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elements32<br />
S c i e n c e n e w S l e t t e r<br />
e v o n i k M e e t S S c i e n c e 2 0 1 0<br />
The Future of Energy<br />
D e S i G n i n G w i t H P o l Y M e r S<br />
Additive Manufacturing:<br />
Digital Layer Construction<br />
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<br />
Percarbonate: the Eco-friendly<br />
Bleach for Growth Markets<br />
3 0 3 1 3 3 2 0 1 0
Patrik Wohlhauser<br />
chairman of the Board<br />
of Management of<br />
evonik Degussa GmbH<br />
e D i t o r i A l<br />
Seizing opportunities<br />
Our Functional Films & Surfaces Project House has successfully ended its work and turned all<br />
projects over to the operative units. The team originally planned to work on eleven topics, but it<br />
was soon clear that four of these could not be implemented reasonably. For some projects, more<br />
research was re quired than time allowed, and for some others, the patent rights were problematic<br />
or the investment costs would have been too high. This is why the project house researchers<br />
concentrated on the seven remaining topics, and the results prove they were right to do so: some<br />
developments are already in the commercialization phase, and others stand at the threshold.<br />
The team also owes its success to correctly assessing and exploiting its opportunities—a principle<br />
we have also followed in portfolio management: in chemicals, we intend to invest consistently in<br />
growth areas. We plan to benefit particularly from the megatrends of resource efficiency, health and<br />
nutrition, as well as globalization of technologies. In these industries, we are already a leader in a<br />
number of key markets, and will continue to expand our good positions.<br />
A prime example is our amino acids for animal nutrition. Adding amino acids to animal feed not<br />
only ensures a well-balanced diet for animals but also conserves resources and protects the environment.<br />
This is the finding of a life cycle assessment carried out by <strong>Evonik</strong> and now certified by Technischer<br />
Überwachungsverein Rheinland, a globally recognized independent auditor. The certificate<br />
proves that we have carefully and impartially evaluated the environmental impact, energy and raw<br />
material consumption of our amino acids over their entire life cycle. And the results allow only one<br />
conclusion: adding our amino acids to animal feed is a highly sustainable form of nourishing animals,<br />
and thus supplying the growing world population with eggs, milk and meat—all with as little environmental<br />
impact as possible. Our amino acids are also an answer to the megatrend of nutrition and<br />
health, and at the same time, driver for positive business development, and an increase in the corporate<br />
value of <strong>Evonik</strong>.<br />
But portfolio management also means creating the right conditions for the operative units to<br />
fully concentrate on their business activities. To this end, a key point of departure are the infrastructure<br />
service so vital to our Group—their importance is clear from the figures: in Germany and<br />
Antwerp, these services are currently provided by about 7,000 employees, who generate a total<br />
of €1.6 billion in sales. On October 1, we will combine the site services into a single site service unit<br />
that will stand at eye level with the chemical business units. This will allow us to harness the performance<br />
potential of these services more effectively and continue evolving to meet market requirements.<br />
Here, too, we are seizing the opportunity for productivity, sustainable growth, and longterm<br />
job security.<br />
elements32 | 2010 n e w S<br />
contents<br />
4 New manufacturing plant for catalysts<br />
in Shanghai<br />
4 Controlling stake in colloidal silica<br />
maker purchased<br />
5 Catalysis: <strong>Evonik</strong> expands its presence<br />
in India<br />
5 Heads of agreement on joint venture to<br />
produce superabsorbents in Saudia Arabia<br />
Making a statement with<br />
lighting: the tulip.MGX<br />
light from Materialise<br />
has the kind of delicate<br />
hollow structures that<br />
can only be created by<br />
additive manufacturing<br />
(see also page 18ff)<br />
e vo n i k M e e t S S c i e n c e 2 0 1 0<br />
6 The future of energy<br />
i n n o vAt i o n M A n AG e M e n t<br />
12 Functional Films & Surfaces Project House:<br />
Transferability as a measure of success<br />
n e w S<br />
16 HyaCare® Filler CL – the topical wrinkle smoother<br />
16 PLEXIGLAS RESIST® AAA: new multi-skin<br />
sheets with anti-algae technology<br />
17 nano+art competition –<br />
day and night in nanoworld<br />
D e S i G n i n G w i t H P o lY M e r S<br />
18 Digital layer construction: additive manufacturing<br />
holds untapped potential, particularly for low-volume<br />
production<br />
U n i v e r S i t Y<br />
24 Committed to young talent: twenty-seven <strong>Evonik</strong><br />
employees currently teach at German universities<br />
coAt i n G & B i n D i n G t e c H n o lo G i e S<br />
26 Hot Stamping: It‘s a safe bet you‘ll be noticed<br />
28 Percarbonate: the eco-friendly bleach for growth markets<br />
36 e v e n t S A n D c r e D i t S<br />
elements32 evonik science newsletter
+++ <strong>Evonik</strong> <strong>Industries</strong> to expand its Asian special polymer capacities<br />
evonik industries that is already one of the leading global providers<br />
of methacrylate chemical products now plans to expand its production<br />
capacities for PMMA molding compounds at its facilities south<br />
of Shanghai (china), and in taichung (taiwan). Fur ther more,<br />
evonik has expanded its methacrylic acid capacities in the Shanghai<br />
MAtcH supercomplex, which began operating just nine months<br />
ago. „we want to grow in particular in places where markets develop<br />
at aboveaverage rates. our polymer business in Asia is showing<br />
remarkable growth rates. that’s why we decided to invest<br />
quickly and consistently in the expansion of our plants,“ explained<br />
Dr. klaus engel, chairman of evonik industries’ ex ec utive Board.<br />
the taichung plant began running in 2007 as part of the joint<br />
venture evonik Forhouse optical Polymers corporation. it produces<br />
some 40,000 metric tons of PleXiGlAS® molding compounds<br />
a year for light guide panels used in flatscreen monitors,<br />
Produced in Shanghai,<br />
PLEXIGLAS® molding<br />
compounds are supplied<br />
to the automotive industry<br />
in Asia, among others.<br />
PLEXIGLAS® CoolTouch®<br />
specialty compounds,<br />
for example, with their<br />
heat-reflective effect,<br />
are suitable for roof<br />
applications<br />
+++ New production plant for active pharmaceutical ingredients in China<br />
evonik industries has started up a production plant for active<br />
pharmaceutical ingredients in china. it will supply the chinese<br />
market, among others, and has a capacity of 70 cubic meters that<br />
can be doubled if required. the plant, in the city of nanning in<br />
Guangxi province, has been set up in collaboration with a european<br />
pharmaceutical company for which evonik will produce various<br />
active ingredients under a multiyear supply contract and in<br />
compliance with cGMP (current Good Manufacturing Practices),<br />
the pharmaceutical industry‘s chief quality assurance guidelines.<br />
the plant was erected in just 15 months. „that would not have<br />
been possible without the excellent support of the administration<br />
of the autonomous province of Guangxi, the city of nanning, and<br />
wuming district,“ said Dr. HansJosef ritzert, head of evonik‘s<br />
ex clusive Synthesis & Amino Acids Business line, at the official<br />
opening ceremony, attended by customers from all over the world<br />
elements32 evonik science newsletter<br />
news<br />
and demand for these flatscreen monitors has risen significantly,<br />
particularly in Asia. the expanded taichung plant, with capacities<br />
to produce another 20,000 metric tons a year, is scheduled to become<br />
operational in the second quarter of 2011.<br />
Since november 2008, in its first expansion stage, the Shanghai<br />
PMMA plant had been producing some 18,000 metric tons a<br />
year. the products are supplied as a comprehensive line of<br />
PleXiGlAS® molding compounds to various industries in Asia, including<br />
the automotive, lighting, and electronics industries. the<br />
de mand for PleXiGlAS® molding compounds also has increased<br />
considerably in these market segments, prompting the company<br />
to accelerate the construction of a second expansion stage with<br />
capacities of another 18,000 metric tons a year. the expanded<br />
pro duction capacities will become operational in the second half<br />
of 2011.<br />
Beyond that, evonik has expanded its<br />
production capacity of methacrylic acid at<br />
the MAtcH supercomplex in Shang hai to<br />
25,000 metric tons. Pro duc tion at the expanded<br />
capacity has begun this May.<br />
these steps are the continuation of a<br />
series of Asian investments for evonik indu<br />
stries: nine months ago, in november<br />
2009, the Group finished building the<br />
MAtcH supercomplex for producing polymers,<br />
polymer precursors, and coating systems<br />
in Shanghai and began operating the<br />
€ 250 million plant. the plant is the Group’s<br />
largest investment in china.<br />
as well as chinese political figures. evonik has been active in nanning<br />
since 2001, initially as a partner in a joint venture and since<br />
2005 as the sole owner of this company. now operating as evonik<br />
rexim (nanning) Pharmaceuticals co. ltd., the company produces<br />
cGMPcompliant amino acids and amino acid derivatives by<br />
biotechnological processes. with the new activeingredient production<br />
plant evonik now has another strong foothold in nanning.<br />
„the new plant is an expression of our horizontal integration<br />
strategy,“ said ritzert. the term „horizontal integration“ stands<br />
for a network of western (europe, nAFtA) and Asian production<br />
sites from which evonik offers customers tailored and exclusive<br />
solutions along the entire value chain of active pharmaceutical<br />
ingredients. „with this plant we will further consolidate our position<br />
as a high performing partner for exclusive synthesis,“ added<br />
ritzert.<br />
3
+++ New manufacturing plant for catalysts in Shanghai<br />
evonik industries officially commissioned in June, 2010, a new<br />
manufacturing plant for precious metal powder catalysts in<br />
Shang hai (china). the pharmaceuticals, finechemicals, and industrialchemicals<br />
sectors use the catalysts made there to manufacture<br />
products such as vitamins, pharmaceutical agents, and intermediate<br />
products for polyurethane used, among other things, in<br />
carseat foams and refrigerator insulation. Several customers, government<br />
agency representatives, and evonik employees attended<br />
the inauguration of the plant. evonik is the worldwide leader in<br />
precious metal powder catalysts. in addition to the Shanghai plant,<br />
the Group operates similar production sites in Hanau (Ger many);<br />
tsukuba (Japan); Americana (Brazil); and calvert city (kentucky,<br />
USA).<br />
“the new facility now allows us to supply the chinese market<br />
straight from a local source,” says Dr. wilfried eul, head of<br />
evonik’s catalysts Business line. the Shanghai site is ideal, given<br />
its proximity to the Jiangsu and Zhejiang Provinces, which are<br />
home to a host of pharmaceuticals and finechemicals companies.<br />
Proximity to chinese customers means that products and services<br />
can be optimally geared to the needs of that industry. “this enables<br />
us to participate even more intensely in the booming chinese<br />
pharmaceuticals and finechemicals markets and to augment<br />
our market position,” adds eul.<br />
with this move, evonik has now maximized its china services,<br />
which include everything from sampling to technical service,<br />
cat alyst production, and precious metal management. “what this<br />
means,” explains tim Busse, Director Asia, catalysts Business line,<br />
+++ Controlling stake in colloidal silica maker purchased<br />
evonik Degussa corporation has purchased a controlling interest<br />
in Harris & Ford Silco, llc of Portland, oregon, from indianapolisbased<br />
Harris & Ford, llc. the company has been renamed evonik<br />
Silco Materials, llc and will become part of one of the world’s<br />
leading specialty chemicals companies. „this is an important, strategic<br />
addition to evonik’s inorganic Materials Business Unit and<br />
further positions evonik as a key supplier of specialized chemicals<br />
in high tech growth industries such as the semiconductor sector,“<br />
said Jack l. clem, Senior vice President & General Manager of<br />
evonik’s inorganic Materials Business Unit and head of the Busi<br />
Colloidal silica and ultra-high purity silica are a key<br />
component of the chemical mechanical polishing (CMP)<br />
process in the semiconductor manufacturing industry<br />
Inauguration ceremony for the new<br />
manufacturing plant for catalysts in Shanghai<br />
“is that we’re able to act much faster in supplying the types of<br />
catalysts our customers need to meet their specific demands.”<br />
Preciousmetal recycling is another of the key services provided in<br />
addition to technical service support for customers who employ<br />
catalysts. the recycling service, which evonik provides in close<br />
co operation with Heraeus (www.heraeus.com) in Shanghai,<br />
entails recovering precious metal from within china and thereby<br />
establishing a closed domestic cycle for precious metals. that<br />
cre ates a clear cost benefit for customers. “the market has appreci<br />
ated evonik’s catalysts and their powerful uses, coupled with<br />
the comprehensive service we offer,” says Busse. this attitude<br />
was reflected by the many participants who attended the recently<br />
held seminars for customers from the regional pharmaceuticals,<br />
color ants, and vitamins industries and the finechemicals and<br />
agrochem icals sectors.<br />
ness Unit’s north American activities. „with this transaction, evonik<br />
will be able to provide our customers with highquality and customized<br />
silica manufactured in an ultra clean environment.“<br />
evonik Silco Materials manufactures colloidal silica and ultrahigh<br />
purity silica, a key component of the chemical mechanical<br />
polishing (cMP) process in the semiconductor manufacturing industry.<br />
evonik Silco Materials’ proximity to the major semiconductor<br />
manufacturers on the west coast and proprietary technology<br />
combined with evonik’s worldclass research and Develop ment,<br />
complimentary product portfolio, and close relationships with<br />
global corporations create a unique platform that strengthens the<br />
inorganic Materials Business Unit and creates longterm growth<br />
through turnkey solutions for the cMP market.<br />
evonik Silco Materials is a leader in the development of colloidal<br />
silica and is a leading source of standard and custom, highquality,<br />
low metals and ultra pure silica sols. in addition, each sol<br />
may be customized for particle size, stabilizing ion, pH, sodium<br />
content, particle size distribution, and concentration. the com <br />
p any will remain in Portland. „this acquisition is good news for<br />
evonik’s customers and customers of the newlynamed evonik<br />
Silco Materials, llc,“ said clem. “colloidal silica is a growth market<br />
and evonik is a growthoriented company.”<br />
4 elements32 evonik science newsletter
+++ Catalysis: <strong>Evonik</strong> expands its presence in India<br />
evonik has acquired the precious metal powder catalysts business<br />
of ravindra Heraeus Pvt. limited, Udaipur (rajasthan, india). As<br />
stipulated in the agreement, all knowhow, technology, and business<br />
relationships with catalyst customers will pass from ravindra<br />
Heraeus to evonik, while the production equipment will remain<br />
with the indian company. Both partners have also concluded longterm<br />
agreements concerning contract manufacturing and precious<br />
metal recycling. Based on these agreements, ravindra Heraeus<br />
