chairman of the executive Board
of evonik, and Dr. Moayyed i. Al­Qurtas, ceo of tasnee, signed
a corresponding “Heads of
Agree ment” in riyadh. „this is
an important step for the evonik
Group in the growing Middle
east market and represents a
significant expansion of our leading
position in super absorbent
polymers“, commented en gel.
evonik is a world­leading producer
of super absorbent poly ­
mers, a key basic material for
the manufacture of diapers and
feminine hygiene products.
the proposed joint venture
for super absorbent polymers
will benefit from advantageous
access to raw materials: SAMco,
a joint venture of tasnee and
Sahara (Saudi Acrylic Acid
company, SAAc) and Dow
chemicals will supply the acrylic
acid required to produce super
absorbent polymers from a neighbouring plant. Propylene, a key
raw material for acrylic acid, will be sourced by SAMco from a
nearby plant operated by tasnee and Sahara (tasnee Sahara
olefins company, tSoc) and lyondell Basell. the planned production
facility will thus be embedded in integrated production
structures, making it the first downstream project of its type in the
Middle east region.
5

e v o n i k M e e t S S c i e n c e 2 0 1 0
the Future of energy
in June, more than 200 experts met in Marl at evonik‘s invitation and
discussed the potential paths to and implications of sustainable energy and
resource management—all in the spirit of the Year of Science 2010.
Against a backdrop of environmental and climate
problems, as well as dwindling resources, energy
is the number one concern of the “Year of Science
2010—the Future of Energy,” an initiative of the
Federal Ministry of Education and Research (BMBF). How
will we supply energy in the future? And what should society
do to use natural resources as efficiently as possible?
There are no simple answers to these questions, but ideas
and visions abound. At its now regular scientific forum
“Evonik Meets Science” on June 7 and 8, Evonik created a
plat form for experts to discuss these open questions, gather
ideas, and network. More than 200 participants accepted the
invitation to Marl.
“Evonik Meets Science” was held very much in the spirit
of the Year of Science, because resource efficiency concerns
not just the energy industry, but chemistry as well: chem ical
products and technologies are fundamental to improving
use of resources. But a number of innovations are needed.
“Science and research are the ambitious parents of advancement,”
said Dr. Klaus Engel, chairman of the executive
board of Evonik Industries AG in his opening speech to the
conference. Evonik committed itself to this interrelationship
long ago: „One-fifth of our chemical sales is based on products
that are less than five
years old,” said Engel.
Dr. Klaus Engel
Member of the Executive Board
of Evonik Industries AG
6 elements32 evonik science newsletter

In October 2008, Evonik established the Science-to-Business
(S2B) Center Eco² under management of the strategic research
unit Creavis Technologies & Innovation, where experts
develop interdisciplinary solutions for resource and
energy efficiency. In the search for sustainable use of resources,
they work not only with other units in the Group
but with some 40 external partners from research and industry.
So it is not surprising that this year‘s „Evonik Meets
Science“ took up the research topics of the S2B Center Eco²
in strong support of the BMBF‘s initiative—and held days of
action for school children to promote enthusiasm in the
younger generation for the natural sciences, technology and
especially energy, a key issue for the future.
Dr. Stefan Nordhoff, head of the S2B Center Eco²,
stressed that sustainability, resource efficiency and profitability
are by no means mutually exclusive: “A study by the
management consulting firm McKinsey from last year showed
that there are various technologies
that are making money
right now, and will make
even more in the future.“
The portfolio of the S2B Center
Eco² is clearly aligned to
these growth areas.
Dr. Stefan Nordhoff
head of the S2B Center Eco²
elements32 evonik science newsletter
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Open Innovation
e v o n i k M e e t S S c i e n c e 2 0 1 0
Seeing the bigger picture can be helpful, particularly in a
period marked by the kind of technological upheavals society
is currently experiencing in the energy sector. this is
why this year’s evonik Meets Science scientific forum was
de vot ed to the topics of energy and resource efficiency.
“evonik is positioning itself as an innovator in this area, and
intends to continue building on this position,“ said Dr. thomas
Haeberle, member of the Board of Management of evonik
Degussa GmbH. “chemicals and energy are strong partners
on this path, as the leSSY lithium­electricity storage system
shows,” added Joachim rumstadt, chairman of the Board of
Management of evonik Steag GmbH.
Dr. Peter nagler, head of innovation Management
chemicals & creavis at evonik, pointed to the company’s
strategic research activities, which are bundled into crossunit
areas of competence, project houses, and science­tobusiness
(S2B) centers. “in the S2B centers, we develop
innovations associated with higher research risks,“ said
nagler.
the S2B center eco² under direction of creavis is one
of the facilities for seeing this bigger picture. it combines
five lines of development—co 2 separation and use, energy
production, energy­effi cient customer solutions, energy
storage, and energy effi ciency in evonik processes—and one
overarching theme, the life cycle Assessment (see elements
31). At evonik Meets Science, external partners from
universities reported on the state of the technology, as they
saw it, for each of these lines of development. the conference
closed with an interactive marketplace in the S2B
center eco², where the employees of the center presented
their research projects with the help of numerous exhibits,
graphic presentations, and interactive animations, and held
discussions on their specific areas of study. their projects
and project ideas, such as carbon dioxide utilization from
waste gas streams, the development of lightweight components
for automotive manufacture, as well as the intelligent
utilization of hard coal flue ash, convincingly demonstrated
the “energy” they put into their work.
Dr. Thomas Haeberle
member of the Board
of Management of
Evonik Degussa GmbH
Joachim Rumstadt
Chairman of the Board
of Management of
Evonik Steag GmbH
Dr. Peter Nagler
head of Innovation
Management Chemicals
& Creavis at Evonik
7

What is resource efficiency?
But as Prof. Matthias Finkbeiner of the Institute for Technical
Environmental Protection of the Technical University of
Ber lin pointed out, resource efficiency is by no means a
clearly defined concept: it can be understood as either the
greatest added value that can be generated with the least
amount of raw materials, or in the wider sense of the EU
Commission. In 2005, the Commission defined the term „resource“
in such a way that it includes not only raw materials,
but biotic resources, renewable energies, land areas, as
well as air, water and soil. They all factor into the resource
efficiency denominator, with value added as the numerator.
Then, a life cycle assessment (LCA) records a system’s input
and output, which ranges from raw material generation,
through production, maintenance and consumption, to recycling
and disposal. An LCA can also be used operationally to
monitor a product as it is being developed. “The method
also lends itself to risk screening,” said Finkbeiner.
“Internationally, the life cycle assessment is the most recognized
method for evaluating environmental impact, because
it is the only method that can cover a broad range of applications
consistently and uniformly across nations.“
But taking an example from the automotive industry,
Finkbeiner also stressed that an LCA should never be interpreted
in the absence of values: based only on the indicators,
the LCA of a small car can look better or worse than
that of a luxury limousine. In addition to the way resource
efficiency is defined, and whatever else is included as a resource
in the evaluation, the result of a calculation depends
on the indicators selected for the value added and environmental
pollution.
Finkbeiner is convinced that, despite these limitations,
the concept of resource efficiency promotes sustainable development.
He compared the situation to that of Maslow’s
famous Hierarchy of Needs from the field of psychology, in
which the basic needs of an individual must be met first before
he can climb to the next level, such as cultural creativity.
As Finkbeiner pointed out, an environmental and sustainability
assessment is structured quite similarly: “A company
should think seriously about its carbon footprint, for ex -
am ple, until it is developed into an LCA.“ At the top of this
hierarchy, then, is the life cycle sustainability assessment,
which also considers value-oriented social aspects.
Prof. Matthias Finkbeiner
of the Institute for Technical
Environmental Protection at the
TU Berlin
CCS as a sound interim solution
Using carbon dioxide capture and storage (CCS) as an example,
Prof. Klaus Görner, holder of the Chair for En vi ronmental
and Plant Engineering at the University of Duisburg-
Essen, explained that technological issues are not always a
matter of long-term goals but also temporary solutions.
Today’s fossil-fuel power plants reach efficiency levels
of between 43 (brown coal), 46 (hard coal ), and 60 percent
(gas). Hard-coal-fired steam power plants, which reach
such levels of efficiency, operate at 600 °C. While the efficiency
level can be improved by over 50 percent by rais ing
the temperature to the level envisioned for the next generation
of power plants (700 °C), this will not, in his opinion,
meet the climate goals of the EU. The only way Europe can
cut CO2 emissions to 20 percent below its 1990 levels is
through higher energy efficiency in power plants, use of
renewable energies, and additional optimization measures.
To reduce emissions by the ambitious target of 30 percent,
one possibility is the above-mentioned CCS technology.
CCS technology can catch 90 percent of the carbon dioxide
from a power plant. “CCS is suitable for new plants
and some old plants,” said Görner. “Transport and storage
are technically feasible but not widely accepted by the public.”
In the power plant, three different technologies can
separate the CO2 either before the gasified coal is actually
burned (pre-combustion), while it is being burned (oxycombustion),
or after it is burned, as the last step in flue
gas cleaning (post-combustion). At the current state of the
technology, however, all of these methods reduce the efficiency
level of the power plant by 9 to 13 percent, because
energy is required for separation. Here, it is the job of science,
in cooperation with producers and operators, to help
reach a net efficiency of significantly over 40 percent by
raising the base efficiency
level to over 50 percent and
reducing inefficiencies to
below 8 percentage points.
This is the only way to preserve
coal as a resource and,
at the same time, protect the
environment.
Prof. Klaus Görner
holder of the Chair for Environ -
mental and Plant Engineering at the
University of Duisburg-Essen
8 elements32 evonik science newsletter

Fiber-reinforced composites reduce the weight of cars
In addition to energy management, mobility is another key
factor in the future prevention of CO2 emissions. One approach
is to reduce the weight of vehicles. Weight-optimized
structural components for cars can be produced from the
kind of fiber-reinforced composites currently used in the
aerospace industry. “Production of such components is
large ly manual right now, but automobile manufacture will
require automated processes,” said Prof. Thomas Gries, holder
of the Chair for Textile Machinery at the Institute for
Textile Technology at RWTH Aachen. Gries coordinates
the interdisciplinary cooperation of Aachen scientists researching
fiber-reinforced composites. Their work centers
on products, production machines and processes, as well as
design, simulation and measuring processes for semi-finish ed
textile products and composite components.
An important step in this work is robotic production of
near-net-shape textile preforms. In these three-dimensional
textile structures, the reinforcing fibers are oriented to the
inner flow of forces, which ensures maximum mechanical
rigidity and strength at the lowest possible weight. “We
have developed the production technology for this, so we
are now concentrating on the engineering and design tools,“
said Gries. While initial applications have already found their
way into vehicles, textile composites are still a very new
technology, suitable only for piece counts of fewer than
100,000 per year.
In addition to vehicle construction, Gries also sees potential
for fiber-reinforced composites in energy technology.
The diameter of the rotorblades of wind power plants,
for example, will continue to increase, which will accelerate
lightweight construction. Textile structures will be particularly
attractive for load optimization of components. Fuel
cells could also benefit from
fiber-reinforced composites
used to reinforce polymer
mem branes.
Prof. Thomas Gries
holder of the Chair for Textile
Machinery at the Institute for Textile
Technology at RWTH Aachen
elements32 evonik science newsletter
>>>
e v o n i k M e e t S S c i e n c e 2 0 1 0
Multiaxial fabrics with integrated stringers (top)
Three-dimensional textile preform for car underbodies (middle)
Design for an automated robotic preform production process (below)
Cutting
Inline quality
management
Handling
Preform center
Binder application
Sewing
9

Supplying energy safely requires
powerful energy buffers
But it makes no difference how lightweight a vehicle can be
made through structural measures or how much CO 2 can be
eliminated: in the end, the most important consideration
when it comes to tomorrow‘s mobile and stationary energy
supply is still energy storage. The reason for this is that
renew able energies generate extremely uneven loads on supply
networks, which are currently compensated by regulatable
power plants and, to a lesser extent, pumped-storage
power plants, which have limited potential.
Accumulators and supercondensers are the only highly
effective means for storing electrical power. Prof. Martin
Winter of the Institute for Physical Chemistry at the Uni versity
of Münster believes that lithium-ion technology will
play a key role in this technology. As he sees it, there are
four reasons for this: high cell voltage, high energy and power
densities, low self-discharge rates, and the ability to exploit
the battery‘s entire capacity without damaging it. “The
lithium-ion battery is an evolutionary technology, because
so many different materials can be used to produce it. It’s
ideal for quickly buffering power spikes in a matter of
hours,” said Winter. Suitable for small- to medium-sized decentralized
energy buffers, lithium-ion technology will probably
also play a role in future vehicle-to-grid designs, for
which the batteries of electric vehicles would serve as temporary
buffers for power spikes. This would take advantage of
the fact that many vehicles are not moved for most of the day.
But there are also clear ideas for stationary applications:
the LESSY (lithium electricity storage system) prototype,
made up of about 5,000 individual lithium ceramic cells, will
be developed this year at Evonik‘s coal-fired power plant in
Völklingen, Saarland. With an input and output of 1 MW and
a storage capacity of about 700 kWh, LESSY is slated to provide
primary regulation. Evonik’s partners on the project include
its own subsidiary Li-Tec Battery GmbH, a joint venture
with Daimler AG, and the University of Münster, under
the direction of Winter, among others. The Federal Ministry
for Education and Research is funding the project under its
LIB 2015 research initiative.
Prof. Martin Winter
of the Institute for
Physical Chemistry at the
University of Münster
Hydrogen as a future primary energy store?
Compared to lithium-ion technology, the sustainable production
of hydrogen is still in its infancy. The volatile gas
would be an attractive source of primary energy because it
contains more energy per weight units than any other chemical
fuel. “Currently, however, 96 percent of hydrogen is
generated from fossil energy sources. Renewable energies
would be preferable so that hydrogen could play a larger
role in sustainable energy concepts,” said Dr. Henrik Junge,
group leader at the Leibniz-Institut für Katalyse e.V.
(LIKAT). To this end, LIKAT is researching photocatalytic
hydrogen production from water and—as buffer—the release
of hydrogen from formic acid.
For the first topic, LIKAT is testing an iridium-based
photosensitizer embedded in an iron complex, and is using
it to reach a turnover number (as a measurement for the
effectiveness of the catalyst) of 3,000. A fuel cell equipped
with this photosensitizer supplied 18 mW of constant power
for 30 minutes in a test setup. The second LIKAT project,
the release of hydrogen from formic acid, is based on a CO2 neutral cycle, and uses a ruthenium catalyst to release the
hydrogen. On the pilot scale, at room temperature, the process
ran for over eleven days and achieved a 99 percent
yield: 0.9 liters of hydrogen per hour. There is still a long
way to go, however, before
the LIKAT projects can be
used on the commercial scale.
Junge compared the current
state of the technology to the
status of nuclear fusion research.
Dr. Henrik Junge
group leader at the Leibniz-Institut
für Katalyse e.V. (LIKAT)
10 elements32 evonik science newsletter

The energy of the future has many sources
According to Prof. Ferdi Schüth, director of the Max Planck
Institute of Coal Research in Mülheim, methanol, hydrocarbons,
methane, and ethanol are a few of the possible alternatives
to hydrogen-based chemical buffers, at least on the
strength of their achievable energy densities. But all substances
also have drawbacks or limitations.
In his presentation, Schüth stressed that the storage densities
of lithium-ion batteries for vehicles lagged behind the
values forecast six years ago, and appear to have reached a
plateau. “Naturally, we should continue to devote time and
energy to exploring this technology, with industry setting
the pace,“ said Schüth, „but it is also time for us to start thinking
about what will come after lithium-ion technology.“
Schüth feels we are facing a paradigm shift when it comes
to energy supply. Put simply, our current energy supply is
based on largely isolated use of various primary energy
sources: electricity comes from coal and nuclear power
plants, while heat and mobility is covered by oil and natural
gas. Schüth expects electricity and mobility—through the
energy buffer connection—to merge to form a single field of
application in the future. When this happens, we will be
dealing with a mixture potentially consisting of nuclear
power, coal, solar thermal energy, photovoltaics, water and
wind power, geothermal energy, natural gas and biogas, as
well as oil. Future demand for heat, on the other hand, will
be met primarily by solar thermal energy, with a small portion
being covered by oil, natural gas and biogas. So our
energy supply would rest on many pillars, not just a few.
And the decision about which technology is best suited
to which country and application is ultimately a social one.
The fact that Brazil’s energy industry, for example, is based
on sugarcane ethanol reduces
CO2 emissions significantly,
but the use of fertilizers
increases water pollution
caused by phosphates. l
Prof. Ferdi Schüth
director of the Max Planck Institute
of Coal Research in Mülheim
(Germany)
elements32 evonik science newsletter
E v o n i k M E E t s s c i E n c E 2 0 1 0
Our current energy system
Nuclear energy
Electricity Heat Mobility
A possible future energy system
Nuclear energy
Brown coal
Coal
Hard coal
Electricity Traction- Mobility
battery
Storage
Solar thermal
energy
Storage
Photovoltaics
Water
Geothermal etc.
Storage
Wind
Methane
storage
Natural gas
and biogas
Natural gas
Oil
Oil
Heat
Heat storage
Solar thermal
energy
11

F U n c t i o n A l F i l M S & S U r F A c e S P r o J e c t H o U S e
transferability as a Measure of
the Functional Films & Surfaces Project House, evonik’s seventh project house, has successfully
concluded its work under the direction of the strategic research unit creavis technologies &
innovation. Four key factors were vital to its success: consistent project management, the right
combination of internal and external expertise, openness—even to uncomfortable truths—and
the right team of motivated people.
In the beginning, there were 100 project ideas at various
stages of development and thought, the fruit of countless
discussions within Evonik‘s Chemicals Business Area.
Dr. Jochen Ackermann, head of the newly-established
Func tional Films & Surfaces Project House, introduced the
idea of the project house to the Group—the heads of the
business units and business lines, and to the heads of R&D—
over a six-month period. The project house was officially
launched on January 1, 2007, which meant it would con clude
on De cem ber 31, 2009—the usual three-year run for a project
house as an element of the strategic research and development
unit Creavis Technologies & Innovation in the Evonik
Group. “This approach allows us to open up new markets,
material and system competencies, product innovations, and
technol ogies that the business units would have difficulty
working into their day-to-day activities,” says Dr. Harald
Schmidt, head of Creavis.
In late 2006, it was time to evaluate the 100 project ideas:
What did the market look like? What competencies could
be built within the Group in the relatively short three-year
time period? Which employees in the business units were
available? To what extent were there patent problems or
technological hurdles? And who were the potential development
partners outside the Group? In the meeting of the
steering committee, which comprises representatives of top
management—executives, managing directors of Evonik
Degussa GmbH, as well as the heads of the business units,
business lines, and Creavis—the decision was made to tackle
eleven specific projects.
The steering committee also defined the concept, costs,
resources and objectives. “Each project was to furnish a system-level
demonstrator—not just a laboratory prototype but
a production sample, if possible, that had been used and
test ed in the final application,” says Ackermann. “Also, each
12 elements32 evonik science newsletter

Success
project needed a business plan that outlined what the business
units had to do to make a sustainable business out of the
project, how high the required investment costs would be,
how the subsequent business model might look, and what
could be expected in terms of financial planning.”
If you fail, fail early
elements32 evonik science newsletter
Dr. Jochen Ackermann
(pictured 6th from left)
and his 15 member
project house team
The newly established project house pursued a clear project
management plan that divided the three years into the following
phases: exploration (first year), definition (second
year) and validation (third year). “After the first year, we set
the specific development objective for all projects, along
with a detailed milestone plan for the remaining two years,
which would leave no more room for major deviations,“
says Ackermann. Earlier, in consultation with the business
units and steering committee, four projects had been cut
i n n o v A t i o n M A n A G e M e n t
from the project portfolio because they could not be realistically
implemented. There were several reasons for the decision:
Some projects were too research-intensive for the
time available, the patent situation was problematic, there
was no realistic business model for Evonik, the investment
costs would have been too high, or the idea was simply too
late for the market. “If you fail, fail early”, says Ackermann.
This is the only way to avoid wasting time with projects with
an uncertain future—something neither the project house
nor the Group needed.
The seven continued projects (see box on page 15) can
be divided into two categories: projects focused on establishing
a prod uct or system competence, and projects focused
on develop ing a technology platform. In the first year of the
project house, most of the work involved evaluating the
projects and forming a powerful team. Fifteen employees,
on aver age, worked at the project house. Then, laboratory
tests were run in the second year and the first half of the
third, while the second half of the third year was devoted to
transferring the developments to the Group.
Employees of the Functional Films & Surfaces Project
House drew important conclusions from an audit and life
cycle analysis of past project houses: “If you lack some important
expertise for specific applications in your own
house, you should consult someone from the user‘s industry,“
says Ackermann. “Indeed, these were one of the steps
that began opening our eyes to the direction we have to
take.“ A technology consultant with a good overview and
the right contacts is also helpful, since some experiments
and test runs take more time and equipment than is available
to carry out in-house. The outstanding reputation of the
project houses among the customers and partners made this
process easier.
The „operative project teams” proved to be another key
element in the success of the project house. “In addition to
the project manager from the project house, these teams
were made up of colleagues from the business units,” says
Ackermann. These were product managers, sales >>>
13