will continue to produce precious metal catalysts for the indian<br />
market and recycle used catalysts at its site in Udaipur on behalf<br />
of evonik. the catalysts for evonik‘s existing indian customers are<br />
currently imported from Germany. in the future, these products<br />
will also be manufactured by ravindra Heraeus in india.<br />
Precious metal powder catalysts are used in the pharmaceuticals,<br />
fine chemicals and industrial chemicals industries for such<br />
purposes as selective and costeffective chemical synthesis of<br />
pharmaceutical or agricultural active ingredients. the pharmaceuticals<br />
and fine chemicals markets in india have posted aboveaverage<br />
growth for several years, owing in part to the outsourcing<br />
strategies of pharmaceutical and agricultural companies, which no<br />
elements32 evonik science newsletter<br />
news<br />
longer produce the active ingredients themselves. “with Heraeus<br />
as a strong, capable partner, we can now supply our highquality<br />
precious metal powder catalysts to customers in india from local<br />
production and offer them the complete package of services for<br />
precious metal management,“ said Dr. wilfried eul, head of<br />
evonik’s catalysts Business line.<br />
For the customer, this means a short processing time and integration<br />
into the local precious metal loop to avoid import duties<br />
and lengthy importation processes. “this will allow us to step up<br />
our participation in india’s aboveaverage growth in pharmaceuticals<br />
and fine chemicals, and expand our leading position in precious<br />
metal powder catalysts,” says eul. currently, evonik produces<br />
precious metal powder catalysts at its sites in Hanau<br />
(Germany); tsukuba (Japan); Americana (Brazil); calvert city<br />
(kentucky, USA); and lately also in Shanghai (china).<br />
ravindra Heraeus, a precious metal company, is a joint venture<br />
between the worldwide leading precious metal and technology<br />
company Heraeus located in Hanau (Germany) and the family<br />
enterprise ravindra choksi (india). each partner holds a 50 percent<br />
stake in the joint venture.<br />
+++ Heads of agreement on joint venture to produce superabsorbents in Saudia Arabia<br />
Superabsorbents are a key base material for the manufacture<br />
of hygienic products such as diapers. The photo shows<br />
an applied-technology laboratory at <strong>Evonik</strong>’s Krefeld site<br />
evonik industries, national industrialization company (tasnee)<br />
and Sahara Petrochemicals are planning to set up a joint venture<br />
to produce super absorbent polymers. their intention is to build a<br />
stateoftheart worldscale facility with capacity of 80,000 metric<br />
tons p.a. at Jubail in SaudiArabia. Startup would be in the first<br />
quarter of 2013. Dr. klaus engel, chairman of the executive Board<br />
of evonik, and Dr. Moayyed i. AlQurtas, ceo of tasnee, signed<br />
a corresponding “Heads of<br />
Agree ment” in riyadh. „this is<br />
an important step for the evonik<br />
Group in the growing Middle<br />
east market and represents a<br />
significant expansion of our leading<br />
position in super absorbent<br />
polymers“, commented en gel.<br />
evonik is a worldleading producer<br />
of super absorbent poly <br />
mers, a key basic material for<br />
the manufacture of diapers and<br />
feminine hygiene products.<br />
the proposed joint venture<br />
for super absorbent polymers<br />
will benefit from advantageous<br />
access to raw materials: SAMco,<br />
a joint venture of tasnee and<br />
Sahara (Saudi Acrylic Acid<br />
company, SAAc) and Dow<br />
chemicals will supply the acrylic<br />
acid required to produce super<br />
absorbent polymers from a neighbouring plant. Propylene, a key<br />
raw material for acrylic acid, will be sourced by SAMco from a<br />
nearby plant operated by tasnee and Sahara (tasnee Sahara<br />
olefins company, tSoc) and lyondell Basell. the planned production<br />
facility will thus be embedded in integrated production<br />
structures, making it the first downstream project of its type in the<br />
Middle east region.<br />
5
e v o n i k M e e t S S c i e n c e 2 0 1 0<br />
the Future of energy<br />
in June, more than 200 experts met in Marl at evonik‘s invitation and<br />
discussed the potential paths to and implications of sustainable energy and<br />
resource management—all in the spirit of the Year of Science 2010.<br />
Against a backdrop of environmental and climate<br />
problems, as well as dwindling resources, energy<br />
is the number one concern of the “Year of Science<br />
2010—the Future of Energy,” an initiative of the<br />
Federal Ministry of Education and Research (BMBF). How<br />
will we supply energy in the future? And what should society<br />
do to use natural resources as efficiently as possible?<br />
There are no simple answers to these questions, but ideas<br />
and visions abound. At its now regular scientific forum<br />
“<strong>Evonik</strong> Meets Science” on June 7 and 8, <strong>Evonik</strong> created a<br />
plat form for experts to discuss these open questions, gather<br />
ideas, and network. More than 200 participants accepted the<br />
invitation to Marl.<br />
“<strong>Evonik</strong> Meets Science” was held very much in the spirit<br />
of the Year of Science, because resource efficiency concerns<br />
not just the energy industry, but chemistry as well: chem ical<br />
products and technologies are fundamental to improving<br />
use of resources. But a number of innovations are needed.<br />
“Science and research are the ambitious parents of advancement,”<br />
said Dr. Klaus Engel, chairman of the executive<br />
board of <strong>Evonik</strong> <strong>Industries</strong> AG in his opening speech to the<br />
conference. <strong>Evonik</strong> committed itself to this interrelationship<br />
long ago: „One-fifth of our chemical sales is based on products<br />
that are less than five<br />
years old,” said Engel.<br />
Dr. Klaus Engel<br />
Member of the Executive Board<br />
of <strong>Evonik</strong> <strong>Industries</strong> AG<br />
6 elements32 evonik science newsletter
In October 2008, <strong>Evonik</strong> established the Science-to-Business<br />
(S2B) Center Eco² under management of the strategic research<br />
unit Creavis Technologies & Innovation, where experts<br />
develop interdisciplinary solutions for resource and<br />
energy efficiency. In the search for sustainable use of resources,<br />
they work not only with other units in the Group<br />
but with some 40 external partners from research and industry.<br />
So it is not surprising that this year‘s „<strong>Evonik</strong> Meets<br />
Science“ took up the research topics of the S2B Center Eco²<br />
in strong support of the BMBF‘s initiative—and held days of<br />
action for school children to promote enthusiasm in the<br />
younger generation for the natural sciences, technology and<br />
especially energy, a key issue for the future.<br />
Dr. Stefan Nordhoff, head of the S2B Center Eco²,<br />
stressed that sustainability, resource efficiency and profitability<br />
are by no means mutually exclusive: “A study by the<br />
management consulting firm McKinsey from last year showed<br />
that there are various technologies<br />
that are making money<br />
right now, and will make<br />
even more in the future.“<br />
The portfolio of the S2B Center<br />
Eco² is clearly aligned to<br />
these growth areas.<br />
Dr. Stefan Nordhoff<br />
head of the S2B Center Eco²<br />
elements32 evonik science newsletter<br />
>>><br />
Open Innovation<br />
e v o n i k M e e t S S c i e n c e 2 0 1 0<br />
Seeing the bigger picture can be helpful, particularly in a<br />
period marked by the kind of technological upheavals society<br />
is currently experiencing in the energy sector. this is<br />
why this year’s evonik Meets Science scientific forum was<br />
de vot ed to the topics of energy and resource efficiency.<br />
“evonik is positioning itself as an innovator in this area, and<br />
intends to continue building on this position,“ said Dr. thomas<br />
Haeberle, member of the Board of Management of evonik<br />
Degussa GmbH. “chemicals and energy are strong partners<br />
on this path, as the leSSY lithiumelectricity storage system<br />
shows,” added Joachim rumstadt, chairman of the Board of<br />
Management of evonik Steag GmbH.<br />
Dr. Peter nagler, head of innovation Management<br />
chemicals & creavis at evonik, pointed to the company’s<br />
strategic research activities, which are bundled into crossunit<br />
areas of competence, project houses, and sciencetobusiness<br />
(S2B) centers. “in the S2B centers, we develop<br />
innovations associated with higher research risks,“ said<br />
nagler.<br />
the S2B center eco² under direction of creavis is one<br />
of the facilities for seeing this bigger picture. it combines<br />
five lines of development—co 2 separation and use, energy<br />
production, energyeffi cient customer solutions, energy<br />
storage, and energy effi ciency in evonik processes—and one<br />
overarching theme, the life cycle Assessment (see elements<br />
31). At evonik Meets Science, external partners from<br />
universities reported on the state of the technology, as they<br />
saw it, for each of these lines of development. the conference<br />
closed with an interactive marketplace in the S2B<br />
center eco², where the employees of the center presented<br />
their research projects with the help of numerous exhibits,<br />
graphic presentations, and interactive animations, and held<br />
discussions on their specific areas of study. their projects<br />
and project ideas, such as carbon dioxide utilization from<br />
waste gas streams, the development of lightweight components<br />
for automotive manufacture, as well as the intelligent<br />
utilization of hard coal flue ash, convincingly demonstrated<br />
the “energy” they put into their work.<br />
Dr. Thomas Haeberle<br />
member of the Board<br />
of Management of<br />
<strong>Evonik</strong> Degussa GmbH<br />
Joachim Rumstadt<br />
Chairman of the Board<br />
of Management of<br />
<strong>Evonik</strong> Steag GmbH<br />
Dr. Peter Nagler<br />
head of Innovation<br />
Management Chemicals<br />
& Creavis at <strong>Evonik</strong><br />
7
What is resource efficiency?<br />
But as Prof. Matthias Finkbeiner of the Institute for Technical<br />
Environmental Protection of the Technical University of<br />
Ber lin pointed out, resource efficiency is by no means a<br />
clearly defined concept: it can be understood as either the<br />
greatest added value that can be generated with the least<br />
amount of raw materials, or in the wider sense of the EU<br />
Commission. In 2005, the Commission defined the term „resource“<br />
in such a way that it includes not only raw materials,<br />
but biotic resources, renewable energies, land areas, as<br />
well as air, water and soil. They all factor into the resource<br />
efficiency denominator, with value added as the numerator.<br />
Then, a life cycle assessment (LCA) records a system’s input<br />
and output, which ranges from raw material generation,<br />
through production, maintenance and consumption, to recycling<br />
and disposal. An LCA can also be used operationally to<br />
monitor a product as it is being developed. “The method<br />
also lends itself to risk screening,” said Finkbeiner.<br />
“Internationally, the life cycle assessment is the most recognized<br />
method for evaluating environmental impact, because<br />
it is the only method that can cover a broad range of applications<br />
consistently and uniformly across nations.“<br />
But taking an example from the automotive industry,<br />
Finkbeiner also stressed that an LCA should never be interpreted<br />
in the absence of values: based only on the indicators,<br />
the LCA of a small car can look better or worse than<br />
that of a luxury limousine. In addition to the way resource<br />
efficiency is defined, and whatever else is included as a resource<br />
in the evaluation, the result of a calculation depends<br />
on the indicators selected for the value added and environmental<br />
pollution.<br />
Finkbeiner is convinced that, despite these limitations,<br />
the concept of resource efficiency promotes sustainable development.<br />
He compared the situation to that of Maslow’s<br />
famous Hierarchy of Needs from the field of psychology, in<br />
which the basic needs of an individual must be met first before<br />
he can climb to the next level, such as cultural creativity.<br />
As Finkbeiner pointed out, an environmental and sustainability<br />
assessment is structured quite similarly: “A company<br />
should think seriously about its carbon footprint, for ex -<br />
am ple, until it is developed into an LCA.“ At the top of this<br />
hierarchy, then, is the life cycle sustainability assessment,<br />
which also considers value-oriented social aspects.<br />
Prof. Matthias Finkbeiner<br />
of the Institute for Technical<br />
Environmental Protection at the<br />
TU Berlin<br />
CCS as a sound interim solution<br />
Using carbon dioxide capture and storage (CCS) as an example,<br />
Prof. Klaus Görner, holder of the Chair for En vi ronmental<br />
and Plant Engineering at the University of Duisburg-<br />
Essen, explained that technological issues are not always a<br />
matter of long-term goals but also temporary solutions.<br />
Today’s fossil-fuel power plants reach efficiency levels<br />
of between 43 (brown coal), 46 (hard coal ), and 60 percent<br />
(gas). Hard-coal-fired steam power plants, which reach<br />
such levels of efficiency, operate at 600 °C. While the efficiency<br />
level can be improved by over 50 percent by rais ing<br />
the temperature to the level envisioned for the next generation<br />
of power plants (700 °C), this will not, in his opinion,<br />
meet the climate goals of the EU. The only way Europe can<br />
cut CO2 emissions to 20 percent below its 1990 levels is<br />
through higher energy efficiency in power plants, use of<br />
renewable energies, and additional optimization measures.<br />
To reduce emissions by the ambitious target of 30 percent,<br />
one possibility is the above-mentioned CCS technology.<br />
CCS technology can catch 90 percent of the carbon dioxide<br />
from a power plant. “CCS is suitable for new plants<br />
and some old plants,” said Görner. “Transport and storage<br />
are technically feasible but not widely accepted by the public.”<br />
In the power plant, three different technologies can<br />
separate the CO2 either before the gasified coal is actually<br />
burned (pre-combustion), while it is being burned (oxycombustion),<br />
or after it is burned, as the last step in flue<br />
gas cleaning (post-combustion). At the current state of the<br />
technology, however, all of these methods reduce the efficiency<br />
level of the power plant by 9 to 13 percent, because<br />
energy is required for separation. Here, it is the job of science,<br />
in cooperation with producers and operators, to help<br />
reach a net efficiency of significantly over 40 percent by<br />
raising the base efficiency<br />
level to over 50 percent and<br />
reducing inefficiencies to<br />
below 8 percentage points.<br />
This is the only way to preserve<br />
coal as a resource and,<br />
at the same time, protect the<br />
environment.<br />
Prof. Klaus Görner<br />
holder of the Chair for Environ -<br />
mental and Plant Engineering at the<br />
University of Duisburg-Essen<br />
8 elements32 evonik science newsletter
Fiber-reinforced composites reduce the weight of cars<br />
In addition to energy management, mobility is another key<br />
factor in the future prevention of CO2 emissions. One approach<br />
is to reduce the weight of vehicles. Weight-optimized<br />
structural components for cars can be produced from the<br />
kind of fiber-reinforced composites currently used in the<br />
aerospace industry. “Production of such components is<br />
large ly manual right now, but automobile manufacture will<br />
require automated processes,” said Prof. Thomas Gries, holder<br />
of the Chair for Textile Machinery at the Institute for<br />
Textile Technology at RWTH Aachen. Gries coordinates<br />
the interdisciplinary cooperation of Aachen scientists researching<br />
fiber-reinforced composites. Their work centers<br />
on products, production machines and processes, as well as<br />
design, simulation and measuring processes for semi-finish ed<br />
textile products and composite components.<br />
An important step in this work is robotic production of<br />
near-net-shape textile preforms. In these three-dimensional<br />
textile structures, the reinforcing fibers are oriented to the<br />
inner flow of forces, which ensures maximum mechanical<br />
rigidity and strength at the lowest possible weight. “We<br />
have developed the production technology for this, so we<br />
are now concentrating on the engineering and design tools,“<br />
said Gries. While initial applications have already found their<br />
way into vehicles, textile composites are still a very new<br />
technology, suitable only for piece counts of fewer than<br />
100,000 per year.<br />
In addition to vehicle construction, Gries also sees potential<br />
for fiber-reinforced composites in energy technology.<br />
The diameter of the rotorblades of wind power plants,<br />
for example, will continue to increase, which will accelerate<br />
lightweight construction. Textile structures will be particularly<br />
attractive for load optimization of components. Fuel<br />
cells could also benefit from<br />
fiber-reinforced composites<br />
used to reinforce polymer<br />
mem branes.<br />
Prof. Thomas Gries<br />
holder of the Chair for Textile<br />
Machinery at the Institute for Textile<br />
Technology at RWTH Aachen<br />
elements32 evonik science newsletter<br />
>>><br />
e v o n i k M e e t S S c i e n c e 2 0 1 0<br />
Multiaxial fabrics with integrated stringers (top)<br />
Three-dimensional textile preform for car underbodies (middle)<br />
Design for an automated robotic preform production process (below)<br />
Cutting<br />
Inline quality<br />
management<br />
Handling<br />
Preform center<br />
Binder application<br />
Sewing<br />
9
Supplying energy safely requires<br />
powerful energy buffers<br />
But it makes no difference how lightweight a vehicle can be<br />
made through structural measures or how much CO 2 can be<br />
eliminated: in the end, the most important consideration<br />
when it comes to tomorrow‘s mobile and stationary energy<br />
supply is still energy storage. The reason for this is that<br />
renew able energies generate extremely uneven loads on supply<br />
networks, which are currently compensated by regulatable<br />
power plants and, to a lesser extent, pumped-storage<br />
power plants, which have limited potential.<br />
Accumulators and supercondensers are the only highly<br />
effective means for storing electrical power. Prof. Martin<br />
Winter of the Institute for Physical Chemistry at the Uni versity<br />
of Münster believes that lithium-ion technology will<br />
play a key role in this technology. As he sees it, there are<br />
four reasons for this: high cell voltage, high energy and power<br />
densities, low self-discharge rates, and the ability to exploit<br />
the battery‘s entire capacity without damaging it. “The<br />
lithium-ion battery is an evolutionary technology, because<br />
so many different materials can be used to produce it. It’s<br />
ideal for quickly buffering power spikes in a matter of<br />
hours,” said Winter. Suitable for small- to medium-sized decentralized<br />
energy buffers, lithium-ion technology will probably<br />
also play a role in future vehicle-to-grid designs, for<br />
which the batteries of electric vehicles would serve as temporary<br />
buffers for power spikes. This would take advantage of<br />
the fact that many vehicles are not moved for most of the day.<br />
But there are also clear ideas for stationary applications:<br />
the LESSY (lithium electricity storage system) prototype,<br />
made up of about 5,000 individual lithium ceramic cells, will<br />
be developed this year at <strong>Evonik</strong>‘s coal-fired power plant in<br />
Völklingen, Saarland. With an input and output of 1 MW and<br />
a storage capacity of about 700 kWh, LESSY is slated to provide<br />
primary regulation. <strong>Evonik</strong>’s partners on the project include<br />
its own subsidiary Li-Tec Battery GmbH, a joint venture<br />
with Daimler AG, and the University of Münster, under<br />
the direction of Winter, among others. The Federal Ministry<br />
for Education and Research is funding the project under its<br />
LIB 2015 research initiative.<br />
Prof. Martin Winter<br />
of the Institute for<br />
Physical Chemistry at the<br />
University of Münster<br />
Hydrogen as a future primary energy store?<br />
Compared to lithium-ion technology, the sustainable production<br />
of hydrogen is still in its infancy. The volatile gas<br />
would be an attractive source of primary energy because it<br />
contains more energy per weight units than any other chemical<br />
fuel. “Currently, however, 96 percent of hydrogen is<br />
generated from fossil energy sources. Renewable energies<br />
would be preferable so that hydrogen could play a larger<br />
role in sustainable energy concepts,” said Dr. Henrik Junge,<br />
group leader at the Leibniz-Institut für Katalyse e.V.<br />
(LIKAT). To this end, LIKAT is researching photocatalytic<br />
hydrogen production from water and—as buffer—the release<br />
of hydrogen from formic acid.<br />
For the first topic, LIKAT is testing an iridium-based<br />
photosensitizer embedded in an iron complex, and is using<br />
it to reach a turnover number (as a measurement for the<br />
effectiveness of the catalyst) of 3,000. A fuel cell equipped<br />
with this photosensitizer supplied 18 mW of constant power<br />
for 30 minutes in a test setup. The second LIKAT project,<br />
the release of hydrogen from formic acid, is based on a CO2 neutral cycle, and uses a ruthenium catalyst to release the<br />
hydrogen. On the pilot scale, at room temperature, the process<br />
ran for over eleven days and achieved a 99 percent<br />
yield: 0.9 liters of hydrogen per hour. There is still a long<br />
way to go, however, before<br />
the LIKAT projects can be<br />
used on the commercial scale.<br />
Junge compared the current<br />
state of the technology to the<br />
status of nuclear fusion research.<br />
Dr. Henrik Junge<br />
group leader at the Leibniz-Institut<br />
für Katalyse e.V. (LIKAT)<br />
10 elements32 evonik science newsletter
The energy of the future has many sources<br />
According to Prof. Ferdi Schüth, director of the Max Planck<br />
Institute of Coal Research in Mülheim, methanol, hydrocarbons,<br />
methane, and ethanol are a few of the possible alternatives<br />
to hydrogen-based chemical buffers, at least on the<br />
strength of their achievable energy densities. But all substances<br />
also have drawbacks or limitations.<br />
In his presentation, Schüth stressed that the storage densities<br />
of lithium-ion batteries for vehicles lagged behind the<br />
values forecast six years ago, and appear to have reached a<br />
plateau. “Naturally, we should continue to devote time and<br />
energy to exploring this technology, with industry setting<br />
the pace,“ said Schüth, „but it is also time for us to start thinking<br />
about what will come after lithium-ion technology.“<br />
Schüth feels we are facing a paradigm shift when it comes<br />
to energy supply. Put simply, our current energy supply is<br />
based on largely isolated use of various primary energy<br />
sources: electricity comes from coal and nuclear power<br />
plants, while heat and mobility is covered by oil and natural<br />
gas. Schüth expects electricity and mobility—through the<br />
energy buffer connection—to merge to form a single field of<br />
application in the future. When this happens, we will be<br />
dealing with a mixture potentially consisting of nuclear<br />
power, coal, solar thermal energy, photovoltaics, water and<br />
wind power, geothermal energy, natural gas and biogas, as<br />
well as oil. Future demand for heat, on the other hand, will<br />
be met primarily by solar thermal energy, with a small portion<br />
being covered by oil, natural gas and biogas. So our<br />
energy supply would rest on many pillars, not just a few.<br />
And the decision about which technology is best suited<br />
to which country and application is ultimately a social one.<br />
The fact that Brazil’s energy industry, for example, is based<br />
on sugarcane ethanol reduces<br />
CO2 emissions significantly,<br />
but the use of fertilizers<br />
increases water pollution<br />
caused by phosphates. l<br />
Prof. Ferdi Schüth<br />
director of the Max Planck Institute<br />
of Coal Research in Mülheim<br />
(Germany)<br />
elements32 evonik science newsletter<br />
E v o n i k M E E t s s c i E n c E 2 0 1 0<br />
Our current energy system<br />
Nuclear energy<br />
Electricity Heat Mobility<br />
A possible future energy system<br />
Nuclear energy<br />
Brown coal<br />
Coal<br />
Hard coal<br />
Electricity Traction- Mobility<br />
battery<br />
Storage<br />
Solar thermal<br />
energy<br />
Storage<br />
Photovoltaics<br />
Water<br />
Geothermal etc.<br />
Storage<br />
Wind<br />
Methane<br />
storage<br />
Natural gas<br />
and biogas<br />
Natural gas<br />
Oil<br />
Oil<br />
Heat<br />
Heat storage<br />
Solar thermal<br />
energy<br />
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<br />
transferability as a Measure of<br />
the Functional Films & Surfaces Project House, evonik’s seventh project house, has successfully<br />
concluded its work under the direction of the strategic research unit creavis technologies &<br />
innovation. Four key factors were vital to its success: consistent project management, the right<br />
combination of internal and external expertise, openness—even to uncomfortable truths—and<br />
the right team of motivated people.<br />
In the beginning, there were 100 project ideas at various<br />
stages of development and thought, the fruit of countless<br />
discussions within <strong>Evonik</strong>‘s Chemicals Business Area.<br />
Dr. Jochen Ackermann, head of the newly-established<br />
Func tional Films & Surfaces Project House, introduced the<br />
idea of the project house to the Group—the heads of the<br />
business units and business lines, and to the heads of R&D—<br />
over a six-month period. The project house was officially<br />
launched on January 1, 2007, which meant it would con clude<br />
on De cem ber 31, 2009—the usual three-year run for a project<br />
house as an element of the strategic research and development<br />
unit Creavis Technologies & Innovation in the <strong>Evonik</strong><br />
Group. “This approach allows us to open up new markets,<br />
material and system competencies, product innovations, and<br />
technol ogies that the business units would have difficulty<br />
working into their day-to-day activities,” says Dr. Harald<br />
Schmidt, head of Creavis.<br />
In late 2006, it was time to evaluate the 100 project ideas:<br />
What did the market look like? What competencies could<br />
be built within the Group in the relatively short three-year<br />
time period? Which employees in the business units were<br />
available? To what extent were there patent problems or<br />
technological hurdles? And who were the potential development<br />
partners outside the Group? In the meeting of the<br />
steering committee, which comprises representatives of top<br />
management—executives, managing directors of <strong>Evonik</strong><br />
Degussa GmbH, as well as the heads of the business units,<br />
business lines, and Creavis—the decision was made to tackle<br />
eleven specific projects.<br />
The steering committee also defined the concept, costs,<br />
resources and objectives. “Each project was to furnish a system-level<br />
demonstrator—not just a laboratory prototype but<br />
a production sample, if possible, that had been used and<br />
test ed in the final application,” says Ackermann. “Also, each<br />
12 elements32 evonik science newsletter
Success<br />
project needed a business plan that outlined what the business<br />
units had to do to make a sustainable business out of the<br />
project, how high the required investment costs would be,<br />
how the subsequent business model might look, and what<br />
could be expected in terms of financial planning.”<br />
If you fail, fail early<br />
elements32 evonik science newsletter<br />
Dr. Jochen Ackermann<br />
(pictured 6th from left)<br />
and his 15 member<br />
project house team<br />
The newly established project house pursued a clear project<br />
management plan that divided the three years into the following<br />
phases: exploration (first year), definition (second<br />
year) and validation (third year). “After the first year, we set<br />
the specific development objective for all projects, along<br />
with a detailed milestone plan for the remaining two years,<br />
which would leave no more room for major deviations,“<br />
says Ackermann. Earlier, in consultation with the business<br />
units and steering committee, four projects had been cut<br />
i n n o v A t i o n M A n A G e M e n t<br />
from the project portfolio because they could not be realistically<br />
implemented. There were several reasons for the decision:<br />
Some projects were too research-intensive for the<br />
time available, the patent situation was problematic, there<br />
was no realistic business model for <strong>Evonik</strong>, the investment<br />
costs would have been too high, or the idea was simply too<br />
late for the market. “If you fail, fail early”, says Ackermann.<br />
This is the only way to avoid wasting time with projects with<br />
an uncertain future—something neither the project house<br />
nor the Group needed.<br />
The seven continued projects (see box on page 15) can<br />
be divided into two categories: projects focused on establishing<br />
a prod uct or system competence, and projects focused<br />
on develop ing a technology platform. In the first year of the<br />
project house, most of the work involved evaluating the<br />
projects and forming a powerful team. Fifteen employees,<br />
on aver age, worked at the project house. Then, laboratory<br />
tests were run in the second year and the first half of the<br />
third, while the second half of the third year was devoted to<br />
transferring the developments to the Group.<br />
Employees of the Functional Films & Surfaces Project<br />
House drew important conclusions from an audit and life<br />
cycle analysis of past project houses: “If you lack some important<br />
expertise for specific applications in your own<br />
house, you should consult someone from the user‘s industry,“<br />
says Ackermann. “Indeed, these were one of the steps<br />
that began opening our eyes to the direction we have to<br />
take.“ A technology consultant with a good overview and<br />
the right contacts is also helpful, since some experiments<br />
and test runs take more time and equipment than is available<br />
to carry out in-house. The outstanding reputation of the<br />
project houses among the customers and partners made this<br />
process easier.<br />
The „operative project teams” proved to be another key<br />
element in the success of the project house. “In addition to<br />
the project manager from the project house, these teams<br />
were made up of colleagues from the business units,” says<br />
Ackermann. These were product managers, sales >>><br />
13
Developed in the project house<br />
amongst others:<br />
Coated rubber granu late as infill<br />
for artificial turf (above)<br />
PLEXIGLAS® film with Fresnel<br />
lenses on the surface. These kinds<br />
of microstructured films have<br />
been used for such applications<br />
as solar concentrators in photo -<br />
voltaics (below)<br />
Flexible printed circuit boards<br />
based on polymer films (right)<br />
experts, controllers, developers, application engineers—<br />
colleagues who were or would be involved with the project<br />
in one form or another. “We always prepared very stringently<br />
for this meeting, and this also meant concrete tasks<br />
for the participants.” Thanks to these almost monthly meetings,<br />
the business unit was always up to date on the latest<br />
informa tion.<br />
“Mentors” guarantee successful transfer<br />
In Ackermann‘s estimation, the critical phase of a project<br />
house is the transfer of project results to the Group. “We<br />
discussed transferring results as early as the middle of the<br />