Developed in the project house
amongst others:
Coated rubber granu late as infill
for artificial turf (above)
PLEXIGLAS® film with Fresnel
lenses on the surface. These kinds
of microstructured films have
been used for such applications
as solar concentrators in photo -
voltaics (below)
Flexible printed circuit boards
based on polymer films (right)
experts, controllers, developers, application engineers—
colleagues who were or would be involved with the project
in one form or another. “We always prepared very stringently
for this meeting, and this also meant concrete tasks
for the participants.” Thanks to these almost monthly meetings,
the business unit was always up to date on the latest
informa tion.
“Mentors” guarantee successful transfer
In Ackermann‘s estimation, the critical phase of a project
house is the transfer of project results to the Group. “We
discussed transferring results as early as the middle of the
third year.“ The two central questions were where they
should transfer the results and when. The proven approach
had been that management would allow the project house to
conduct its research until the end of the three-year period
and only then initiate the actual transfer. This phase had
now ended in the middle of the year. Ackermann himself did
not become head of Business Development for the Acrylic
Polymers Business Line until May 2010.
14 elements32 evonik science newsletter

The Projects
Barrier films for flexible thin-film photovoltaic modules:
re placement of the rigid glass covering in thin­film solar modules
by a barrier film based on PleXiGlAS® that offers permanent
protection against the effects of weather, shows a transparency
to sunlight comparable to the glass, and acts as a barrier
against water vapor and oxygen. Status: transferred to the
business unit; available by the roll from production tests; samples
sent to customers.
Luminescent solar concentrators:
A concentrator based on PleXiGlAS® sheets to increase the
yield of conventional solar cells. it does this by shifting some of
the sun’s rays that would not activate the semiconductor material
of the cells because of its defined bandwidth into a wavelength
range where the solar cells can absorb it. Status: Demon
strator available.
Flexible printed circuit boards based on polymer films:
De vel opment of a cost­efficient copper­polymer laminate
based on high­temperature plastics that can be used to produce
flex ible circuit boards. Status: transferred to the business unit;
pilot plant for sample production.
Coated rubber granulate as infill for artificial turf:
Development of a rubber granulate based on shredded scrap
tires, to be used as infill for artificial turf. A newly developed
two­component coating enables the production of granulate
“For each transfer, the business line would appoint a
mentor to look after the project, and then the product,” explains
Ackermann. “And in 2011, for the first time, these
mentors will also give a report on the progress in the business
unit to the steering committee,” adds Schmidt.
According to Ackermann, four factors determined the
success of the project house:
• Consistent project and portfolio management
• The decision whether to fundamentally build competencies
internally and/or externally
• Under the keyword “open innovation,” contact with
coop er ation partners that ranged from formal R&D cooperation
agreements to the use of test and production
facilities
• And formation of an effective and, above all, highly motivated
team.
Ackermann selected his employees to create a diverse group:
experienced researchers, but also university gradu ates; the
young and not-so-young, men and women, physicists, engineers,
chemists and material scientists.
elements32 evonik science newsletter
i n n o v A t i o n M A n A G e M e n t
with considerable advantages over today‘s conventional offerings.
Status: expan sion of the business by creavis technologies
& innovation; scale­up to production scale at customer.
Surface functionalization of PLEXIGLAS®:
Development of a technology platform for inline functionalization
of PleXiGlAS® semi­finished products, which allows
high­gloss or matt­finished surfaces with high abrasion resistance—integrated
into the production process. Status:
transferred to the business unit; pilot plant for sample production.
Abrasion-proof matt-finished PLEXIGLAS®:
Development of a tech nology platform for the production of
matt­finished coatings for PleXiGlAS® semi­finished products
that show a haptic effect and are extremely abrasion­resistant—
integrated into the production process. Status: transferred to
the business unit; scale­up to production scale.
Prismatic PLEXIGLAS® elements for light management:
Development of a technology platform for microstructuring
PMMA surfaces, which can be used to produce PleXiGlAS®
light covers with highly precise prismatic struc tures for uniform
ambient lighting without glare. Status: transferred to the business
unit; presentation of the product at the light+Building
trade fair in April 2010.
While the focus of the first year was on forming a real
team, the second year was devoted to the questions of where
a member stood in the project and also personally, and how
the team functioned. “My project managers often presented
their results to the steering committee and the business
units personally. After all, it was their work. And they had
to support it themselves.” That increased their motivation to
make the project a success, but also their pride in the joint
achievement. After all: “You’re nothing without your team,”
says Ackermann. l
15

+++ HyaCare® Filler CL – the topical wrinkle smoother
within the last couple of years a wellknown active ingredient has
seen its revival in various segments of the personal care market.
Hyaluronic acid still serves the needs of today’s consumers and cosmetic
formulators. Beside this, it is used quite often as dermal filler.
Following those trends, evonik´s care Specialties Business
line provides a range of active ingredients based on hyaluronic
acid.
cross­linked hyaluronic acid is well known for its use as dermal
filler. Dermatologists inject it directly into the skin to physically
fill up wrinkles from within.
Many consumers do not like
such an invasive and expensive
approach. therefore, they are
look ing for cosmetics alternatives
based on formulations which
mimic the immediate wrinkle
reducing properties of dermal
fillers. As a log ic consequence
evonik has enlarged its hyaluronic
acid technology plat form
for personal care products and
launched Hyacare® Filler cl.
Due to its 3­dimensional network
structure, Hyacare® Filler
cl contributes instantly to the
reduction of facial wrinkles and
fine lines, as well as increases
the elasticity of the skin. Be­
cause of its high water­binding and strong short­term moisturization
properties, Hyacare® Filler cl supports effectively the
hydra tion of the skin. it can be used for all anti­aging applications
where an instant effect as well as moisturization is desired.
Hyacare® Filler cl is a unique crosslinked version of Hyacare®.
Hyacare®, a fermentation­derived high­quality biopolysaccharide
of high purity, is obtained by a solvent­free process. it is skiniden
tical hyaluronic acid with a medium molecular weight of 700
kDa. Due to its intrinsic film­forming properties it restores the
elasticity of the skin and reduces
the appearance of wrinkles. Besides
this effect it reinforces the
skin‘s natural short and longterm
moisturization.
Another product based on
the hyaluronic acid technology
is Hyacare® 50 that was
evonik´s first product in this
area. it represents hyaluronic
acid with a very low molecular
weight version of 50 kDa. Due
to its strong skin­permeation
properties, Hyacare® 50 has a
pronounced bio­activity and can
rejuvenate the skin by effectively
strengthen dermal­epidermal
tight junctions (filling
wrinkles from the inside).
+++ PLEXIGLAS RESIST® AAA: new multi-skin sheets with anti-algae technology
A spic­and­span, transparent roof adorns the terrace, carport, or
sunroom of many a home. Such roofs look all the more unsightly,
however, if—like many surfaces exposed to the elements—they
become overgrown by a greenish­brown film. Many people
simply refer to it as „algae“. they then have to fetch a ladder and
invest a lot of energy cleaning the roof. And that is no mean feat;
after all, it is often difficult just to access such a roof.
evonik has a far more convenient solution: a new multi­skin
sheet called PleXiGlAS reSiSt® AAA. this highquality,
next­generation multi­skin sheet is the
world’s first plastic multi­skin sheet featuring a nanotech­based
anti­algae design. this special coat ing
takes advantage of the sun’s Uv radiation to essentially
prevent algae, moss, pollen, and the like from
adhering to the sheets. the next rainfall washes
away virtually all of the remaining decomposed
matter. And it goes without saying that this new
high­performance innovation is entirely non­toxic
and bioneutral.
in addition, the new multi­skin sheets also meet
sophisticated expectations regarding design and co­
lor in construction: PleXiGlAS reSiSt® AAA is available not
only in a clear version, but also white or in an elegant gray, too.
And then there are the product benefits that PleXiGlAS reSiSt®
has long been known for: excellent Uv resistance and weather
resistance, for example. in fact, evonik issues a 30­year warranty
against yellowing for its transparent PleXiGlAS® products. At
the end of the day, this range of properties grants homeowners a
lot of spare time underneath a clean and durable roof.
Relax instead of clean—thanks to new
PLEXIGLAS RESIST® AAA multi-skin sheets
16 elements32 evonik science newsletter

+++ nano+art competition – day and night in nanoworld
elements32 evonik science newsletter
news
this year’s nano+art competition revolved around the theme of “Day” or “night,” and attracted eye­catching artwork from next­
generation women scientists who drew their inspiration from their own research. now in its fifth year, nano4women—an initiative
sponsored by the German federal government—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.
Angler in the Moonlight by Anna reckmann of cologne, A Light Shining in the Darkness by Maryam Hadji Abouzar from
Aachen, and Nano-grass Field by Aruna ivaturi of the University of cambridge were awarded the first three places, along with a
total of € 1,750 in prize money from evonik industries.
Besides evonik industries AG, partners throughout Germany in the joint project include the Helmholtz Association, the Hessennanotech
Action line of the Hessian Ministry of economics, the Fraunhofer institute for Mechanics of Materials in Halle/Saale,
Martin luther University of Halle­wittenberg, and science2public ­ Society for Science communications. the venue for this year‘s
nano+art competition was the tecHnoSeUM in Mannheim, which is still showing a special exhibition called nano! nutzen und
visionen einer neuen technologie (“nano! Uses and visions for a new technology”). the exhibition will run until october 3, 2010.
third place, and a check for € 250, went to Aruna ivaturi of the nanoscience
centre at the University of cambridge, for her Nano-grass Field. taken
with a scanning electron microscope, the image is a cross­section of a nanograss
field made of zinc oxide nano­rods (60 nm average diameter and 1 μm
average length), produced by a hydrothermal process based on a layer of
zinc shoots.
An intriguing picture that attracted the most attention
on account of its composition, as the jury remarked.
Angler in the Moonlight made Anna reckmann from
cologne the winner of this year’s nano+art competition.
She is delighted with the check for over € 1,000
that she received from evonik. the award­winning
entry is a scanning electron microscope image of an
organic field­effect transistor that was deposited on a
polymer fiber. reckmann works and researches at
the University of cologne’s institute for Physical
chemistry in the field of surface coatings/nanoparticle
synthesis.
Maryam Hadji Abouzar, who studies the manufacture
of nanostructures at the FH Aachen, was awarded
second place, along with a check for over € 500.
A Light Shining in the Darkness is a fluorescence
microscopic image of DnA strands, 6 nm in size, that
are marked with cy3 (fluorescent dye) and applied
to a silanized Sio 2 surface. the composition of the
DnA­based buffer solution prevents homogeneous
immobilization.
17