third year.“ The two central questions were where they<br />
should transfer the results and when. The proven approach<br />
had been that management would allow the project house to<br />
conduct its research until the end of the three-year period<br />
and only then initiate the actual transfer. This phase had<br />
now ended in the middle of the year. Ackermann himself did<br />
not become head of Business Development for the Acrylic<br />
Polymers Business Line until May 2010.<br />
14 elements32 evonik science newsletter
The Projects<br />
Barrier films for flexible thin-film photovoltaic modules:<br />
re placement of the rigid glass covering in thinfilm solar modules<br />
by a barrier film based on PleXiGlAS® that offers permanent<br />
protection against the effects of weather, shows a transparency<br />
to sunlight comparable to the glass, and acts as a barrier<br />
against water vapor and oxygen. Status: transferred to the<br />
business unit; available by the roll from production tests; samples<br />
sent to customers.<br />
Luminescent solar concentrators:<br />
A concentrator based on PleXiGlAS® sheets to increase the<br />
yield of conventional solar cells. it does this by shifting some of<br />
the sun’s rays that would not activate the semiconductor material<br />
of the cells because of its defined bandwidth into a wavelength<br />
range where the solar cells can absorb it. Status: Demon<br />
strator available.<br />
Flexible printed circuit boards based on polymer films:<br />
De vel opment of a costefficient copperpolymer laminate<br />
based on hightemperature plastics that can be used to produce<br />
flex ible circuit boards. Status: transferred to the business unit;<br />
pilot plant for sample production.<br />
Coated rubber granulate as infill for artificial turf:<br />
Development of a rubber granulate based on shredded scrap<br />
tires, to be used as infill for artificial turf. A newly developed<br />
twocomponent coating enables the production of granulate<br />
“For each transfer, the business line would appoint a<br />
mentor to look after the project, and then the product,” explains<br />
Ackermann. “And in 2011, for the first time, these<br />
mentors will also give a report on the progress in the business<br />
unit to the steering committee,” adds Schmidt.<br />
According to Ackermann, four factors determined the<br />
success of the project house:<br />
• Consistent project and portfolio management<br />
• The decision whether to fundamentally build competencies<br />
internally and/or externally<br />
• Under the keyword “open innovation,” contact with<br />
coop er ation partners that ranged from formal R&D cooperation<br />
agreements to the use of test and production<br />
facilities<br />
• And formation of an effective and, above all, highly motivated<br />
team.<br />
Ackermann selected his employees to create a diverse group:<br />
experienced researchers, but also university gradu ates; the<br />
young and not-so-young, men and women, physicists, engineers,<br />
chemists and material scientists.<br />
elements32 evonik science newsletter<br />
i n n o v A t i o n M A n A G e M e n t<br />
with considerable advantages over today‘s conventional offerings.<br />
Status: expan sion of the business by creavis technologies<br />
& innovation; scaleup to production scale at customer.<br />
Surface functionalization of PLEXIGLAS®:<br />
Development of a technology platform for inline functionalization<br />
of PleXiGlAS® semifinished products, which allows<br />
highgloss or mattfinished surfaces with high abrasion resistance—integrated<br />
into the production process. Status:<br />
transferred to the business unit; pilot plant for sample production.<br />
Abrasion-proof matt-finished PLEXIGLAS®:<br />
Development of a tech nology platform for the production of<br />
mattfinished coatings for PleXiGlAS® semifinished products<br />
that show a haptic effect and are extremely abrasionresistant—<br />
integrated into the production process. Status: transferred to<br />
the business unit; scaleup to production scale.<br />
Prismatic PLEXIGLAS® elements for light management:<br />
Development of a technology platform for microstructuring<br />
PMMA surfaces, which can be used to produce PleXiGlAS®<br />
light covers with highly precise prismatic struc tures for uniform<br />
ambient lighting without glare. Status: transferred to the business<br />
unit; presentation of the product at the light+Building<br />
trade fair in April 2010.<br />
While the focus of the first year was on forming a real<br />
team, the second year was devoted to the questions of where<br />
a member stood in the project and also personally, and how<br />
the team functioned. “My project managers often presented<br />
their results to the steering committee and the business<br />
units personally. After all, it was their work. And they had<br />
to support it themselves.” That increased their motivation to<br />
make the project a success, but also their pride in the joint<br />
achievement. After all: “You’re nothing without your team,”<br />
says Ackermann. l<br />
15
+++ HyaCare® Filler CL – the topical wrinkle smoother<br />
within the last couple of years a wellknown active ingredient has<br />
seen its revival in various segments of the personal care market.<br />
Hyaluronic acid still serves the needs of today’s consumers and cosmetic<br />
formulators. Beside this, it is used quite often as dermal filler.<br />
Following those trends, evonik´s care Specialties Business<br />
line provides a range of active ingredients based on hyaluronic<br />
acid.<br />
crosslinked hyaluronic acid is well known for its use as dermal<br />
filler. Dermatologists inject it directly into the skin to physically<br />
fill up wrinkles from within.<br />
Many consumers do not like<br />
such an invasive and expensive<br />
approach. therefore, they are<br />
look ing for cosmetics alternatives<br />
based on formulations which<br />
mimic the immediate wrinkle<br />
reducing properties of dermal<br />
fillers. As a log ic consequence<br />
evonik has enlarged its hyaluronic<br />
acid technology plat form<br />
for personal care products and<br />
launched Hyacare® Filler cl.<br />
Due to its 3dimensional network<br />
structure, Hyacare® Filler<br />
cl contributes instantly to the<br />
reduction of facial wrinkles and<br />
fine lines, as well as increases<br />
the elasticity of the skin. Be<br />
cause of its high waterbinding and strong shortterm moisturization<br />
properties, Hyacare® Filler cl supports effectively the<br />
hydra tion of the skin. it can be used for all antiaging applications<br />
where an instant effect as well as moisturization is desired.<br />
Hyacare® Filler cl is a unique crosslinked version of Hyacare®.<br />
Hyacare®, a fermentationderived highquality biopolysaccharide<br />
of high purity, is obtained by a solventfree process. it is skiniden<br />
tical hyaluronic acid with a medium molecular weight of 700<br />
kDa. Due to its intrinsic filmforming properties it restores the<br />
elasticity of the skin and reduces<br />
the appearance of wrinkles. Besides<br />
this effect it reinforces the<br />
skin‘s natural short and longterm<br />
moisturization.<br />
Another product based on<br />
the hyaluronic acid technology<br />
is Hyacare® 50 that was<br />
evonik´s first product in this<br />
area. it represents hyaluronic<br />
acid with a very low molecular<br />
weight version of 50 kDa. Due<br />
to its strong skinpermeation<br />
properties, Hyacare® 50 has a<br />
pronounced bioactivity and can<br />
rejuvenate the skin by effectively<br />
strengthen dermalepidermal<br />
tight junctions (filling<br />
wrinkles from the inside).<br />
+++ PLEXIGLAS RESIST® AAA: new multi-skin sheets with anti-algae technology<br />
A spicandspan, transparent roof adorns the terrace, carport, or<br />
sunroom of many a home. Such roofs look all the more unsightly,<br />
however, if—like many surfaces exposed to the elements—they<br />
become overgrown by a greenishbrown film. Many people<br />
simply refer to it as „algae“. they then have to fetch a ladder and<br />
invest a lot of energy cleaning the roof. And that is no mean feat;<br />
after all, it is often difficult just to access such a roof.<br />
evonik has a far more convenient solution: a new multiskin<br />
sheet called PleXiGlAS reSiSt® AAA. this highquality,<br />
nextgeneration multiskin sheet is the<br />
world’s first plastic multiskin sheet featuring a nanotechbased<br />
antialgae design. this special coat ing<br />
takes advantage of the sun’s Uv radiation to essentially<br />
prevent algae, moss, pollen, and the like from<br />
adhering to the sheets. the next rainfall washes<br />
away virtually all of the remaining decomposed<br />
matter. And it goes without saying that this new<br />
highperformance innovation is entirely nontoxic<br />
and bioneutral.<br />
in addition, the new multiskin sheets also meet<br />
sophisticated expectations regarding design and co<br />
lor in construction: PleXiGlAS reSiSt® AAA is available not<br />
only in a clear version, but also white or in an elegant gray, too.<br />
And then there are the product benefits that PleXiGlAS reSiSt®<br />
has long been known for: excellent Uv resistance and weather<br />
resistance, for example. in fact, evonik issues a 30year warranty<br />
against yellowing for its transparent PleXiGlAS® products. At<br />
the end of the day, this range of properties grants homeowners a<br />
lot of spare time underneath a clean and durable roof.<br />
Relax instead of clean—thanks to new<br />
PLEXIGLAS RESIST® AAA multi-skin sheets<br />
16 elements32 evonik science newsletter
+++ nano+art competition – day and night in nanoworld<br />
elements32 evonik science newsletter<br />
news<br />
this year’s nano+art competition revolved around the theme of “Day” or “night,” and attracted eyecatching artwork from next<br />
generation women scientists who drew their inspiration from their own research. now in its fifth year, nano4women—an initiative<br />
sponsored by the German federal government—invited entries from female students, graduates, and young scientists working in the<br />
field of nanotechnology at universities, research institutes and other organizations in Germany and europe.<br />
Angler in the Moonlight by Anna reckmann of cologne, A Light Shining in the Darkness by Maryam Hadji Abouzar from<br />
Aachen, and Nano-grass Field by Aruna ivaturi of the University of cambridge were awarded the first three places, along with a<br />
total of € 1,750 in prize money from evonik industries.<br />
Besides evonik industries AG, partners throughout Germany in the joint project include the Helmholtz Association, the Hessennanotech<br />
Action line of the Hessian Ministry of economics, the Fraunhofer institute for Mechanics of Materials in Halle/Saale,<br />
Martin luther University of Hallewittenberg, and science2public Society for Science communications. the venue for this year‘s<br />
nano+art competition was the tecHnoSeUM in Mannheim, which is still showing a special exhibition called nano! nutzen und<br />
visionen einer neuen technologie (“nano! Uses and visions for a new technology”). the exhibition will run until october 3, 2010.<br />
third place, and a check for € 250, went to Aruna ivaturi of the nanoscience<br />
centre at the University of cambridge, for her Nano-grass Field. taken<br />
with a scanning electron microscope, the image is a crosssection of a nanograss<br />
field made of zinc oxide nanorods (60 nm average diameter and 1 μm<br />
average length), produced by a hydrothermal process based on a layer of<br />
zinc shoots.<br />
An intriguing picture that attracted the most attention<br />
on account of its composition, as the jury remarked.<br />
Angler in the Moonlight made Anna reckmann from<br />
cologne the winner of this year’s nano+art competition.<br />
She is delighted with the check for over € 1,000<br />
that she received from evonik. the awardwinning<br />
entry is a scanning electron microscope image of an<br />
organic fieldeffect transistor that was deposited on a<br />
polymer fiber. reckmann works and researches at<br />
the University of cologne’s institute for Physical<br />
chemistry in the field of surface coatings/nanoparticle<br />
synthesis.<br />
Maryam Hadji Abouzar, who studies the manufacture<br />
of nanostructures at the FH Aachen, was awarded<br />
second place, along with a check for over € 500.<br />
A Light Shining in the Darkness is a fluorescence<br />
microscopic image of DnA strands, 6 nm in size, that<br />
are marked with cy3 (fluorescent dye) and applied<br />
to a silanized Sio 2 surface. the composition of the<br />
DnAbased buffer solution prevents homogeneous<br />
immobilization.<br />
17
A D D i t i v e M A n U F A c t U r i n G<br />
Figure 1.<br />
The principle of additive<br />
manufacturing on the<br />
example of laser sintering,<br />
in which a laser is<br />
used to build parts layer<br />
by layer based on a<br />
computer model<br />
Digital Layer Construction<br />
SyLVIA MONSHEIMER<br />
Additive manufacturing holds untapped potential, particularly for low-volume<br />
production. extrusion and injection molding are not always the best way to<br />
mold plastics. An alternative is moldfree production, which combines maximum<br />
flexibility with high customer orientation and cost efficiency. with laser sintering,<br />
for example, it can produce complex and technically demanding industrial<br />
and consumer goods.<br />
M<br />
ost pathbreaking technologies are<br />
based on one simple and persuasive<br />
idea. The same is true of methods for<br />
mold-free production of parts—experts<br />
also refer to this as rapid manufacturing,<br />
rapid prototyping, additive manufacturing, and<br />
additive fabrication.<br />
These buzzwords are based on one principle:<br />
liquids, powders, strands and films are layered to<br />
build three-dimensional structures without the<br />
use of a mold. In the laser sintering process, which<br />
requires powdered starting material, containers<br />
are filled with fine metal, ceramic or plastic powder.<br />
A laser located above the powder bed, and<br />
precision-guided by CAD software and suit able<br />
optics, lights only certain areas of the uppermost<br />
particle layer. These areas melt and solidify after<br />
cooling. An automatic mechanism then low ers the<br />
Laser<br />
Roller Fabrication<br />
Powder delivery system<br />
powder bed<br />
Scanner system<br />
Laser scanning<br />
direction<br />
Sintered powder<br />
particles<br />
Object being fabricated<br />
Powder delivery piston Fabrication piston<br />
floor of the powder container by fractions of millimeters,<br />
and spreads a fresh layer of parti cles.<br />
Again, the laser lights this layer only in certain<br />
places (Fig. 1). The result of this method is a spatial<br />
component built of ultra-thin layers, whose<br />
complexity is limited by almost nothing but the<br />
specified electronic construction data.<br />
This free-form fabrication uses no casting<br />
molds, tools or space consuming production plants.<br />
Additive manufacturing (AM), therefore, is the<br />
counterpart to conventional methods, in which<br />
parts are molded into specified forms, for example,<br />
or cut from a massive block. With AM, components<br />
are created directly from a digital construction<br />
plan. This enables the production of forms that<br />
have been long considered impossible by con ventional<br />
series production—in fact, they can be created<br />
fast, flexibly, and with fewer machines. >>><br />
Laser beam<br />
Laser sintering<br />
Pre-placed powder bed<br />
Unsintered material in previous layers<br />
Source: Materialgeeza/Wikipedia<br />
18 elements32 evonik science newsletter
elements32 evonik science newsletter<br />
D e S i G n i n G w i t H P o l Y M e r S<br />
The FinGripper of Festo AG & Co. KG,<br />
Esslingen, which specializes in automation<br />
engineering. Produced by selective laser<br />
sintering, the FinGripper is light, flexible and<br />
adaptable. Like the human hand, it adjusts<br />
itself to the shape of the object to be gripped,<br />
KG<br />
which allows fast and safe handling of ripe<br />
Co.<br />
fruit, bulbs and pressure-sensitive foods.<br />
&<br />
The FinGripper is produced by applying layers<br />
AG<br />