A D D i t i v e M A n U F A c t U r i n G
Figure 1.
The principle of additive
manufacturing on the
example of laser sintering,
in which a laser is
used to build parts layer
by layer based on a
computer model
Digital Layer Construction
SyLVIA MONSHEIMER
Additive manufacturing holds untapped potential, particularly for low-volume
production. extrusion and injection molding are not always the best way to
mold plastics. An alternative is mold­free production, which combines maximum
flexibility with high customer orientation and cost efficiency. with laser sintering,
for example, it can produce complex and technically demanding industrial
and consumer goods.
M
ost pathbreaking technologies are
based on one simple and persuasive
idea. The same is true of methods for
mold-free production of parts—experts
also refer to this as rapid manufacturing,
rapid prototyping, additive manufacturing, and
additive fabrication.
These buzzwords are based on one principle:
liquids, powders, strands and films are layered to
build three-dimensional structures without the
use of a mold. In the laser sintering process, which
requires powdered starting material, containers
are filled with fine metal, ceramic or plastic powder.
A laser located above the powder bed, and
precision-guided by CAD software and suit able
optics, lights only certain areas of the uppermost
particle layer. These areas melt and solidify after
cooling. An automatic mechanism then low ers the
Laser
Roller Fabrication
Powder delivery system
powder bed
Scanner system
Laser scanning
direction
Sintered powder
particles
Object being fabricated
Powder delivery piston Fabrication piston
floor of the powder container by fractions of millimeters,
and spreads a fresh layer of parti cles.
Again, the laser lights this layer only in certain
places (Fig. 1). The result of this method is a spatial
component built of ultra-thin layers, whose
complexity is limited by almost nothing but the
specified electronic construction data.
This free-form fabrication uses no casting
molds, tools or space consuming production plants.
Additive manufacturing (AM), therefore, is the
counterpart to conventional methods, in which
parts are molded into specified forms, for example,
or cut from a massive block. With AM, components
are created directly from a digital construction
plan. This enables the production of forms that
have been long considered impossible by con ventional
series production—in fact, they can be created
fast, flexibly, and with fewer machines. >>>
Laser beam
Laser sintering
Pre-placed powder bed
Unsintered material in previous layers
Source: Materialgeeza/Wikipedia
18 elements32 evonik science newsletter

elements32 evonik science newsletter
D e S i G n i n G w i t H P o l Y M e r S
The FinGripper of Festo AG & Co. KG,
Esslingen, which specializes in automation
engineering. Produced by selective laser
sintering, the FinGripper is light, flexible and
adaptable. Like the human hand, it adjusts
itself to the shape of the object to be gripped,
KG
which allows fast and safe handling of ripe
Co.
fruit, bulbs and pressure-sensitive foods.
&
The FinGripper is produced by applying layers
AG
of polyamide powder 0.1 millimeters thick
on top of each other and selectively melting
Festo
them by laser. The result, after cooling, is a
solid component Photo:
19

Unmistakable:
designer Dan yeffet
used selective laser
sintering to repro duce
his fingerprints in
the Detail.MGX light
by Materialise N.V.
Head quartered in
Leuven, Belgium, the
company specializes
in rapid-proto typing
technologies.
Evonik‘s laser sintering
plant in Marl
The intake manifold for
the Evonik-sponsored
Lotus racing car (s. p. 6)
was produced by laser
sintering from polyamide
12 powder. The geo m-
etry of the intake manifold—a
three-dimen -
sional curved, ellip tical
tube—cannot be pro-
duced by conven tional
metal processing
methods or by injection
molding
This is why additive manufacturing is particularly
common in prototype construction. Prototypes
are essential for stressing and testing components,
checking their fit and functionality,
and—if necessary—optimizing these properties in
a new prototype. When it comes to the processes
used to create prototypes, gathered under the
term “rapid prototyping,” the name says it all:
first and foremost, prototypes must be built fast,
with costs playing a secondary role.
Cost-effective batch production
But additive manufacturing can do more. The opportunity
to analyze and optimize the product in
the virtual stage prior to production, select from a
wide range of materials, and design according to
function means that parts can be not only designed
and developed based on the individual
needs of the customer but produced at lower cost.
Because of the strong expansion in model diversity
in the industry, the demand for adaptive tools
and equipment has grown enormously. The use of
handling robots is a good example: AM-generated
20 elements32 evonik science newsletter
Photo: .MGX by Materialis

grippers can easily adapt to objects of a wide variety
of shapes, and make the gripping process efficient
and flexible.
Between prototype construction and mass production
lies the increasingly important field of
low-volume production. Many product requests
are for relatively high but limited piece counts.
For these products, conventional mass production
with its costly molds and large plants is simply too
expensive.
The special strengths of additive manufacturing
technology, therefore, are even more readily
apparent when it comes to smaller piece counts
(Fig. 2). A few examples of products manufactured
in small batches include headlight housing
for high-priced cars, steering components for vehicles
driven from the right side, and housing for
specialty machines. Not least, lightweight construction
for airplanes and cars is a key sector for
additive manufacturing. Lightweight construction
is an undisputed construction principle in the
trans portation industry, for example, where it is
used to reduce fuel consumption and emissions.
In addition to low-volume production, another
field of application is individually modified components.
Examples include not only medical devices
such as hearing aids, implants or surgical instruments,
and drill guides for operations, but
also helmets and shoes for professional sports and
respirator masks. Until AM technology, the high
costs of creating a mold to produce a single component
made such individual parts as these impossible.
Variants are handled exclusively through
software solutions—from the capture and processing
of the individual data, to a single set of construction
data for each part.
The industry has now developed a whole host
of variations of mold-free production: instead of
solid particles, there are processes that run in
liquid beds. Others work with strands that are
stacked to form a part. The individual layer can be
formed by spraying or pressing binding material
or adhesives. All of these methods have one thing
in common: they can execute even the most complex
forms in a single operation. And they are
flex ible. Without high equipment costs, the part
can be modified and optimized by changing the
spatial construction data until it meets customer
and technical requirements precisely.
New functionalities through
custom-tailored plastics
Thermoplastics are ideal for additive manufacturing:
they are easy to pulverize, can be selectively
melted, and their chemical and physical proper-
elements32 evonik science newsletter
D e S i G n i n G w i t H P o l Y M e r S
Figure 2. Additive manufacturing technologies are significantly more economical
for low-volume production than injection molding, which is cost-effective only
for mass production, owing to the high cost of the mold. The minimum piece count
required before injection molding begins offering cost advantages depends, among
other things, on the size and complexity of the part to be produced and the mold
Cost per unit
Injection molding
Figure 3. Comparison of the material properties of a standard polyamide and an ultraflexible
polyamide specially developed for additive manufacturing
mance Polymers Business Line, experts have spent
roughly ten years developing thermoplastics for
additive manufacturing.
Converting from low-volume production to
additive manufacturing increases the demands on
the materials: aircraft construction requires polymers
that can withstand extremely high temperatures,
and are flame resistant. The sports and shoe
industries need soft materials to manufacture
components with high flexibility. For example,
Evonik developed an ultra-flexible polyamide
(PA) that has eight times the flexibility and five
times the tensile strength of the standard material
(Fig. 3). Another development, namely PEEK
powder for laser sintering, stands out for its high
melting point of 340 °C, which makes it suitable
for parts exposed to high temperatures during
operation. Optimized polymers like this enable
new functionalities, while at the same time creating
ways of replacing other materials, such as
met als, with plastics.
ties can be customized. In Evonik’s High Per for- >>>
Additive manufacturing
Number of units
Standard grade New flexible material
E modulus 1,700 MPa 100–250 MPa
(246,500 psi) (14,500–36,200 psi)
Elongation at break 15 % >100 %
Tensile strength 45 MPa 8 MPa
(6,250 psi) (1,160 psi)
Notched impact strength 3.5 KJ/m² No break
Melting point 186 °C 150 °C
(366 °F) (302 °F)
Common refreshing rate 50 % Not necessary
21

Produced in one piece by
selective laser sintering:
the Faltstuhl One_Shot
.MGX of Materialise N.V.
The chair is on display,
among other places, at
the Museum of Modern
Art in New york
Laser sintering enables layers
only millimeters thick
When it comes to polymers, additive manufacturing
competes with extrusion and injection molding.
One process that is particularly well suited to
plastics is selective laser sintering (SLS), which
can produce layers 0.15 mm thick. Far thinner layers
(down to 0.08 mm) are also possible, although
at this level the powder becomes hard to handle
because interior forces of attraction prevent the
tiny particles from trickling. While chemical flow
aids can prevent adhesion, there is the risk that
the thermal conductivity of the sintered layer will
change at the edges, to the detriment of the process
capability. “Laser sintering” is an historical
term and somewhat misleading: it refers to a
pressure-free process in which only a short processing
time is required for each layer—just
enough time for the areas that form the part to
melt and form a closed melted film.
With polymers, a CO 2 laser is used to directly
stimulate the polymer chain without the need for
an absorber. The speed of the laser is normally
between 5 and 10 m/sec. Under these conditions,
a component will “grow” two to three centimeters
per hour. But a variety of components can be
produced in the same layer almost without losing
speed—the production area can be packed full of
parts. Compared to other additive manufacturing
technologies, powder-based laser sintering has the
advantage that the powder bed around the component
assumes the function of an all-round support—special
supporting structures that hold projecting
forms in position are unnecessary.
Because not only the material itself but the
production process influences the technical properties
of a part, the parameters of AM products
differ from those of injection-molded products.
Comparative measurements show that the density
and elongation of a part produced in layers are
lower, and that the elastic modulus and tensile
strength show higher values (Fig. 4).
New demands through low-volume
production
In addition to new material properties, the use of
laser sintering in low-volume production places
even more demands on the laser sintering process.
Reproducibility and reliability take on a
whole new meaning: the entire quality assurance
system must be ensured—something that played
essentially no role in the creation of prototypes.
Since last year, the Direct Manufacturing
Research Center (DMRC) at the University of Pa derborn
has worked on the challenge of making
22 elements32 evonik science newsletter
Photo: .MGX by Materialise

this transition from prototype production to serial
(low-volume) production. The DMRC is the result
of the merging of eight companies and research
institutes, and receives financial support
from the government of North Rhine-Westphalia.
The four founding companies—Evonik, Boeing,
EOS and MTT Technologies—will invest a total of
€ 2 million in the DMRC over the five-year contract
period. Since the opening of the DMRC in
May 2009, the participating experts have focused
mainly on practical questions, such as man aging
the temperature of the machines being used or
the long-term properties of sintered parts.
While a good, substantive idea for a new technology
can come into being quite suddenly, it may
still have difficulty reaching the heads of key players.
This is true in the case of additive manufacturing.
Many universities teach the conditions for
“freedom of design” and “function-driven design“
inadequately, if at all. While engineers receive intensive
training in conventional processes, they
usually learn very little about freedom of design,
which opens the door for them to additive manufacturing.
Indeed, additive manufacturing is based
on the idea of fundamentally different design,
since the designer must think in terms of complete
functionalities and not decoupled component
parts.
Standards as pathbreakers
Lack of training at the universities is not the only
hurdle. In the past, development, modification
and use of mold-free production processes was
quite unsystematic. This is why there are currently
no standards to promote widespread use of the
process and regulate evaluation of existing products.
As a result, part testing yields different values
for elasticity module, tensile strength and elongation,
for example, depending on the set of param
eters used (Fig. 5). Both the ISO and ASTM,
however, are working on developing the first
standards for laser sintering. ISO 27547-1 is already
in force for the production of test bodies. VDI is
also drafting guidelines.
Despite the hurdles and unanswered questions
that still exist, the importance of AM will grow
appreciably over the next ten years. The advantages
outweigh these problems: developers can
produce functional hollow structures in small
batches, and the structures can be precisely modified
to changing stress requirements. The components
can be customized with specific porosities
or surfaces, and ultra-lightweight components are
also possible. Here, the airline industry is one of
the pioneers. There are already about 30 SLSsintered
components installed in the Boeing 787.
elements32 evonik science newsletter
D e S i G n i n G w i t H P o l Y M e r S
Figure 4. Comparison of the technical properties of a part produced by
laser sintering and one produced by injection molding
Test method Laser sintered Injection molded
test bar test bar
Density g/cm³ DIN 53479 0.95 1.04
E modulus MPa DIN 53457 1,700 1,400
Tensile strength MPa DIN 53455 48 46
Elongation % DIN 53455 18 >50
Figure 5. Depending on the parameter set, tests on the same part can yield differing
values and make evaluation more difficult. Standards should improve this situation
Test method Parameter Parameter Parameter
set 1 set 2 set 1,
upright built
Density g/cm³ 0.91 0.9 0.91
Modulus of elasticity MPa DIN 53457 1,872 1,920 1,921
Tensile strength MPa DIN 53455 49 48 49
Elongation % DIN 53455 18,2 8,4 7
According to estimates by Airbus Industries, an
aircraft produced entirely through additive manufacturing
would be 30 percent lighter and 60 percent
more cost-effective than current machines.
Resources and energy efficiency—combined
with economical production—are the central challenges
of the future for Germany, if it intends to
remain competitive in a fast-changing world. In
the past, it was often the work of people that think
outside the box and therefore helped breathe life
into a new technology. They also play a role in additive
manufacturing. One thing is certain: sooner
or later, additive manufacturing technologies will
become key players in placing advanced industrial
production on a cost- and resource-efficient footing.
l
SyLVIA MONSHEIMER
Born in 1965
Sylvia Monsheimer is responsible for
global market development of additive
manufacturing for evonik’s High
Performance Polymers Business line.
Previously, she managed the business
line’s Strategic innovation Projects department.
Monsheim came to evonik
in 1989 after receiving her degree in
construction engineering. Since then,
she has held a wide variety of positions
in application engineering for high performance polymers. Her
more than ten­year focus on powder development and application
engineering for selective laser sintering and other tool­free processes
is a hallmark of her work at High Performance Polymers.
+49 2365 49-5911, sylvia.monsheimer@evonik.com
23

twenty­seven evonik employees currently teach at German universities
committed to young Talent
Engineers and chemists have only heard of the jam­packed
lecture halls that plague so many business management,
law, or German studies students in Germany. But even if
they have little trouble finding a laboratory internship or a
topic for their final paper, so many realize in hindsight that they
did not always have such a great advantage after all—as when
they take their first steps in industrial research and find out that
not every thing they do in the laboratory can be transferred to the
industrial scale. indeed, compared to subjects requiring master’s
and doctoral theses, industrial engineering moves within a complex
interplay of innovation, profitability, sustainability, administrative
regulations, and standards.
“Graduates are experts in the subject area of their final paper,
but they lack the ability to spot economically attractive processes,“
observed Prof. karlheinz Drauz. Drauz is familiar with both sides:
of the 30 years he has worked for evonik, he has spent the last
22 years also teaching industrial chemistry at the University of
würzburg, and as an honorary professor for 18 of those years. He
is one of 27 evonik employ ees who lecture at German universities
in addition to work ing for evonik. Dr. Manfred nagel, who works
in evonik’s Process technology & engineering unit, also holds a
teaching position. the 44­year­old engineer has taught process
technology at kit—the karlsruhe institute of technology—
for three years, and still remembers his own days as a student:
„i didn‘t have a sense of the practical relevance of my major back
then either,“ he says. “Students today are unbelievably open to
new ideas, flexible and determined, but they have a very fuzzy
picture of what an engineer actually does every day.”
Bring that picture into sharp focus is what evonik want to do.
while Drauz, for example, teaches organic chemistry, he covers not
only technical synthesis of active substances, biotechnology and
vitamin production, but also chemical substance law, chemical marketing,
and disposal. He has also hired business administration professors
to give the students some insight into the business tools of
an industrial chemist. “it takes money to do this, naturally, and
evonik has generously shouldered the costs,” he says. “excursions
to various evonik production sites round out the course.“
Process engineering at evonik, the traditional point of entry
into the Group for engineers, also emphasizes a practical orientation.
together with his colleague Prof. Herbert riemenschneider,
nagel holds a series of lectures every year that ends with a daylong
excursion for students to evonik‘s site in Hanau. the program
includes tours of pilot plants, production plants, project
hous es, and virtual chemical plants. Students also have the opportunity
to talk to experienced engineers, and finally, discuss career
possibilities with company representatives. “that goes down extremely
well, because the students want to know what makes a
company tick,“ says nagel. “An on­site visit lets them see not only
how multi­faceted engineering is as a career, but also that, in addition
to technical expertise, social skills, and teamwork skills are
also important.”
Such commitment also conveys trust: over the years, Drauz
assisted a great many students who needed advice—on postgraduate
studies, study abroad, job applications, stipends, or opportunities
for women in the industry. this is time­consuming, but the
dual burden from teaching at the university and working in the
com pany was never a problem. “the company supported me in
every way,” stresses Drauz. And it got a few things in return for
that support. “over the years, you get to know which students are
really good,“ says Drauz, who assisted a number of students over
several semesters. “And, naturally, these are the ones you recruit
for the com pany.” So several outstanding university graduates
have found their way from würzburg to the company and made
careers there.
the subject means a lot to nagel as well. “evonik is one of the
top employers for chemical and process engineers,” he explains.
“we sustain this reputation by actively cultivating our network
and establishing contacts with young talent.” the kit is an ideal
institution for this. with some 8,000 employees, it is the largest
research institute in Germany, and one of the largest worldwide.
„it houses not only excellent researchers but excellent facilities.
this is why it attracts so many gifted researchers from inside and
outside Germany,“ says nagel. “And like any other company, we
are look ing for the best.”
Part of networking is making contact with university colleagues,
and Drauz has been able to persuade a great many of
the appeal of industrial chemistry: “Professors come to hear my
lec tures too, because as an industrial chemist, i have the kind of
experience they understandably lack. Some of them have even
included the contents of my lectures in their examinations.” the
atmosphere of the university, and contact with young chemists
trying to find their way is something he does not want to miss. So
even though he will retire as of August 31, he plans to continue
teaching for the next few years. “i think it‘s important to know
how today‘s young people think, and to interact with them,“ says
Drauz, father of two grown sons, who are also students. „And i
want to convey the fasci nation that natural sciences hold, even for
industrial researchers,“ he adds. “it’s enriching—professionally,
but also personally,“ says nagel. l
Dr. Wolfgang Nagel
teaches process engineering
at KIT (Karlsruhe
Institute of Technology)
24 elements32 evonik science newsletter