of polyamide powder 0.1 millimeters thick<br />
on top of each other and selectively melting<br />
Festo<br />
them by laser. The result, after cooling, is a<br />
solid component Photo:<br />
19
Unmistakable:<br />
designer Dan yeffet<br />
used selective laser<br />
sintering to repro duce<br />
his fingerprints in<br />
the Detail.MGX light<br />
by Materialise N.V.<br />
Head quartered in<br />
Leuven, Belgium, the<br />
company specializes<br />
in rapid-proto typing<br />
technologies.<br />
<strong>Evonik</strong>‘s laser sintering<br />
plant in Marl<br />
The intake manifold for<br />
the <strong>Evonik</strong>-sponsored<br />
Lotus racing car (s. p. 6)<br />
was produced by laser<br />
sintering from polyamide<br />
12 powder. The geo m-<br />
etry of the intake manifold—a<br />
three-dimen -<br />
sional curved, ellip tical<br />
tube—cannot be pro-<br />
duced by conven tional<br />
metal processing<br />
methods or by injection<br />
molding<br />
This is why additive manufacturing is particularly<br />
common in prototype construction. Prototypes<br />
are essential for stressing and testing components,<br />
checking their fit and functionality,<br />
and—if necessary—optimizing these properties in<br />
a new prototype. When it comes to the processes<br />
used to create prototypes, gathered under the<br />
term “rapid prototyping,” the name says it all:<br />
first and foremost, prototypes must be built fast,<br />
with costs playing a secondary role.<br />
Cost-effective batch production<br />
But additive manufacturing can do more. The opportunity<br />
to analyze and optimize the product in<br />
the virtual stage prior to production, select from a<br />
wide range of materials, and design according to<br />
function means that parts can be not only designed<br />
and developed based on the individual<br />
needs of the customer but produced at lower cost.<br />
Because of the strong expansion in model diversity<br />
in the industry, the demand for adaptive tools<br />
and equipment has grown enormously. The use of<br />
handling robots is a good example: AM-generated<br />
20 elements32 evonik science newsletter<br />
Photo: .MGX by Materialis
grippers can easily adapt to objects of a wide variety<br />
of shapes, and make the gripping process efficient<br />
and flexible.<br />
Between prototype construction and mass production<br />
lies the increasingly important field of<br />
low-volume production. Many product requests<br />
are for relatively high but limited piece counts.<br />
For these products, conventional mass production<br />
with its costly molds and large plants is simply too<br />
expensive.<br />
The special strengths of additive manufacturing<br />
technology, therefore, are even more readily<br />
apparent when it comes to smaller piece counts<br />
(Fig. 2). A few examples of products manufactured<br />
in small batches include headlight housing<br />
for high-priced cars, steering components for vehicles<br />
driven from the right side, and housing for<br />
specialty machines. Not least, lightweight construction<br />
for airplanes and cars is a key sector for<br />
additive manufacturing. Lightweight construction<br />
is an undisputed construction principle in the<br />
trans portation industry, for example, where it is<br />
used to reduce fuel consumption and emissions.<br />
In addition to low-volume production, another<br />
field of application is individually modified components.<br />
Examples include not only medical devices<br />
such as hearing aids, implants or surgical instruments,<br />
and drill guides for operations, but<br />
also helmets and shoes for professional sports and<br />
respirator masks. Until AM technology, the high<br />
costs of creating a mold to produce a single component<br />
made such individual parts as these impossible.<br />
Variants are handled exclusively through<br />
software solutions—from the capture and processing<br />
of the individual data, to a single set of construction<br />
data for each part.<br />
The industry has now developed a whole host<br />
of variations of mold-free production: instead of<br />
solid particles, there are processes that run in<br />
liquid beds. Others work with strands that are<br />
stacked to form a part. The individual layer can be<br />
formed by spraying or pressing binding material<br />
or adhesives. All of these methods have one thing<br />
in common: they can execute even the most complex<br />
forms in a single operation. And they are<br />
flex ible. Without high equipment costs, the part<br />
can be modified and optimized by changing the<br />
spatial construction data until it meets customer<br />
and technical requirements precisely.<br />
New functionalities through<br />
custom-tailored plastics<br />
Thermoplastics are ideal for additive manufacturing:<br />
they are easy to pulverize, can be selectively<br />
melted, and their chemical and physical proper-<br />
elements32 evonik science newsletter<br />
D e S i G n i n G w i t H P o l Y M e r S<br />
Figure 2. Additive manufacturing technologies are significantly more economical<br />
for low-volume production than injection molding, which is cost-effective only<br />
for mass production, owing to the high cost of the mold. The minimum piece count<br />
required before injection molding begins offering cost advantages depends, among<br />
other things, on the size and complexity of the part to be produced and the mold<br />
Cost per unit<br />
Injection molding<br />
Figure 3. Comparison of the material properties of a standard polyamide and an ultraflexible<br />
polyamide specially developed for additive manufacturing<br />
mance Polymers Business Line, experts have spent<br />
roughly ten years developing thermoplastics for<br />
additive manufacturing.<br />
Converting from low-volume production to<br />
additive manufacturing increases the demands on<br />
the materials: aircraft construction requires polymers<br />
that can withstand extremely high temperatures,<br />
and are flame resistant. The sports and shoe<br />
industries need soft materials to manufacture<br />
components with high flexibility. For example,<br />
<strong>Evonik</strong> developed an ultra-flexible polyamide<br />
(PA) that has eight times the flexibility and five<br />
times the tensile strength of the standard material<br />
(Fig. 3). Another development, namely PEEK<br />
powder for laser sintering, stands out for its high<br />
melting point of 340 °C, which makes it suitable<br />
for parts exposed to high temperatures during<br />
operation. Optimized polymers like this enable<br />
new functionalities, while at the same time creating<br />
ways of replacing other materials, such as<br />
met als, with plastics.<br />
ties can be customized. In <strong>Evonik</strong>’s High Per for- >>><br />
Additive manufacturing<br />
Number of units<br />
Standard grade New flexible material<br />
E modulus 1,700 MPa 100–250 MPa<br />
(246,500 psi) (14,500–36,200 psi)<br />
Elongation at break 15 % >100 %<br />
Tensile strength 45 MPa 8 MPa<br />
(6,250 psi) (1,160 psi)<br />
Notched impact strength 3.5 KJ/m² No break<br />
Melting point 186 °C 150 °C<br />
(366 °F) (302 °F)<br />
Common refreshing rate 50 % Not necessary<br />
21
Produced in one piece by<br />
selective laser sintering:<br />
the Faltstuhl One_Shot<br />
.MGX of Materialise N.V.<br />
The chair is on display,<br />
among other places, at<br />
the Museum of Modern<br />
Art in New york<br />
Laser sintering enables layers<br />
only millimeters thick<br />
When it comes to polymers, additive manufacturing<br />
competes with extrusion and injection molding.<br />
One process that is particularly well suited to<br />
plastics is selective laser sintering (SLS), which<br />
can produce layers 0.15 mm thick. Far thinner layers<br />
(down to 0.08 mm) are also possible, although<br />
at this level the powder becomes hard to handle<br />
because interior forces of attraction prevent the<br />
tiny particles from trickling. While chemical flow<br />
aids can prevent adhesion, there is the risk that<br />
the thermal conductivity of the sintered layer will<br />
change at the edges, to the detriment of the process<br />
capability. “Laser sintering” is an historical<br />
term and somewhat misleading: it refers to a<br />
pressure-free process in which only a short processing<br />
time is required for each layer—just<br />
enough time for the areas that form the part to<br />
melt and form a closed melted film.<br />
With polymers, a CO 2 laser is used to directly<br />
stimulate the polymer chain without the need for<br />
an absorber. The speed of the laser is normally<br />
between 5 and 10 m/sec. Under these conditions,<br />
a component will “grow” two to three centimeters<br />
per hour. But a variety of components can be<br />
produced in the same layer almost without losing<br />
speed—the production area can be packed full of<br />
parts. Compared to other additive manufacturing<br />
technologies, powder-based laser sintering has the<br />
advantage that the powder bed around the component<br />
assumes the function of an all-round support—special<br />
supporting structures that hold projecting<br />
forms in position are unnecessary.<br />
Because not only the material itself but the<br />
production process influences the technical properties<br />
of a part, the parameters of AM products<br />
differ from those of injection-molded products.<br />
Comparative measurements show that the density<br />
and elongation of a part produced in layers are<br />
lower, and that the elastic modulus and tensile<br />
strength show higher values (Fig. 4).<br />
New demands through low-volume<br />
production<br />
In addition to new material properties, the use of<br />
laser sintering in low-volume production places<br />
even more demands on the laser sintering process.<br />
Reproducibility and reliability take on a<br />
whole new meaning: the entire quality assurance<br />
system must be ensured—something that played<br />
essentially no role in the creation of prototypes.<br />
Since last year, the Direct Manufacturing<br />
Research Center (DMRC) at the University of Pa derborn<br />
has worked on the challenge of making<br />
22 elements32 evonik science newsletter<br />
Photo: .MGX by Materialise
this transition from prototype production to serial<br />
(low-volume) production. The DMRC is the result<br />
of the merging of eight companies and research<br />
institutes, and receives financial support<br />
from the government of North Rhine-Westphalia.<br />
The four founding companies—<strong>Evonik</strong>, Boeing,<br />
EOS and MTT Technologies—will invest a total of<br />
€ 2 million in the DMRC over the five-year contract<br />
period. Since the opening of the DMRC in<br />
May 2009, the participating experts have focused<br />
mainly on practical questions, such as man aging<br />
the temperature of the machines being used or<br />
the long-term properties of sintered parts.<br />
While a good, substantive idea for a new technology<br />
can come into being quite suddenly, it may<br />
still have difficulty reaching the heads of key players.<br />
This is true in the case of additive manufacturing.<br />
Many universities teach the conditions for<br />
“freedom of design” and “function-driven design“<br />
inadequately, if at all. While engineers receive intensive<br />
training in conventional processes, they<br />
usually learn very little about freedom of design,<br />
which opens the door for them to additive manufacturing.<br />
Indeed, additive manufacturing is based<br />
on the idea of fundamentally different design,<br />
since the designer must think in terms of complete<br />
functionalities and not decoupled component<br />
parts.<br />
Standards as pathbreakers<br />
Lack of training at the universities is not the only<br />
hurdle. In the past, development, modification<br />
and use of mold-free production processes was<br />
quite unsystematic. This is why there are currently<br />
no standards to promote widespread use of the<br />
process and regulate evaluation of existing products.<br />
As a result, part testing yields different values<br />
for elasticity module, tensile strength and elongation,<br />
for example, depending on the set of param<br />
eters used (Fig. 5). Both the ISO and ASTM,<br />
however, are working on developing the first<br />
standards for laser sintering. ISO 27547-1 is already<br />
in force for the production of test bodies. VDI is<br />
also drafting guidelines.<br />
Despite the hurdles and unanswered questions<br />
that still exist, the importance of AM will grow<br />
appreciably over the next ten years. The advantages<br />
outweigh these problems: developers can<br />
produce functional hollow structures in small<br />
batches, and the structures can be precisely modified<br />
to changing stress requirements. The components<br />
can be customized with specific porosities<br />
or surfaces, and ultra-lightweight components are<br />
also possible. Here, the airline industry is one of<br />
the pioneers. There are already about 30 SLSsintered<br />
components installed in the Boeing 787.<br />
elements32 evonik science newsletter<br />
D e S i G n i n G w i t H P o l Y M e r S<br />
Figure 4. Comparison of the technical properties of a part produced by<br />
laser sintering and one produced by injection molding<br />
Test method Laser sintered Injection molded<br />
test bar test bar<br />
Density g/cm³ DIN 53479 0.95 1.04<br />
E modulus MPa DIN 53457 1,700 1,400<br />
Tensile strength MPa DIN 53455 48 46<br />
Elongation % DIN 53455 18 >50<br />
Figure 5. Depending on the parameter set, tests on the same part can yield differing<br />
values and make evaluation more difficult. Standards should improve this situation<br />
Test method Parameter Parameter Parameter<br />
set 1 set 2 set 1,<br />
upright built<br />
Density g/cm³ 0.91 0.9 0.91<br />
Modulus of elasticity MPa DIN 53457 1,872 1,920 1,921<br />
Tensile strength MPa DIN 53455 49 48 49<br />
Elongation % DIN 53455 18,2 8,4 7<br />
According to estimates by Airbus <strong>Industries</strong>, an<br />
aircraft produced entirely through additive manufacturing<br />
would be 30 percent lighter and 60 percent<br />
more cost-effective than current machines.<br />
Resources and energy efficiency—combined<br />
with economical production—are the central challenges<br />
of the future for Germany, if it intends to<br />
remain competitive in a fast-changing world. In<br />
the past, it was often the work of people that think<br />
outside the box and therefore helped breathe life<br />
into a new technology. They also play a role in additive<br />
manufacturing. One thing is certain: sooner<br />
or later, additive manufacturing technologies will<br />
become key players in placing advanced industrial<br />
production on a cost- and resource-efficient footing.<br />
l<br />
SyLVIA MONSHEIMER<br />
Born in 1965<br />
Sylvia Monsheimer is responsible for<br />
global market development of additive<br />
manufacturing for evonik’s High<br />
Performance Polymers Business line.<br />
Previously, she managed the business<br />
line’s Strategic innovation Projects department.<br />
Monsheim came to evonik<br />
in 1989 after receiving her degree in<br />
construction engineering. Since then,<br />
she has held a wide variety of positions<br />
in application engineering for high performance polymers. Her<br />
more than tenyear focus on powder development and application<br />
engineering for selective laser sintering and other toolfree processes<br />
is a hallmark of her work at High Performance Polymers.<br />
+49 2365 49-5911, sylvia.monsheimer@evonik.com<br />
23
twentyseven evonik employees currently teach at German universities<br />
committed to young Talent<br />
Engineers and chemists have only heard of the jampacked<br />
lecture halls that plague so many business management,<br />
law, or German studies students in Germany. But even if<br />
they have little trouble finding a laboratory internship or a<br />
topic for their final paper, so many realize in hindsight that they<br />
did not always have such a great advantage after all—as when<br />
they take their first steps in industrial research and find out that<br />
not every thing they do in the laboratory can be transferred to the<br />
industrial scale. indeed, compared to subjects requiring master’s<br />