University
FH Aachen
University of
Bochum
FH Darmstadt
tU Darmstadt
tU Dortmund
tU Dresden
University of
erlangennuremberg
FH Frankfurt
University of
Hanover
University of
Hohenheim
kit*
karlsruhe
University of
kassel
University of
Magdeburg
University of
Munster
FH Munster/
Steinfurt
University of
Siegen
University of
Stuttgart
University of
würzburg
1
2 theoretical chemistry
3 technical chemistry/process science
4 industrial property protection for engineers
5
6
7 industrial chemistry
8
9
10
11
12 Material and nanochemistry
13 industrial inorganic chemistry
14
15 Process engineering
16 Process engineering
17 Power engineering
18
19 Macromolecular chemistry
20 Patent information
21 chemical law, reAcH
22 Process technology/industrial crystallization
23 chemical/environmental engineering,
plant engineering
24 industrial inorganic chemistry
25
26
* karlsruhe institute of technology
Subject or teaching position
27 industrial organic chemistry
elements32 evonik science newsletter
Applied polymer sciences/
industrial aspects of polymer technology
civil engineering/
building services engineering
Plastics technology as part of the
Master’s program in polymer sciences
Plastics processing and special problems in
plastics technology
Plastics technology/
plastics and the environment
Process technology/mechanical and
pipeline engineering
Process technology/process and plant design
institute of Plant Production and Agroecology
in the tropics and Subtropics; pesticides
Process technology/micro process
engineering
industrial organic chemistry and industrial
biotechnology
Process engineering
Prof. Karlheinz Drauz retires
U n i v e r S i t i e S
Prof. karlheinz Drauz, 60, will
retire as of August 31, 2010.
Drauz has held various positions in
evonik‘s chemicals Business Area
for the last thirty years, the most
recent being vice president of
international Scientific relations in
the in novation Management
chemicals & creavis unit. in this role, he evaluated the international
university landscape for topics of interest to
evonik, reinforced existing ties to technology centers, research
institutes, and universities, and made contact with
potential new partners. eastern europe and Asia have been
a primary focus.
During this time, he built a database that not only maps
evonik‘s partnerships but also contains information on attractive
potential partners. the database stores more than 5,000
university and company contacts, covering a broad spectrum
of topics—from material sciences, through sustainable raw
materials, to energy generation and storage. “i saw my task
as paving the way for partnerships for the operative divisions,“
says Drauz. “the database, which is accessible to all
evonik units, has now proven itself a key tool in the search
for partners.“ Drauz also established a scientific advisory
board for evonik in china, whose members include three of
china’s most renowned scientists: Prof. Pingkai ouyand
(president of nanjing University of technology), Prof.
charles c. Han (director of the Joint lab of Polymer Science
and Materials) and Prof. Sishen Xie (head of the national
center for nanosciences and nanotechnology).
Drauz, who earned his doctorate in chemistry at the
tech nical University of Stuttgart, began his career at evonik
in 1980 as laboratory director for r&D in amino acids at
Hanau­wolfgang. in 1994 he accepted a position as head of
global r&D at Fine chemicals, where he was also responsible
for active pharmaceutical ingredients and building blocks
pro duction at the wolfgang site. He became head of the
tech nology and research Management department in Fine
chemicals in early 2002 before accepting the position of
chief technology officer in the former exclusive Synthesis &
catalysts Business Unit end of 2003. His scientific activities
focused on the synthesis of amino acids, peptides and biologically
active compounds, asymmetrical synthesis, metal
catalysis, and biocatalysis, and process development. He has
shared in 160 patents and patent applications, and has published
articles in 95 scientific publications. Drauz has also
been an honorary professor of organic chemistry at the University
of würzburg since 1992.
25

H o t S t A M P i n G
it‘s a Safe Bet you‘ll be Noticed
with its binder DeGAlAn®, evonik industries has made it more difficult to counterfeit the euro,
protects soccer fans from tricksters, and adds a quality touch to packaging. Because in an age
when one product can readily replace another, appearance means a great deal more than it ever
did before. if packaging or labels didn’t have their allure, today’s cosmetics, alcoholic beverages,
and sweets would hardly stand out in the crowd.
Creating additional appeal for products and packaging
is quite the trend—for brand-name and noname
products alike. In economically challenging
times, it’s particularly important to offer products
that are clearly distinguishable from the rest. Consumer
attention is a scarce and precious good. It’s vital, therefore,
for bottles, flacons, and other forms of packaging to feature
sophisticated designs that attract people’s attention. Evonik’s
expertise helps make products stand out in the crowd.
DEGALAN® is a methacrylate-based raw material used in
coatings. Marketed by the Coatings & Additives Business
Unit, DEGALAN® binder is added to coatings and inks to
achieve the desired effects on printed labels and packaging.
So how does a strikingly designed label actually end up
on a bottle of wine? How is lacy lettering printed on a box
of chocolates, or a gold cosmetic logo to an eyeliner stick?
The answer is by a process called hot stamping, which is a
special printing process. It involves first applying a negative
image to a polyester foil by means of multiple layers of a
coating, one on top of the other. For that image to be applied
to the product, the foil containing the layers is rotated by 180
degrees and then pressed onto the box, stick, or bottle with
a great deal of pressure and heat.
The combination of heat, pressure, and
the final adhesive layer on top of the
others detaches the coating system
from the foil and attaches it
to the intended surface.
The coat ing system
includes the design
layer,
often an additional layer of metal and a protective coating.
The adhesive ensures that the package sticks to the product
surface. A release layer embedded between the foil and the
coating helps to ensure that the polyester carrier foil and the
print layers can be peeled apart cleanly.
The great advantage of this method is that the various
layers can be printed on top of one another in a single-step
process. The special color effects, metallic effects, and hologram
imprints created in this way could not be produced
by applying multiple layers directly to a product surface.
“Unlike offset or digital printing,” explains Andreas Olschews
ki, global technical sales manager at Evonik’s Coatings
& Additives Business Unit, “this process allows for a
much broader spectrum of technologies, particularly for
products featuring high-end designs, exceptionally frag-
mented images, or designs with a metallic sheen.”
The results are impressive: The images produced are extremely
sharp and they are finely and clearly contoured.
DEGALAN® makes that possible. Because it is used as a cobin
der in the individual layers of the coating, it creates a
sharply contoured image and the color of that image is endowed
with added brilliance. Depending on the binders
used, however, it can do even more. This raw material improves
the film hardness of the protective coatings, making
them more resistant to high stamping temperatures. It can
also enhance the degree of adhesiveness of the image to the
target surface.
“This product,” says Olschewski, “has carved out an incredibly
successful market niche for itself. A lot of manufacturers
like using DEGALAN® binders because they always
produce excellent results.” Evonik’s customers include globally
operating businesses that provide hot-stamping technology.
The application spectrum is immense. Hot stamping
To protect banknotes against counterfeiting,
euro bills feature holograms that are difficult to
reproduce. These holograms are made using
the hot-stamping method, and Evonik supplies
DEGALAN® for use in that process
elements32 evonik science newsletter

Hot stamping involves a process in which a negative image consisting of
multiple layers of lacquer (one on top of the other) is applied to a foil.
The coated foil is then turned around and pressed onto the desired product
with a great deal of pressure and heat. Thanks to the adhesive layer,
the lacquer package detaches from the foil and adheres to the intended
surface
Carrier foil (is peeled off)
foils are used in the graphics industry, of course, but also in
the wood-processing and furniture-making industries.
DEGALAN® can help to create an incredibly realistic rootwood
design, for example, such as is used on the center consoles
in automobiles.
Ensuring that originals stay originals
This printing method serves not only to produce particularly
handsome and detailed designs; it also gives products effective
protection against counterfeiting. An example is the
hologram on the euro bills that represents one of the security
features. Tilt the note to a certain angle and what you see
on the film strip is the nominal value of the note, plus the
euro symbol, against a rainbow-colored background. This
hologram allows to check the authenticity of the notes. It,
too, is produced using the hot-stamping method.
Hence, DEGALAN® is found in paper currencies, bank
and credit cards, ID cards, and other documents. These
shiny images also feature on admission tickets for concerts
or sporting events. Just about everyone carries them around.
Because they are highly counterfeit-proof and to this day
non-reproducible, holograms are increasingly used to provide
protection against brand and product piracy. The trafficking
of fake and imitation products has now taken on an
elements32 evonik science newsletter
Release layer
Top lacquer layer
Design layer
Adhesive layer
Lacquer package
c o A t i n G & B o n D i n G t e c H n o l o G i e S
Admission tickets for, say, a soccer match are particularly susceptible
to reproduction and counterfeiting. Holograms on the tickets in the form
of hot-stamped security foil make them forgery-proof
economic dimension that should not be underestimated.
This fact is reflected in significant losses in profit and puts a
serious strain on the economy.
Fakes are often times not discernible at first glance if the
packaging they come in has been really well reproduced.
Hot-steaming foils are used to print optical authenticity and
security features such as holograms on products. These holograms
have highly specific features; they are extremely
complex and difficult to copy. And so DEGALAN® is offering
a hand in protecting brands and products in that it makes it
possible for customers to distinguish between genuine and
fake goods. l
ANDREAS OLSCHEWSKI
Andreas olschewski spent several
years as a global technical service
manager in evonik’s coatings &
Additives Business Unit, working as
a technical adviser for Acrylic resins.
After an apprenticeship as a coating
technician, he received his engineering
degree from the University of
Applied Science for Print and Media
technology in Stuttgart, specializing
in paints and coatings. He began
his professional career in the Applied technology, Acrylic resins
department at evonik röhm GmbH in 1980.
+49 6151 18-4784, andreas.olschewski@evonik.com
27

P e r c A r B o n A t e
the Eco-friendly Bleach for Growth
DR. STEFAN LEININGER
The profession of soap boiler, a person
who made soaps out of animal fat and
ashes to use for cleaning purposes, developed
in Central and Southern Europe
around the beginning of the 4th century. Back
then, doing the laundry was hard work: dirt had
to be removed by rubbing or beating the articles.
For stubborn stains, the laundress used „grass
bleach,“ which involved spreading the damp
laundry out on the grass. The chemical interaction
between the moisture, sunlight and the
chlorophyll in the plants forms active oxygen
and ozone, which have an oxidizing and bleaching
effect.
The discovery of sodium perborate tetrahydrate
(NaBO 3*4H 2O) in 1898 and the subsequent
development work by Otto Liebknecht at the former
Degussa marks the beginning of the development
of modern detergents. The company
brought the first unblended powdered sodium
perborate onto the market as a laundry detergent
in 1904. Even considering the predictability of the
product’s commercial success, detergent manu-
28 elements32 evonik science newsletter

Markets
elements32 evonik science newsletter
Grass bleach: when
damp laundry is spread
out on grass, the
moisture, sunlight and
chlorophyll create active
oxygen and ozone,
which have an oxidizing
and bleaching effect
c o A t i n G & B o n D i n G t e c H n o l o G i e S
energy crises and resource depletion, consumer
habits and environmental protection
drive researchers and developers to ever
greater achievements and improved products,
and the detergents market is no different.
the trendsetter is a granulated
percarbonate from evonik with especially
high stability. Because of its eco­toxicolo gical
superiority, percarbonate has already
largely replaced expensive perborate as
the bleaching component in detergents on
the european market. it has thus secured
the market leadership of detergent manufacturers
in europe and is also paving the
way for a secure and successful entry into
the growth markets.
facturer Henkel rocketed to prominence quite
suddenly. Henkel launched the first “self-acting”
laundry detergent under the trade name Persil®
on June 6, 1907, thereby rendering grass bleach
obsolete. In addition to 15 percent perborate by
weight as its main ingredient, Persil® also contained
85 percent silicate-based bleaching soda by
Henkel. Laundry boiled just once in Persil® became
clean and hygienic without the need for
rubbing or a separate bleaching step.
Whereas, in the early years, sodium perbo rate
tetrahydrate was produced by reacting electrochemically
generated sodium peroxide with boric
acid, a direct electrolysis process based on aqueous
borate solution developed at the Rheinfelden
works supplied the rising demand beginning in
1920. With the increased availability of hydrogen
peroxide—produced in Weißenstein (Austria) from
1910, and electrochemically via peroxodisulphuric
acid at Rheinfelden beginning in 1928—production
gradually shifted to the process of reacting sodium
metaborate with hydrogen peroxide, which is
used to this day. >>>
29