and doctoral theses, industrial engineering moves within a complex<br />
interplay of innovation, profitability, sustainability, administrative<br />
regulations, and standards.<br />
“Graduates are experts in the subject area of their final paper,<br />
but they lack the ability to spot economically attractive processes,“<br />
observed Prof. karlheinz Drauz. Drauz is familiar with both sides:<br />
of the 30 years he has worked for evonik, he has spent the last<br />
22 years also teaching industrial chemistry at the University of<br />
würzburg, and as an honorary professor for 18 of those years. He<br />
is one of 27 evonik employ ees who lecture at German universities<br />
in addition to work ing for evonik. Dr. Manfred nagel, who works<br />
in evonik’s Process technology & engineering unit, also holds a<br />
teaching position. the 44yearold engineer has taught process<br />
technology at kit—the karlsruhe institute of technology—<br />
for three years, and still remembers his own days as a student:<br />
„i didn‘t have a sense of the practical relevance of my major back<br />
then either,“ he says. “Students today are unbelievably open to<br />
new ideas, flexible and determined, but they have a very fuzzy<br />
picture of what an engineer actually does every day.”<br />
Bring that picture into sharp focus is what evonik want to do.<br />
while Drauz, for example, teaches organic chemistry, he covers not<br />
only technical synthesis of active substances, biotechnology and<br />
vitamin production, but also chemical substance law, chemical marketing,<br />
and disposal. He has also hired business administration professors<br />
to give the students some insight into the business tools of<br />
an industrial chemist. “it takes money to do this, naturally, and<br />
evonik has generously shouldered the costs,” he says. “excursions<br />
to various evonik production sites round out the course.“<br />
Process engineering at evonik, the traditional point of entry<br />
into the Group for engineers, also emphasizes a practical orientation.<br />
together with his colleague Prof. Herbert riemenschneider,<br />
nagel holds a series of lectures every year that ends with a daylong<br />
excursion for students to evonik‘s site in Hanau. the program<br />
includes tours of pilot plants, production plants, project<br />
hous es, and virtual chemical plants. Students also have the opportunity<br />
to talk to experienced engineers, and finally, discuss career<br />
possibilities with company representatives. “that goes down extremely<br />
well, because the students want to know what makes a<br />
company tick,“ says nagel. “An onsite visit lets them see not only<br />
how multifaceted engineering is as a career, but also that, in addition<br />
to technical expertise, social skills, and teamwork skills are<br />
also important.”<br />
Such commitment also conveys trust: over the years, Drauz<br />
assisted a great many students who needed advice—on postgraduate<br />
studies, study abroad, job applications, stipends, or opportunities<br />
for women in the industry. this is timeconsuming, but the<br />
dual burden from teaching at the university and working in the<br />
com pany was never a problem. “the company supported me in<br />
every way,” stresses Drauz. And it got a few things in return for<br />
that support. “over the years, you get to know which students are<br />
really good,“ says Drauz, who assisted a number of students over<br />
several semesters. “And, naturally, these are the ones you recruit<br />
for the com pany.” So several outstanding university graduates<br />
have found their way from würzburg to the company and made<br />
careers there.<br />
the subject means a lot to nagel as well. “evonik is one of the<br />
top employers for chemical and process engineers,” he explains.<br />
“we sustain this reputation by actively cultivating our network<br />
and establishing contacts with young talent.” the kit is an ideal<br />
institution for this. with some 8,000 employees, it is the largest<br />
research institute in Germany, and one of the largest worldwide.<br />
„it houses not only excellent researchers but excellent facilities.<br />
this is why it attracts so many gifted researchers from inside and<br />
outside Germany,“ says nagel. “And like any other company, we<br />
are look ing for the best.”<br />
Part of networking is making contact with university colleagues,<br />
and Drauz has been able to persuade a great many of<br />
the appeal of industrial chemistry: “Professors come to hear my<br />
lec tures too, because as an industrial chemist, i have the kind of<br />
experience they understandably lack. Some of them have even<br />
included the contents of my lectures in their examinations.” the<br />
atmosphere of the university, and contact with young chemists<br />
trying to find their way is something he does not want to miss. So<br />
even though he will retire as of August 31, he plans to continue<br />
teaching for the next few years. “i think it‘s important to know<br />
how today‘s young people think, and to interact with them,“ says<br />
Drauz, father of two grown sons, who are also students. „And i<br />
want to convey the fasci nation that natural sciences hold, even for<br />
industrial researchers,“ he adds. “it’s enriching—professionally,<br />
but also personally,“ says nagel. l<br />
Dr. Wolfgang Nagel<br />
teaches process engineering<br />
at KIT (Karlsruhe<br />
Institute of Technology)<br />
24 elements32 evonik science newsletter
University<br />
FH Aachen<br />
University of<br />
Bochum<br />
FH Darmstadt<br />
tU Darmstadt<br />
tU Dortmund<br />
tU Dresden<br />
University of<br />
erlangennuremberg<br />
FH Frankfurt<br />
University of<br />
Hanover<br />
University of<br />
Hohenheim<br />
kit*<br />
karlsruhe<br />
University of<br />
kassel<br />
University of<br />
Magdeburg<br />
University of<br />
Munster<br />
FH Munster/<br />
Steinfurt<br />
University of<br />
Siegen<br />
University of<br />
Stuttgart<br />
University of<br />
würzburg<br />
1<br />
2 theoretical chemistry<br />
3 technical chemistry/process science<br />
4 industrial property protection for engineers<br />
5<br />
6<br />
7 industrial chemistry<br />
8<br />
9<br />
10<br />
11<br />
12 Material and nanochemistry<br />
13 industrial inorganic chemistry<br />
14<br />
15 Process engineering<br />
16 Process engineering<br />
17 Power engineering<br />
18<br />
19 Macromolecular chemistry<br />
20 Patent information<br />
21 chemical law, reAcH<br />
22 Process technology/industrial crystallization<br />
23 chemical/environmental engineering,<br />
plant engineering<br />
24 industrial inorganic chemistry<br />
25<br />
26<br />
* karlsruhe institute of technology<br />
Subject or teaching position<br />
27 industrial organic chemistry<br />
elements32 evonik science newsletter<br />
Applied polymer sciences/<br />
industrial aspects of polymer technology<br />
civil engineering/<br />
building services engineering<br />
Plastics technology as part of the<br />
Master’s program in polymer sciences<br />
Plastics processing and special problems in<br />
plastics technology<br />
Plastics technology/<br />
plastics and the environment<br />
Process technology/mechanical and<br />
pipeline engineering<br />
Process technology/process and plant design<br />
institute of Plant Production and Agroecology<br />
in the tropics and Subtropics; pesticides<br />
Process technology/micro process<br />
engineering<br />
industrial organic chemistry and industrial<br />
biotechnology<br />
Process engineering<br />
Prof. Karlheinz Drauz retires<br />
U n i v e r S i t i e S<br />
Prof. karlheinz Drauz, 60, will<br />
retire as of August 31, 2010.<br />
Drauz has held various positions in<br />
evonik‘s chemicals Business Area<br />
for the last thirty years, the most<br />
recent being vice president of<br />
international Scientific relations in<br />
the in novation Management<br />
chemicals & creavis unit. in this role, he evaluated the international<br />
university landscape for topics of interest to<br />
evonik, reinforced existing ties to technology centers, research<br />
institutes, and universities, and made contact with<br />
potential new partners. eastern europe and Asia have been<br />
a primary focus.<br />
During this time, he built a database that not only maps<br />
evonik‘s partnerships but also contains information on attractive<br />
potential partners. the database stores more than 5,000<br />
university and company contacts, covering a broad spectrum<br />
of topics—from material sciences, through sustainable raw<br />
materials, to energy generation and storage. “i saw my task<br />
as paving the way for partnerships for the operative divisions,“<br />
says Drauz. “the database, which is accessible to all<br />
evonik units, has now proven itself a key tool in the search<br />
for partners.“ Drauz also established a scientific advisory<br />
board for evonik in china, whose members include three of<br />
china’s most renowned scientists: Prof. Pingkai ouyand<br />
(president of nanjing University of technology), Prof.<br />
charles c. Han (director of the Joint lab of Polymer Science<br />
and Materials) and Prof. Sishen Xie (head of the national<br />
center for nanosciences and nanotechnology).<br />
Drauz, who earned his doctorate in chemistry at the<br />
tech nical University of Stuttgart, began his career at evonik<br />
in 1980 as laboratory director for r&D in amino acids at<br />
Hanauwolfgang. in 1994 he accepted a position as head of<br />
global r&D at Fine chemicals, where he was also responsible<br />
for active pharmaceutical ingredients and building blocks<br />
pro duction at the wolfgang site. He became head of the<br />
tech nology and research Management department in Fine<br />
chemicals in early 2002 before accepting the position of<br />
chief technology officer in the former exclusive Synthesis &<br />
catalysts Business Unit end of 2003. His scientific activities<br />
focused on the synthesis of amino acids, peptides and biologically<br />
active compounds, asymmetrical synthesis, metal<br />
catalysis, and biocatalysis, and process development. He has<br />
shared in 160 patents and patent applications, and has published<br />
articles in 95 scientific publications. Drauz has also<br />
been an honorary professor of organic chemistry at the University<br />
of würzburg since 1992.<br />
25
H o t S t A M P i n G<br />
it‘s a Safe Bet you‘ll be Noticed<br />
with its binder DeGAlAn®, evonik industries has made it more difficult to counterfeit the euro,<br />
protects soccer fans from tricksters, and adds a quality touch to packaging. Because in an age<br />
when one product can readily replace another, appearance means a great deal more than it ever<br />
did before. if packaging or labels didn’t have their allure, today’s cosmetics, alcoholic beverages,<br />
and sweets would hardly stand out in the crowd.<br />
Creating additional appeal for products and packaging<br />
is quite the trend—for brand-name and noname<br />
products alike. In economically challenging<br />
times, it’s particularly important to offer products<br />
that are clearly distinguishable from the rest. Consumer<br />
attention is a scarce and precious good. It’s vital, therefore,<br />
for bottles, flacons, and other forms of packaging to feature<br />
sophisticated designs that attract people’s attention. <strong>Evonik</strong>’s<br />
expertise helps make products stand out in the crowd.<br />
DEGALAN® is a methacrylate-based raw material used in<br />
coatings. Marketed by the Coatings & Additives Business<br />
Unit, DEGALAN® binder is added to coatings and inks to<br />
achieve the desired effects on printed labels and packaging.<br />
So how does a strikingly designed label actually end up<br />
on a bottle of wine? How is lacy lettering printed on a box<br />
of chocolates, or a gold cosmetic logo to an eyeliner stick?<br />
The answer is by a process called hot stamping, which is a<br />
special printing process. It involves first applying a negative<br />
image to a polyester foil by means of multiple layers of a<br />
coating, one on top of the other. For that image to be applied<br />
to the product, the foil containing the layers is rotated by 180<br />
degrees and then pressed onto the box, stick, or bottle with<br />
a great deal of pressure and heat.<br />
The combination of heat, pressure, and<br />
the final adhesive layer on top of the<br />
others detaches the coating system<br />
from the foil and attaches it<br />
to the intended surface.<br />
The coat ing system<br />
includes the design<br />
layer,<br />
often an additional layer of metal and a protective coating.<br />
The adhesive ensures that the package sticks to the product<br />
surface. A release layer embedded between the foil and the<br />
coating helps to ensure that the polyester carrier foil and the<br />
print layers can be peeled apart cleanly.<br />
The great advantage of this method is that the various<br />
layers can be printed on top of one another in a single-step<br />
process. The special color effects, metallic effects, and hologram<br />
imprints created in this way could not be produced<br />
by applying multiple layers directly to a product surface.<br />
“Unlike offset or digital printing,” explains Andreas Olschews<br />
ki, global technical sales manager at <strong>Evonik</strong>’s Coatings<br />
& Additives Business Unit, “this process allows for a<br />
much broader spectrum of technologies, particularly for<br />
products featuring high-end designs, exceptionally frag-<br />
mented images, or designs with a metallic sheen.”<br />
The results are impressive: The images produced are extremely<br />
sharp and they are finely and clearly contoured.<br />
DEGALAN® makes that possible. Because it is used as a cobin<br />
der in the individual layers of the coating, it creates a<br />
sharply contoured image and the color of that image is endowed<br />
with added brilliance. Depending on the binders<br />
used, however, it can do even more. This raw material improves<br />
the film hardness of the protective coatings, making<br />
them more resistant to high stamping temperatures. It can<br />
also enhance the degree of adhesiveness of the image to the<br />
target surface.<br />
“This product,” says Olschewski, “has carved out an incredibly<br />
successful market niche for itself. A lot of manufacturers<br />
like using DEGALAN® binders because they always<br />
produce excellent results.” <strong>Evonik</strong>’s customers include globally<br />
operating businesses that provide hot-stamping technology.<br />
The application spectrum is immense. Hot stamping<br />
To protect banknotes against counterfeiting,<br />
euro bills feature holograms that are difficult to<br />
reproduce. These holograms are made using<br />
the hot-stamping method, and <strong>Evonik</strong> supplies<br />
DEGALAN® for use in that process<br />
elements32 evonik science newsletter
Hot stamping involves a process in which a negative image consisting of<br />
multiple layers of lacquer (one on top of the other) is applied to a foil.<br />
The coated foil is then turned around and pressed onto the desired product<br />
with a great deal of pressure and heat. Thanks to the adhesive layer,<br />
the lacquer package detaches from the foil and adheres to the intended<br />
surface<br />
Carrier foil (is peeled off)<br />
foils are used in the graphics industry, of course, but also in<br />
the wood-processing and furniture-making industries.<br />
DEGALAN® can help to create an incredibly realistic rootwood<br />
design, for example, such as is used on the center consoles<br />
in automobiles.<br />
Ensuring that originals stay originals<br />
This printing method serves not only to produce particularly<br />
handsome and detailed designs; it also gives products effective<br />
protection against counterfeiting. An example is the<br />
hologram on the euro bills that represents one of the security<br />
features. Tilt the note to a certain angle and what you see<br />
on the film strip is the nominal value of the note, plus the<br />
euro symbol, against a rainbow-colored background. This<br />
hologram allows to check the authenticity of the notes. It,<br />
too, is produced using the hot-stamping method.<br />
Hence, DEGALAN® is found in paper currencies, bank<br />
and credit cards, ID cards, and other documents. These<br />