Bleaches with perborate and percarbonate
Comparison between normal and activated bleaches
Remission [%] = Bleaching action
30
25
20
15
10
5
0
HO
HO
O O
B B
O O
Tea, coffee, ...
Activation
OH
OH
2 –
2 Na +
Activation systems for laundry detergents
or Na 2CO 3 • 1.5 H 2O 2
H 2O
H 2O 2 + OH – HOO – + H 2O
0 20 40 60 80
Bleaching activation
Persalt
Percarbonate
or perborate
R
X
O
Temperature [°C]
Oxidized stain
Example: TAED activation
Persalt
OOH –
H 2O / OH –
TAED
Peracetic acid
H 2O 2 + OH – HOO – + H 2O
Activators
• TAED, NOBS
• Ester, amide
• Nitril(quat)
H
O
Washing solution
Catalysts
• Enzyme/mediator
• Metal complex
• O carrier
In-situ peracid (X=O, NH) Bleaches
Activated species
O
M
Modern all-purpose laundry detergent—
clean, pure and fragrant
All-purpose laundry detergent is always “a child
of its time.” Laundry habits, consumer behavior,
re gulations and environmental protection have
always influenced the development of new and advanced
ingredients and formulations. But the principles
of wash performance have never chang ed:
mechanical forces, thermal energy and chemical
reactions do a really good job against dirt and
body oils on laundry. And for over 100 years, the
role of bleach in that success has remained unchanged.
Perfumes, the final ingredients in the
mix, reinforce the impression of cleanness.
“Self-acting” laundry detergents were a hit
from the start, and as purchasing power increased
and drum-type washing machines became available
during the years of the German Economic
Miracle, almost all classes of Germans could now
afford them. But with the steady rise in laundry
detergent sales came a gradual increase in environmental
pollution. The use of phosphate-based
softening systems in laundry detergents caused
eutrophication, an unwanted increase in the chemical
nutrients of bodies of water that generates
excessive plant growth. In the 1980s, this phenomenon
led to increased environmental awareness
and, ultimately, a ban on phosphate-based laundry
detergents in Europe. Today’s laundry detergents
contain either zeolites, polyacrylates or softener
systems based on sustainable raw materials (for
example, citrates, aspartates) to prevent formation
of lime soaps.
The interaction between mechanical energy
(the rotation of the machine’s drum), the temperature
in the washing solution, and the chemical
action of the surfactants control the actual process
for removing dirt and body oils. Surfactants also
hold the dirt and fat particles suspended in the
wash water. The less water today’s water-saving
washing machines use, the more dispersants the
laundry detergent has to provide to prevent the
dirt particles in the concentrated solutions from
settling back on the fibers and turning the laundry
grey.
In their fight against a variety of different
stains, surfactants receive help from enzymes and
bleaches. Enzymes are proteins that convert only
certain organic substances by catalytic action, and
can split into smaller components. Proteases, for
example, are used to fight protein stains, lipases
take on grease, and carbohydrases battle starchy
soiling.
Because an increasing number of foods are
pro duced with non-digestible polysaccharides
(for example, low-calorie products), more expen-
30 elements32 evonik science newsletter

sive advanced all-purpose laundry detergents also
contain enzymes such as mannanases to remove
these stubborn „lifestyle“ stains. Cellulases, on the
other hand, make cotton clothing look clean and
new by removing protruding fibers (microfibriles),
and thereby preventing the graying caused by dirt
deposits on these small fibers.
Bleaches like perborate and percarbonate, on
the other hand, are active against other stains
caused by such foods as tea, coffee, fruits or vegetables.
When dissolved in water, these peroxybased
substances release hydrogen peroxide,
which develops its bleaching power at high temperatures
directly through its perhydroxyl anion,
or at low temperatures by forming singlet oxygen
in the presence of activators. The cleaning action
of these bleaches involves not only oxidation of
the chromophoric conjugated double bonds in
dye molecules (chromophores) but the splitting
of the molecules into smaller components. In most
cases, stains altered in this way are then easier
for surfactants to dissolve and remove from the
fibers.
In addition to its stain-removing properties,
the active components generated from the persalts
in the washing process also display biocidic
properties that kill bacteria, pathogenic germs
and fungal spores. Laundry is not only clean after
being washed with all-purpose laundry detergent,
it is pure (free from germs).
Another ingredient of many all-purpose detergents
is fragrance in the form of various and
sometimes distinctive perfume oils. Worldwide,
fragrance preferences differ widely. While detergents
in Germany contain little to no perfume,
fragrance components are quite substantial in
the United States and Japan, where a stronger
fragrance suggests cleanliness and freshness.
Be cause of the high allergenic potential of many
perfumes, however, an increasing number of products
with reduced or no perfume oils can be found
on supermarket shelves.
Washing can be cool
Because hydrogen peroxide is fully effective only
at 95° C (boil wash), a temperature most fabric
items sold today cannot tolerate, all-purpose
laundry detergents in Europe have also contained
bleach activators like tetraacetylethylene diamine
(TAED), since the 1970s. In the washing machine,
TAED reacts with the hydrogen peroxide released
from the bleach to form peracetic acid under perhydrolysis.
Because TAED reaches its full bleaching
power at 40 to 60° C, laundry can be made
clean and sanitary even at lower temperatures.
This cuts energy costs significantly. In the
elements32 evonik science newsletter
>>>
c o A t i n G & B o n D i n G t e c H n o l o G i e S
Laundry tips
White stripes on the laundry items
normally residue from the laundry detergent or softeners
(zeolites) on the fibers that forms when, for example, too
much powdered detergent is used or the washing machine
is overloaded. Follow measuring instructions and make sure
to fill the machine so that there is a hand‘s breadth between
the laundry and drum. the residue can be removed easily by
gently beating the articles.
Machine and laundry items have an unpleasant odor
caused by bacteria, especially when you routinely use liquid
laundry detergent. once a month, wash at 60 °c (140 °F)
with an all­purpose detergent or use stain remover regularly.
Saving energy and water
Always fill the machine to capacity. two half­filled machines
use more energy and water than one fully loaded machine.
Saving energy
wash temperatures of 30–40 °c (86–104 °F) are sufficient
in most cases. At these temperatures, an all­purpose laundry
detergent will usually get even towels, bed linens and underwear
hygienically clean. laundry will become absolutely
germ­free—in the case of infectious diseases, for example—
when washed at 60 °c with a suitable all­purpose laundry
detergent.
Saving water
Do not use the pre­wash cycle. with an all­purpose laundry
detergent, the main wash cycle will get normally soiled
laundry clean, and you will save up to 19 liters (about 5 gallons)
of water.
31

Still common practice in developing
countries: washing by hand. But
growing prosperity is making washing
machines and automatic laundry
detergents more affordable
United States, the activator of choice is nonanoyloxybenzolsulfonate,
NOBS, which forms pernonanic
acid with hydrogen peroxide.
TAED and NOBS are only partially effective
below 30° C because the corresponding peracids
are not as reactive under these conditions. As a
result, countries that have traditionally used primarily
cold water to do laundry, such as the United
States, Japan and a few countries in Southern
Europe, tend to use hypochlorite as their bleaching
agent. This is why the chlorine released as a byproduct
is also associated with hygiene and cleanliness
in the United States.
Laundry detergent markets in flux
The laundry detergent market is subject to continual
change. While the environmental movement
of the 1980s, for example, spurred a trend
toward compact laundry detergents and concentrates,
as well as a ban on phosphate-based detergents
in Europe, today’s changing demographics
are lowering sales figures and increasing competition
in Europe’s all-purpose laundry detergent
market. With the number of households of individuals
and households made up of senior citizens
being on the rise and the number of households
with children being on the drop, a clear trend toward
more synthetic fibers and delicate clothing
but less stained and dirty laundry is seen.
Over the past ten years, this trend has resulted
in a significant shift in market shares in favor of
liquid laundry detergent over conventional powdered
laundry detergents. This trend appears to
have stopped, however, since liquid laundry detergents
are reaching their limits (see info box on
liquid laundry detergents). To offset the limited
cleaning power of liquid laundry detergents, detergent
manufacturers have now brought an array
of bleaches and stain removers onto the market.
Traditional laundry habits are changing, however—not
just in Europe but worldwide. Unlike
Europe, the developing countries are faster-growing
markets, since greater prosperity and purchasing
power also means closets filled with more
clothes. And more clothes means increased sales
of washing machines and automatic laundry detergents.
In developed countries like the United
States and Japan, growing environmental awareness
is increasing consumers’ willingness to buy
European washing machines (front loaders), which
are more energy-efficient and watersav ing than the
technically and mechanically less complex Amer i -
can washing machines (top load ers). At the same
time, demand for low-foaming European all-purpose
laundry detergents designed specifically for
these machines is also on the rise.
32 elements32 evonik science newsletter

Perborate – a star fades
Perborate was the bleaching component of Eu -
ro pe‘s all-purpose laundry detergents for nearly
100 years, and has been gradually replaced by
percarbonate only in the last decade. In countries
with high humidity and dramatic temperature
fluctuations, perborate is still used in laundry detergents
because of its chemical stability. Uncoated
and thus less stable percarbonate was historically
used mainly as a stain remover for pretreatment
purposes or an additive for the main wash cycle.
Changes in the raw materials market and more
recent eco-toxicological evaluations, however,
have resulted in increased use of percarbonate as
a replacement for perborate in the laundry detergents
of regions with difficult climates. Because
Borax is mined only in China, Turkey and the
United States, the construction boom in China and
the Middle East has led to a severe shortage of the
raw material. Limited supply and a sharp rise in
demand have pushed the price of borates so high
that perborates are now significantly more expensive
than percarbonate.
Percarbonate – an unstable powerhouse
In Europe, laundry detergent manufacturers successfully
completed the gradual transition to percarbonate
about ten years ago. Demanding climates,
such as those in Central and South America,
Africa and the Middle East, however, can quickly
diminish the bleaching power of laundry detergents
formulated with percarbonate. Moreover,
percarbonate‘s greater sensitivity to humidity raises
its risk potential, which is further exacer bated by
the heightened safety requirements dur ing both
transport and production.
Percarbonate is less stable than perborate primarily
because of its molecular and crystalline
structures. Characteristic for both is that they release
hydrogen peroxide very easily in contact
with water or humidity. Unlike percarbonates, perborates
are true peroxygen compounds, in which
the oxygen is bound to the boron atom in the presence
of a peroxo group. The boron and oxygen
atoms in these compounds form a six-membered
ring system with highly stable energy.
Percarbonate, on the other hand, is an addition
compound. The hydrogen peroxide molecules
in the crystal lattice are bound relatively
loosely by hydrogen bridges, similar to crystal
water molecules. In the presence of atmospheric
humidity, water molecules from the air can diffuse
into the crystals and force the hydrogen peroxide
molecules out of their positions in the crys-
elements32 evonik science newsletter
c o A t i n G & B o n D i n G t e c H n o l o G i e S
Liquid laundry detergent
liquid laundry detergents contain—besides lots of water—
surfactants and organic solvents but no bleaching agent.
As the consumer test foundation Stiftung warentest so impressively
confirms time and again, their cleaning efficiency
is poor. this is why laundry detergent manufacturers advise
consumers to use bleaching salts or bleach boosters in addition
to liquid detergents—additives that are quite expensive
but contain the same percarbonate and activator found in
every all­purpose laundry detergent. liquid laundry detergents
do contain optical brightening agents as whiteners—
Uv­active organic substances or titanium dioxide—that lay
on the fibers and thereby generate a certain whitening effect.
But they do not kill germs on laundry. on the contrary:
detergent residues collect on the plastic parts of the washing
machine‘s interior, such as the detergent compartment,
the plastic hose or the rubber seals, and provide a breeding
ground for bacteria and fungi. A „biofilm“ forms, and in
the worst case scenario, these bacteria and fungi can migrate
to the laundry
then easily degrades to water and oxygen under
increased heat. The water and the increased temperature,
in turn, accelerate the degradation process
until the percarbonate is completely converted
(autocatalytic degradation process).
Evonik tames percarbonate
There are essentially two processes available for
the production of percarbonate: the crystalliza tion
process and the granulation process. Pro duced by
the classical wet process, in which sodium carbonate
solution is mixed with hydrogen peroxide and
cooled, percarbonate has open-pored crystals
with a large surface area that is hard to coat.
In the 1990s, Evonik developed a spray granulation
process for creating sodium percarbonate
crystals as round particles with a small, smooth
surface. In a second process step, the coating step,
this surface is covered in an extremely dense, homogeneous
coating made of inorganic salts such as
sodium sulfate. This coat ing acts as a diffusion barrier
and prevents water molecules on the outside
from diffusing inside, and hydrogen peroxide molecules
on the inside from diffusing outside.
tal lattice. The hydrogen peroxide that is released >>>
33

Evonik’s percarbonate
plant in Rheinfelden
Evonik’s coating method for producing
stabilized percarbonate
1. Spray granulation 2. Spray coating
Scanning electron microscope image of
the coating-stabilized percarbonate
100:1
Na 2CO 3 solution
H 2O 2 solution
Air Sodium percarbonate Air
100:1
Na 2SO 4
3.90 µm
6.64 µm
5.20 µm
6.35 µm
6.29 µm
4.31 µm
5.53 µm
4.72 µm
500:1 50µm
Percarbonate: stable and sustainable
In the past three years, scientists from Evonik‘s
Industrial Chemicals Business Unit have refined
the coating method in the production process for
percarbonate, and significantly improved the stability
of the exterior covering and, therefore, the
strength of percarbonate against humidity and
other influences. The improved percarbonate displays
all the physico-chemical properties expected
of an advanced, sustainable product. It has a
good free flowing property and an excellent storage
stability, with an outstanding shelf-life in formulations.
And thanks to its high bulk density, it
is particularly well suited to use in compact
laundry detergents.
Percarbonate is also attractive for compact
laundry detergents because, unlike perborate, it
is multi-functional. In addition to the oxidative action
of hydrogen peroxide it also contains soda,
which promotes the alkalinity of the wash solution
and enhances the cleaning action (2 in 1). Se p -
arate formulation of soda ash, therefore, can be
reduced significantly.
The best evidence of the high chemical and
mechanical resistance of the improved percarbonate
is its good storage stability in the finished
laundry detergent, which retains its cleaning power
longer. The bleaching agent no longer has to
be overdosed in laundry detergent production.
Instead, smaller quantities of raw materials can be
used for the same level of efficiency. The improved
stability of the percarbonate during storage of the
laundry detergent means that enzyme systems with
greater sensitivity to oxygen can be used in such
products as concentrated laundry detergents,
where they develop a good cleaning action.
The world converts to granulated
percarbonate from Evonik
Because percarbonate is an oxidizing substance, it
poses a special risk that requires policies for safeguarding
its production, transport, storage and
processing. The sites have to have a permit, and
may store only certain quantities. Customers, in
turn, receive advice from Evonik on storage of the
stabilized percarbonate. Having already assisted
various customers with the transition from perborate
to percarbonate in the past, Evonik is currently
spearheading conversion of the remaining
production plants that make laundry and cleaning
detergents.
To this end, Evonik developed various cus -
t omer-specific validation tests for product qualification
purposes to ensure that the percarbonate
coating, for instance, would not be damaged
34 elements32 evonik science newsletter

Big bags of sodium percarbonate
ready to be shipped
to destinations worldwide
dur ing delivery of the material from the storage
silo to the production process. Based on elaborate
safety measure ments and models, Evonik was
able to show that granulated percarbonate is ideal
for use under extreme climatic and production
conditions. But because transport law defines it as
a hazardous material with special requirements,
Evonik also analyzed the transport of percarbonate
from its own production plants to the laundry
detergent factories of its clients across the globe.
Certain laundry detergents in the growth markets
of the Middle East and Africa already contain
granulated percarbonate from Evonik, even
though the worldwide transition from perborate
to percarbonate is still underway. Benefiting from
its technological leadership position and a superior
product quality developed in recent years, Evonik
is being recognized as a reliable and competent
partner to the global consumer goods industry. l
elements32 evonik science newsletter
c o A t i n G & B o n D i n G t e c H n o l o G i e S
Bleaching salt for special applications
the bleaching agent percarbonate is the primary component
of most conventional bleaching salts. in addition to stain
removal in the laundry, the “active oxygen” that forms as
the percarbonate dissolves in water has other practical uses.
examples:
Coffee and tea pots
Dissolves the calcium­caffeine complex that leaves a brown
film on the porcelain. to remove the film, fill the pot with
warm water and add a spoonful of bleaching salts. Allow
the salts time to work (they will foam), then rinse the pot
thoroughly with water. You can also add a small drop of
dish washing liquid for greater cleaning effect.
Tar and oil stains on tiles and stoneware
the active oxygen “inserts” itself under the tar/oil film,
decomposes there, and the oxygen generated dissolves the
film off the subsurface.
Organic waste bins
Prevents unpleasant smells. combined with the activator
(tAeD) contained in the bleaching salt, percarbonate forms
peracetic acid, which kills bacteria. Peracetic acid is environmentally
safe because it breaks down into oxygen and acetic
acid.
Fish pond
keep silt from overtaking your pond. the percarbonate
brings active oxygen to the silt without injuring the fish (as
long as the correct amount is used). the soda in the percarbonate
also acts as a neutralizing agent on overacidified
ponds.
Mold stains
on tile grout, for example: mix the bleaching salt with
enough water to make a paste (wearing rubber gloves),
apply the paste to the mold stain, allow to work, then
rinse with water.
DR. STEFAN LEININGER
Stefan leininger is in charge of application engineering
for the non­Pulp & Paper unit of the Active oxygens
Business line, and manages product and process
development for detergent base materials. in this latter
role, he works closely with customers on the global
transition from perborate to percarbonate. leininger
earned his doctorate in chemistry at the University of
kaiserslautern in 1996, and then spent three years in
research at the University of Utah in the United States
before coming to evonik in 1999. Among his activities
prior to starting in his current position in 2004,
leininger was involved in the development of titanium silicate catalyzed chemical
processes for ammoximation and epoxidation based on hydrogen peroxide.
+49 6181 59-3295, stefan.leininger@evonik.com
35

S E P T E M B E R 1 0
09/03–09/04/2010
150th Anniversary
weltkongress chemie
karlsruhe (germany)
www.kit.edu
09/17–09/21/2010
126th GDnÄ Meeting
dresden (germany)
www.gdnae.de
O C T O B E R 1 0
10/03–10/05/2010
Polydays 2010 – Polymers in
Biomedicine and electronics
berlin (germany)
www.gdch.de/makro2010/
N O V E M B E R 1 0
11/07–11/09/2010
6th German conference
on chemoinformatics
goslar (germany)
www.gdch.de/gcc2010
Evonik Industries AG
Rellinghauser Straße 1–11
45128 Essen
Germany
www.evonik.com
16.12.–21.12.2007
09/06–09/07/2010
International 3rd Aachen­osaka Symposium Joint on
Catalysis Symposium & Fine Chemicals
singapur aachen (germany)
www.cfc2007.org/index.html
www.seleca.rwth­aachen.de/
09/21–09/23/2010
Processnet Annual Meeting 2010
aachen (germany)
http://events.dechema.de/jt2010
10/10–10/13/2010
Green Solvents for Synthesis
berchtesgarden (germany)
www.dechema.de/gsfs2010
11/25–11/26/2010
Aachen Dresden international
textile conference
dresden (germany)
www.aachen­dresden­itc.de/
09/13–09/15/2010
orcHeM 2010
weimar (germany)
www.gdch.de/orchem2010/
09/22–09/24/2010
75th Annual Meeting GDch
coating chemistry
werningerode (germany)
www.gdch.de/lackchemie2010
10/10–10/13/2010
10th international workshop on
Polymer reaction engineering
hamburg (germany)
www.dechema.de/pre10
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
Editors
Dr. Karin Assmann
(responsible)
Evonik Services GmbH
Editorial Department
karin.assmann@evonik.com
Contributing Editors
Dr. Angelika Fallert-Müller
Christa Friedl
Nina Labitzke
Michael Vogel
events
Design
Michael Stahl, Munich (Germany)
Photos
Evonik Industries
Karsten Bootmann
Stefan Wildhirt
Fotolia/Lucky Dragon (p. 31)
Fotolia/Conny (p. 32)
mauritius images/Clover/
amanaimages (p. 29 oben)
mauritius images/John
Warburton-Lee (p. 29 unten)
.MGX by Materialise (cover)
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