shiny images also feature on admission tickets for concerts<br />
or sporting events. Just about everyone carries them around.<br />
Because they are highly counterfeit-proof and to this day<br />
non-reproducible, holograms are increasingly used to provide<br />
protection against brand and product piracy. The trafficking<br />
of fake and imitation products has now taken on an<br />
elements32 evonik science newsletter<br />
Release layer<br />
Top lacquer layer<br />
Design layer<br />
Adhesive layer<br />
Lacquer package<br />
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<br />
Admission tickets for, say, a soccer match are particularly susceptible<br />
to reproduction and counterfeiting. Holograms on the tickets in the form<br />
of hot-stamped security foil make them forgery-proof<br />
economic dimension that should not be underestimated.<br />
This fact is reflected in significant losses in profit and puts a<br />
serious strain on the economy.<br />
Fakes are often times not discernible at first glance if the<br />
packaging they come in has been really well reproduced.<br />
Hot-steaming foils are used to print optical authenticity and<br />
security features such as holograms on products. These holograms<br />
have highly specific features; they are extremely<br />
complex and difficult to copy. And so DEGALAN® is offering<br />
a hand in protecting brands and products in that it makes it<br />
possible for customers to distinguish between genuine and<br />
fake goods. l<br />
ANDREAS OLSCHEWSKI<br />
Andreas olschewski spent several<br />
years as a global technical service<br />
manager in evonik’s coatings &<br />
Additives Business Unit, working as<br />
a technical adviser for Acrylic resins.<br />
After an apprenticeship as a coating<br />
technician, he received his engineering<br />
degree from the University of<br />
Applied Science for Print and Media<br />
technology in Stuttgart, specializing<br />
in paints and coatings. He began<br />
his professional career in the Applied technology, Acrylic resins<br />
department at evonik röhm GmbH in 1980.<br />
+49 6151 18-4784, andreas.olschewski@evonik.com<br />
27
P e r c A r B o n A t e<br />
the Eco-friendly Bleach for Growth<br />
DR. STEFAN LEININGER<br />
The profession of soap boiler, a person<br />
who made soaps out of animal fat and<br />
ashes to use for cleaning purposes, developed<br />
in Central and Southern Europe<br />
around the beginning of the 4th century. Back<br />
then, doing the laundry was hard work: dirt had<br />
to be removed by rubbing or beating the articles.<br />
For stubborn stains, the laundress used „grass<br />
bleach,“ which involved spreading the damp<br />
laundry out on the grass. The chemical interaction<br />
between the moisture, sunlight and the<br />
chlorophyll in the plants forms active oxygen<br />
and ozone, which have an oxidizing and bleaching<br />
effect.<br />
The discovery of sodium perborate tetrahydrate<br />
(NaBO 3*4H 2O) in 1898 and the subsequent<br />
development work by Otto Liebknecht at the former<br />
Degussa marks the beginning of the development<br />
of modern detergents. The company<br />
brought the first unblended powdered sodium<br />
perborate onto the market as a laundry detergent<br />
in 1904. Even considering the predictability of the<br />
product’s commercial success, detergent manu-<br />
28 elements32 evonik science newsletter
Markets<br />
elements32 evonik science newsletter<br />
Grass bleach: when<br />
damp laundry is spread<br />
out on grass, the<br />
moisture, sunlight and<br />
chlorophyll create active<br />
oxygen and ozone,<br />
which have an oxidizing<br />
and bleaching effect<br />
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<br />
energy crises and resource depletion, consumer<br />
habits and environmental protection<br />
drive researchers and developers to ever<br />
greater achievements and improved products,<br />
and the detergents market is no different.<br />
the trendsetter is a granulated<br />
percarbonate from evonik with especially<br />
high stability. Because of its ecotoxicolo gical<br />
superiority, percarbonate has already<br />
largely replaced expensive perborate as<br />
the bleaching component in detergents on<br />
the european market. it has thus secured<br />
the market leadership of detergent manufacturers<br />
in europe and is also paving the<br />
way for a secure and successful entry into<br />
the growth markets.<br />
facturer Henkel rocketed to prominence quite<br />
suddenly. Henkel launched the first “self-acting”<br />
laundry detergent under the trade name Persil®<br />
on June 6, 1907, thereby rendering grass bleach<br />
obsolete. In addition to 15 percent perborate by<br />
weight as its main ingredient, Persil® also contained<br />
85 percent silicate-based bleaching soda by<br />
Henkel. Laundry boiled just once in Persil® became<br />
clean and hygienic without the need for<br />
rubbing or a separate bleaching step.<br />
Whereas, in the early years, sodium perbo rate<br />
tetrahydrate was produced by reacting electrochemically<br />
generated sodium peroxide with boric<br />
acid, a direct electrolysis process based on aqueous<br />
borate solution developed at the Rheinfelden<br />
works supplied the rising demand beginning in<br />
1920. With the increased availability of hydrogen<br />
peroxide—produced in Weißenstein (Austria) from<br />
1910, and electrochemically via peroxodisulphuric<br />
acid at Rheinfelden beginning in 1928—production<br />
gradually shifted to the process of reacting sodium<br />
metaborate with hydrogen peroxide, which is<br />
used to this day. >>><br />
29
Bleaches with perborate and percarbonate<br />
Comparison between normal and activated bleaches<br />
Remission [%] = Bleaching action<br />
30<br />
25<br />
20<br />
15<br />
10<br />
5<br />
0<br />
HO<br />
HO<br />
O O<br />
B B<br />
O O<br />
Tea, coffee, ...<br />
Activation<br />
OH<br />
OH<br />
2 –<br />
2 Na +<br />
Activation systems for laundry detergents<br />
or Na 2CO 3 • 1.5 H 2O 2<br />
H 2O<br />
H 2O 2 + OH – HOO – + H 2O<br />
0 20 40 60 80<br />
Bleaching activation<br />
Persalt<br />
Percarbonate<br />
or perborate<br />
R<br />
X<br />
O<br />
Temperature [°C]<br />
Oxidized stain<br />
Example: TAED activation<br />
Persalt<br />
OOH –<br />
H 2O / OH –<br />
TAED<br />
Peracetic acid<br />
H 2O 2 + OH – HOO – + H 2O<br />
Activators<br />
• TAED, NOBS<br />
• Ester, amide<br />
• Nitril(quat)<br />
H<br />
O<br />
Washing solution<br />
Catalysts<br />
• Enzyme/mediator<br />
• Metal complex<br />
• O carrier<br />
In-situ peracid (X=O, NH) Bleaches<br />
Activated species<br />
O<br />
M<br />
Modern all-purpose laundry detergent—<br />
clean, pure and fragrant<br />
All-purpose laundry detergent is always “a child<br />
of its time.” Laundry habits, consumer behavior,<br />
re gulations and environmental protection have<br />
always influenced the development of new and advanced<br />
ingredients and formulations. But the principles<br />
of wash performance have never chang ed:<br />
mechanical forces, thermal energy and chemical<br />
reactions do a really good job against dirt and<br />
body oils on laundry. And for over 100 years, the<br />
role of bleach in that success has remained unchanged.<br />
Perfumes, the final ingredients in the<br />
mix, reinforce the impression of cleanness.<br />
“Self-acting” laundry detergents were a hit<br />
from the start, and as purchasing power increased<br />
and drum-type washing machines became available<br />
during the years of the German Economic<br />
Miracle, almost all classes of Germans could now<br />
afford them. But with the steady rise in laundry<br />
detergent sales came a gradual increase in environmental<br />
pollution. The use of phosphate-based<br />
softening systems in laundry detergents caused<br />
eutrophication, an unwanted increase in the chemical<br />
nutrients of bodies of water that generates<br />
excessive plant growth. In the 1980s, this phenomenon<br />
led to increased environmental awareness<br />
and, ultimately, a ban on phosphate-based laundry<br />
detergents in Europe. Today’s laundry detergents<br />
contain either zeolites, polyacrylates or softener<br />
systems based on sustainable raw materials (for<br />
example, citrates, aspartates) to prevent formation<br />
of lime soaps.<br />
The interaction between mechanical energy<br />
(the rotation of the machine’s drum), the temperature<br />
in the washing solution, and the chemical<br />
action of the surfactants control the actual process<br />
for removing dirt and body oils. Surfactants also<br />
hold the dirt and fat particles suspended in the<br />
wash water. The less water today’s water-saving<br />
washing machines use, the more dispersants the<br />
laundry detergent has to provide to prevent the<br />
dirt particles in the concentrated solutions from<br />
settling back on the fibers and turning the laundry<br />
grey.<br />
In their fight against a variety of different<br />
stains, surfactants receive help from enzymes and<br />
bleaches. Enzymes are proteins that convert only<br />
certain organic substances by catalytic action, and<br />
can split into smaller components. Proteases, for<br />
example, are used to fight protein stains, lipases<br />
take on grease, and carbohydrases battle starchy<br />
soiling.<br />
Because an increasing number of foods are<br />
pro duced with non-digestible polysaccharides<br />
(for example, low-calorie products), more expen-<br />
30 elements32 evonik science newsletter
sive advanced all-purpose laundry detergents also<br />
contain enzymes such as mannanases to remove<br />
these stubborn „lifestyle“ stains. Cellulases, on the<br />
other hand, make cotton clothing look clean and<br />
new by removing protruding fibers (microfibriles),<br />
and thereby preventing the graying caused by dirt<br />
deposits on these small fibers.<br />
Bleaches like perborate and percarbonate, on<br />
the other hand, are active against other stains<br />
caused by such foods as tea, coffee, fruits or vegetables.<br />
When dissolved in water, these peroxybased<br />
substances release hydrogen peroxide,<br />
which develops its bleaching power at high temperatures<br />
directly through its perhydroxyl anion,<br />
or at low temperatures by forming singlet oxygen<br />
in the presence of activators. The cleaning action<br />
of these bleaches involves not only oxidation of<br />
the chromophoric conjugated double bonds in<br />
dye molecules (chromophores) but the splitting<br />
of the molecules into smaller components. In most<br />
cases, stains altered in this way are then easier<br />
for surfactants to dissolve and remove from the<br />
fibers.<br />
In addition to its stain-removing properties,<br />
the active components generated from the persalts<br />
in the washing process also display biocidic<br />
properties that kill bacteria, pathogenic germs<br />
and fungal spores. Laundry is not only clean after<br />
being washed with all-purpose laundry detergent,<br />
it is pure (free from germs).<br />
Another ingredient of many all-purpose detergents<br />
is fragrance in the form of various and<br />
sometimes distinctive perfume oils. Worldwide,<br />
fragrance preferences differ widely. While detergents<br />
in Germany contain little to no perfume,<br />
fragrance components are quite substantial in<br />
the United States and Japan, where a stronger<br />
fragrance suggests cleanliness and freshness.<br />
Be cause of the high allergenic potential of many<br />
perfumes, however, an increasing number of products<br />
with reduced or no perfume oils can be found<br />
on supermarket shelves.<br />
Washing can be cool<br />
Because hydrogen peroxide is fully effective only<br />
at 95° C (boil wash), a temperature most fabric<br />
items sold today cannot tolerate, all-purpose<br />
laundry detergents in Europe have also contained<br />
bleach activators like tetraacetylethylene diamine<br />
(TAED), since the 1970s. In the washing machine,<br />
TAED reacts with the hydrogen peroxide released<br />
from the bleach to form peracetic acid under perhydrolysis.<br />
Because TAED reaches its full bleaching<br />
power at 40 to 60° C, laundry can be made<br />
clean and sanitary even at lower temperatures.<br />
This cuts energy costs significantly. In the<br />
elements32 evonik science newsletter<br />
>>><br />
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<br />
Laundry tips<br />
White stripes on the laundry items<br />
normally residue from the laundry detergent or softeners<br />
(zeolites) on the fibers that forms when, for example, too<br />
much powdered detergent is used or the washing machine<br />
is overloaded. Follow measuring instructions and make sure<br />
to fill the machine so that there is a hand‘s breadth between<br />
the laundry and drum. the residue can be removed easily by<br />
gently beating the articles.<br />
Machine and laundry items have an unpleasant odor<br />
caused by bacteria, especially when you routinely use liquid<br />
laundry detergent. once a month, wash at 60 °c (140 °F)<br />
with an allpurpose detergent or use stain remover regularly.<br />
Saving energy and water<br />
Always fill the machine to capacity. two halffilled machines<br />
use more energy and water than one fully loaded machine.<br />
Saving energy<br />
wash temperatures of 30–40 °c (86–104 °F) are sufficient<br />
in most cases. At these temperatures, an allpurpose laundry<br />
detergent will usually get even towels, bed linens and underwear<br />
hygienically clean. laundry will become absolutely<br />
germfree—in the case of infectious diseases, for example—<br />
when washed at 60 °c with a suitable allpurpose laundry<br />
detergent.<br />
Saving water<br />
Do not use the prewash cycle. with an allpurpose laundry<br />
detergent, the main wash cycle will get normally soiled<br />
laundry clean, and you will save up to 19 liters (about 5 gallons)<br />
of water.<br />
31
Still common practice in developing<br />
countries: washing by hand. But<br />
growing prosperity is making washing<br />
machines and automatic laundry<br />
detergents more affordable<br />
United States, the activator of choice is nonanoyloxybenzolsulfonate,<br />
NOBS, which forms pernonanic<br />
acid with hydrogen peroxide.<br />
TAED and NOBS are only partially effective<br />
below 30° C because the corresponding peracids<br />
are not as reactive under these conditions. As a<br />
result, countries that have traditionally used primarily<br />
cold water to do laundry, such as the United<br />
States, Japan and a few countries in Southern<br />
Europe, tend to use hypochlorite as their bleaching<br />
agent. This is why the chlorine released as a byproduct<br />
is also associated with hygiene and cleanliness<br />
in the United States.<br />
Laundry detergent markets in flux<br />
The laundry detergent market is subject to continual<br />
change. While the environmental movement<br />
of the 1980s, for example, spurred a trend<br />
toward compact laundry detergents and concentrates,<br />
as well as a ban on phosphate-based detergents<br />
in Europe, today’s changing demographics<br />
are lowering sales figures and increasing competition<br />
in Europe’s all-purpose laundry detergent<br />
market. With the number of households of individuals<br />
and households made up of senior citizens<br />
being on the rise and the number of households<br />
with children being on the drop, a clear trend toward<br />
more synthetic fibers and delicate clothing<br />
but less stained and dirty laundry is seen.<br />
Over the past ten years, this trend has resulted<br />
in a significant shift in market shares in favor of<br />
liquid laundry detergent over conventional powdered<br />
laundry detergents. This trend appears to<br />
have stopped, however, since liquid laundry detergents<br />
are reaching their limits (see info box on<br />
liquid laundry detergents). To offset the limited<br />
cleaning power of liquid laundry detergents, detergent<br />
manufacturers have now brought an array<br />
of bleaches and stain removers onto the market.<br />
Traditional laundry habits are changing, however—not<br />
just in Europe but worldwide. Unlike<br />
Europe, the developing countries are faster-growing<br />
markets, since greater prosperity and purchasing<br />
power also means closets filled with more<br />
clothes. And more clothes means increased sales<br />
of washing machines and automatic laundry detergents.<br />
In developed countries like the United<br />
States and Japan, growing environmental awareness<br />
is increasing consumers’ willingness to buy<br />
European washing machines (front loaders), which<br />
are more energy-efficient and watersav ing than the<br />
technically and mechanically less complex Amer i -<br />
can washing machines (top load ers). At the same<br />
time, demand for low-foaming European all-purpose<br />
laundry detergents designed specifically for<br />
these machines is also on the rise.<br />
32 elements32 evonik science newsletter
Perborate – a star fades<br />
Perborate was the bleaching component of Eu -<br />
ro pe‘s all-purpose laundry detergents for nearly<br />
100 years, and has been gradually replaced by<br />
percarbonate only in the last decade. In countries<br />
with high humidity and dramatic temperature<br />
fluctuations, perborate is still used in laundry detergents<br />
because of its chemical stability. Uncoated<br />
and thus less stable percarbonate was historically<br />
used mainly as a stain remover for pretreatment<br />
purposes or an additive for the main wash cycle.<br />
Changes in the raw materials market and more<br />
recent eco-toxicological evaluations, however,<br />
have resulted in increased use of percarbonate as<br />
a replacement for perborate in the laundry detergents<br />
of regions with difficult climates. Because<br />
Borax is mined only in China, Turkey and the<br />
United States, the construction boom in China and<br />
the Middle East has led to a severe shortage of the<br />
raw material. Limited supply and a sharp rise in<br />
demand have pushed the price of borates so high<br />
that perborates are now significantly more expensive<br />
than percarbonate.<br />
Percarbonate – an unstable powerhouse<br />
In Europe, laundry detergent manufacturers successfully<br />
completed the gradual transition to percarbonate<br />
about ten years ago. Demanding climates,<br />
such as those in Central and South America,<br />
Africa and the Middle East, however, can quickly<br />
diminish the bleaching power of laundry detergents<br />
formulated with percarbonate. Moreover,<br />
percarbonate‘s greater sensitivity to humidity raises<br />
its risk potential, which is further exacer bated by<br />
the heightened safety requirements dur ing both<br />
transport and production.<br />
Percarbonate is less stable than perborate primarily<br />
because of its molecular and crystalline<br />
structures. Characteristic for both is that they release<br />
hydrogen peroxide very easily in contact<br />
with water or humidity. Unlike percarbonates, perborates<br />
are true peroxygen compounds, in which<br />
the oxygen is bound to the boron atom in the presence<br />
of a peroxo group. The boron and oxygen<br />
atoms in these compounds form a six-membered<br />
ring system with highly stable energy.<br />
Percarbonate, on the other hand, is an addition<br />
compound. The hydrogen peroxide molecules<br />
in the crystal lattice are bound relatively<br />
loosely by hydrogen bridges, similar to crystal<br />
water molecules. In the presence of atmospheric<br />
humidity, water molecules from the air can diffuse<br />
into the crystals and force the hydrogen peroxide<br />
molecules out of their positions in the crys-<br />
elements32 evonik science newsletter<br />
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<br />
Liquid laundry detergent<br />
liquid laundry detergents contain—besides lots of water—<br />
surfactants and organic solvents but no bleaching agent.<br />
As the consumer test foundation Stiftung warentest so impressively<br />
confirms time and again, their cleaning efficiency<br />
is poor. this is why laundry detergent manufacturers advise<br />
consumers to use bleaching salts or bleach boosters in addition<br />
to liquid detergents—additives that are quite expensive<br />
but contain the same percarbonate and activator found in<br />
every allpurpose laundry detergent. liquid laundry detergents<br />
do contain optical brightening agents as whiteners—<br />
Uvactive organic substances or titanium dioxide—that lay<br />
on the fibers and thereby generate a certain whitening effect.<br />
But they do not kill germs on laundry. on the contrary:<br />
detergent residues collect on the plastic parts of the washing<br />
machine‘s interior, such as the detergent compartment,<br />
the plastic hose or the rubber seals, and provide a breeding<br />
ground for bacteria and fungi. A „biofilm“ forms, and in<br />
the worst case scenario, these bacteria and fungi can migrate<br />
to the laundry<br />
then easily degrades to water and oxygen under<br />
increased heat. The water and the increased temperature,<br />
in turn, accelerate the degradation process<br />
until the percarbonate is completely converted<br />
(autocatalytic degradation process).<br />
<strong>Evonik</strong> tames percarbonate<br />
There are essentially two processes available for<br />
the production of percarbonate: the crystalliza tion<br />
process and the granulation process. Pro duced by<br />
the classical wet process, in which sodium carbonate<br />
solution is mixed with hydrogen peroxide and<br />
cooled, percarbonate has open-pored crystals<br />
with a large surface area that is hard to coat.<br />
In the 1990s, <strong>Evonik</strong> developed a spray granulation<br />
process for creating sodium percarbonate<br />
crystals as round particles with a small, smooth<br />
surface. In a second process step, the coating step,<br />
this surface is covered in an extremely dense, homogeneous<br />
coating made of inorganic salts such as<br />
sodium sulfate. This coat ing acts as a diffusion barrier<br />
and prevents water molecules on the outside<br />
from diffusing inside, and hydrogen peroxide molecules<br />
on the inside from diffusing outside.<br />
tal lattice. The hydrogen peroxide that is released >>><br />
33
<strong>Evonik</strong>’s percarbonate<br />
plant in Rheinfelden<br />
<strong>Evonik</strong>’s coating method for producing<br />
stabilized percarbonate<br />
1. Spray granulation 2. Spray coating<br />
Scanning electron microscope image of<br />
the coating-stabilized percarbonate<br />
100:1<br />
Na 2CO 3 solution<br />
H 2O 2 solution<br />
Air Sodium percarbonate Air<br />
100:1<br />
Na 2SO 4<br />
3.90 µm<br />
6.64 µm<br />
5.20 µm<br />
6.35 µm<br />
6.29 µm<br />
4.31 µm<br />
5.53 µm<br />
4.72 µm<br />
500:1 50µm<br />
Percarbonate: stable and sustainable<br />
In the past three years, scientists from <strong>Evonik</strong>‘s<br />
Industrial Chemicals Business Unit have refined<br />
the coating method in the production process for<br />
percarbonate, and significantly improved the stability<br />
of the exterior covering and, therefore, the<br />
strength of percarbonate against humidity and<br />
other influences. The improved percarbonate displays<br />
all the physico-chemical properties expected<br />
of an advanced, sustainable product. It has a<br />
good free flowing property and an excellent storage<br />
stability, with an outstanding shelf-life in formulations.<br />
And thanks to its high bulk density, it<br />
is particularly well suited to use in compact<br />
laundry detergents.<br />
Percarbonate is also attractive for compact<br />
laundry detergents because, unlike perborate, it<br />
is multi-functional. In addition to the oxidative action<br />
of hydrogen peroxide it also contains soda,<br />
which promotes the alkalinity of the wash solution<br />
and enhances the cleaning action (2 in 1). Se p -<br />
arate formulation of soda ash, therefore, can be<br />
reduced significantly.<br />
The best evidence of the high chemical and<br />
mechanical resistance of the improved percarbonate<br />
is its good storage stability in the finished<br />
laundry detergent, which retains its cleaning power<br />
longer. The bleaching agent no longer has to<br />
be overdosed in laundry detergent production.<br />
Instead, smaller quantities of raw materials can be<br />
used for the same level of efficiency. The improved<br />
stability of the percarbonate during storage of the<br />
laundry detergent means that enzyme systems with<br />
greater sensitivity to oxygen can be used in such<br />
products as concentrated laundry detergents,<br />
where they develop a good cleaning action.<br />
The world converts to granulated<br />
percarbonate from <strong>Evonik</strong><br />
Because percarbonate is an oxidizing substance, it<br />
poses a special risk that requires policies for safeguarding<br />
its production, transport, storage and<br />
processing. The sites have to have a permit, and<br />
may store only certain quantities. Customers, in<br />
turn, receive advice from <strong>Evonik</strong> on storage of the<br />
stabilized percarbonate. Having already assisted<br />
various customers with the transition from perborate<br />
to percarbonate in the past, <strong>Evonik</strong> is currently<br />
spearheading conversion of the remaining<br />
production plants that make laundry and cleaning<br />
detergents.<br />
To this end, <strong>Evonik</strong> developed various cus -<br />
t omer-specific validation tests for product qualification<br />
purposes to ensure that the percarbonate<br />
coating, for instance, would not be damaged<br />
34 elements32 evonik science newsletter
Big bags of sodium percarbonate<br />
ready to be shipped<br />
to destinations worldwide<br />
dur ing delivery of the material from the storage<br />
silo to the production process. Based on elaborate<br />
safety measure ments and models, <strong>Evonik</strong> was<br />
able to show that granulated percarbonate is ideal<br />
for use under extreme climatic and production<br />
conditions. But because transport law defines it as<br />
a hazardous material with special requirements,<br />
<strong>Evonik</strong> also analyzed the transport of percarbonate<br />
from its own production plants to the laundry<br />
detergent factories of its clients across the globe.<br />
Certain laundry detergents in the growth markets<br />
of the Middle East and Africa already contain<br />
granulated percarbonate from <strong>Evonik</strong>, even<br />
though the worldwide transition from perborate<br />
to percarbonate is still underway. Benefiting from<br />
its technological leadership position and a superior<br />
product quality developed in recent years, <strong>Evonik</strong><br />
is being recognized as a reliable and competent<br />
partner to the global consumer goods industry. l<br />
elements32 evonik science newsletter<br />
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<br />
Bleaching salt for special applications<br />
the bleaching agent percarbonate is the primary component<br />
of most conventional bleaching salts. in addition to stain<br />
removal in the laundry, the “active oxygen” that forms as<br />
the percarbonate dissolves in water has other practical uses.<br />
examples:<br />
Coffee and tea pots<br />
Dissolves the calciumcaffeine complex that leaves a brown<br />
film on the porcelain. to remove the film, fill the pot with<br />
warm water and add a spoonful of bleaching salts. Allow<br />
the salts time to work (they will foam), then rinse the pot<br />
thoroughly with water. You can also add a small drop of<br />
dish washing liquid for greater cleaning effect.<br />
Tar and oil stains on tiles and stoneware<br />
the active oxygen “inserts” itself under the tar/oil film,<br />
decomposes there, and the oxygen generated dissolves the<br />
film off the subsurface.<br />
Organic waste bins<br />
Prevents unpleasant smells. combined with the activator<br />
(tAeD) contained in the bleaching salt, percarbonate forms<br />
peracetic acid, which kills bacteria. Peracetic acid is environmentally<br />
safe because it breaks down into oxygen and acetic<br />
acid.<br />
Fish pond<br />
keep silt from overtaking your pond. the percarbonate<br />
brings active oxygen to the silt without injuring the fish (as<br />
long as the correct amount is used). the soda in the percarbonate<br />
also acts as a neutralizing agent on overacidified<br />
ponds.<br />
Mold stains<br />
on tile grout, for example: mix the bleaching salt with<br />
enough water to make a paste (wearing rubber gloves),<br />
apply the paste to the mold stain, allow to work, then<br />
rinse with water.<br />
DR. STEFAN LEININGER<br />
Stefan leininger is in charge of application engineering<br />
for the nonPulp & Paper unit of the Active oxygens<br />
Business line, and manages product and process<br />
development for detergent base materials. in this latter<br />
role, he works closely with customers on the global<br />
transition from perborate to percarbonate. leininger<br />
earned his doctorate in chemistry at the University of<br />
kaiserslautern in 1996, and then spent three years in<br />
research at the University of Utah in the United States<br />
before coming to evonik in 1999. Among his activities<br />
prior to starting in his current position in 2004,<br />
leininger was involved in the development of titanium silicate catalyzed chemical<br />
processes for ammoximation and epoxidation based on hydrogen peroxide.<br />
+49 6181 59-3295, stefan.leininger@evonik.com<br />
35
S E P T E M B E R 1 0<br />
09/03–09/04/2010<br />
150th Anniversary<br />
weltkongress chemie<br />
karlsruhe (germany)<br />
www.kit.edu<br />
09/17–09/21/2010<br />
126th GDnÄ Meeting<br />
dresden (germany)<br />
www.gdnae.de<br />
O C T O B E R 1 0<br />
10/03–10/05/2010<br />
Polydays 2010 – Polymers in<br />
Biomedicine and electronics<br />
berlin (germany)<br />
www.gdch.de/makro2010/<br />
N O V E M B E R 1 0<br />
11/07–11/09/2010<br />
6th German conference<br />
on chemoinformatics<br />
goslar (germany)<br />
www.gdch.de/gcc2010<br />
<strong>Evonik</strong> <strong>Industries</strong> AG<br />
Rellinghauser Straße 1–11<br />
45128 Essen<br />
Germany<br />
www.evonik.com<br />
16.12.–21.12.2007<br />
09/06–09/07/2010<br />
International 3rd Aachenosaka Symposium Joint on<br />
Catalysis Symposium & Fine Chemicals<br />
singapur aachen (germany)<br />
www.cfc2007.org/index.html<br />
www.seleca.rwthaachen.de/<br />
09/21–09/23/2010<br />
Processnet Annual Meeting 2010<br />
aachen (germany)<br />
http://events.dechema.de/jt2010<br />
10/10–10/13/2010<br />
Green Solvents for Synthesis<br />
berchtesgarden (germany)<br />
www.dechema.de/gsfs2010<br />
11/25–11/26/2010<br />
Aachen Dresden international<br />
textile conference<br />
dresden (germany)<br />
www.aachendresdenitc.de/<br />
09/13–09/15/2010<br />
orcHeM 2010<br />
weimar (germany)<br />
www.gdch.de/orchem2010/<br />
09/22–09/24/2010<br />
75th Annual Meeting GDch<br />
coating chemistry<br />
werningerode (germany)<br />
www.gdch.de/lackchemie2010<br />
10/10–10/13/2010<br />
10th international workshop on<br />
Polymer reaction engineering<br />
hamburg (germany)<br />
www.dechema.de/pre10<br />
Credits<br />
Publisher<br />
<strong>Evonik</strong> Degussa GmbH<br />
Innovation Management<br />
Chemicals & Creavis<br />
Rellinghauser Straße 1–11<br />
45128 Essen<br />
Germany<br />
Scientific Advisory Board<br />
Dr. Norbert Finke<br />
<strong>Evonik</strong> Degussa GmbH<br />
Innovation Management<br />
Chemicals & Creavis<br />
norbert.finke@evonik.com<br />
Editors<br />
Dr. Karin Assmann<br />
(responsible)<br />
<strong>Evonik</strong> Services GmbH<br />
Editorial Department<br />
karin.assmann@evonik.com<br />
Contributing Editors<br />
Dr. Angelika Fallert-Müller<br />
Christa Friedl<br />
Nina Labitzke<br />
Michael Vogel<br />
events<br />
Design<br />
Michael Stahl, Munich (Germany)<br />
Photos<br />
<strong>Evonik</strong> <strong>Industries</strong><br />
Karsten Bootmann<br />
Stefan Wildhirt<br />
Fotolia/Lucky Dragon (p. 31)<br />
Fotolia/Conny (p. 32)<br />
mauritius images/Clover/<br />
amanaimages (p. 29 oben)<br />
mauritius images/John<br />
Warburton-Lee (p. 29 unten)<br />
.MGX by Materialise (cover)<br />
Printed by<br />
Laupenmühlen Druck<br />
GmbH & Co.KG<br />
Bochum (Germany)<br />
Reproduction only with permission<br />
of the editorial office<br />
<strong>Evonik</strong> <strong>Industries</strong> is a worldwide<br />
manufacturer of PMMA products sold<br />
under the PLEXIGLAS® trademark<br />
on the European, Asian, African, and<br />
Australian continents and under the<br />
ACRYLITE® trademark in the America