elements 48, Issue 3 | 2014 · 22 Sustainability Report 2013 coating & bonding tecHnologies 24...

Plastic-Metal Hybrids

Paring down lightweight constructiondesigning witH PolyMers

Structural foam for the aviation industry: ready for takeoff!coating & bonding tecHnologies

Linerless labels: adhesives with nothing underneath

elements48Quarterly Science Newsletter Issue 3|2014

elements48 Issue 3|2014

2 contents

6

16

34

cover Picture

New structural foam from Evonik opens up numerous application possibilities in the field of aviation

news

4 Christian Kullmann appointed to Evonik’s Executive Board 4 New hydrogen peroxide plant officially opened in Jilin 4 New isophorone facilities in China onstream 5 Evonik sets the course for polyamide 12 5 Financing available for Biolys® plant in Volgodonsk

Plastic-Metal Hybrids

6 New adhesion promoter for plastic-metal hybrids: paring down lightweight construction

catalysis

12 Amines by a gentler process

interview

14 Strategic partnerships with universities

news

15 Stronger involvement of external partners in R&D

designing witH PolyMers

16 Structural foam for the aviation industry: ready for takeoff!

corPorate resPonsibility

22 Sustainability Report 2013

coating & bonding tecHnologies

24 Linerless labels: adhesives with nothing underneath

news

30 New research center at Rheinfelden site 30 New building for applied technology for tire and rubber inaugurated 31 Investmentinbiotechnologycompany 31 New Technology Center for Electronic Solutions in Taiwan 31 Russian joint venture OOO DESTEK celebrates ten years of success

catalysis

32 Evonik consolidates catalyst research in China

news

33 Evonik invests in specialist in biobased lubricants 33 Testing products on the race track

corPorate ForesigHt

34 Unearthing the oceans’ hidden treasures

news

39 Evonik builds dispersant plant in Essen 39 Investment in new silica plant in Brazil

39 Credits


3editorial

TeamworkBrazil has Neymar, Argentina has Messi, and Portugal has Ronaldo—but Germany has a team. This is how the success of the German national soccer team in the World Cup can be summed up. As the World Cup victory clearly demonstrated, success may depend on the skills of individuals, but the true value of those skills does not unfold until they are blended together in a team. That applies to research, too: a well-positioned team, one with all of the right skills and one that works well together, has an excellent chance of having a project produce an innovation.

This is why we are integrating our research, development, applications engineering, and production competencies, both in Wesseling and in Rhein-felden (p. 30): In Rheinfelden, for instance, we are strengthening our silane chemistry network and building a new research center. In Wesseling we have launched a new applications engineering building, a move that unites the world’s largest precipitated silica production operations with research, development, and applications engineering—all at one site.

The significance of the team concept extends far beyond individual com-panies, however, especially when it comes to developing complex system solutions. This is why we built our technology center in Taiwan—so that we could work with researchers in industry and academia to develop Electronic Solutions on site (p. 31)—and are continuing to expand our international research networks through strategic university partnerships all over the world (p. 14–15). In the HYLIGHT project sponsored by Germany’s Federal Ministry of Education and Research (BMFB) we worked with eight partners to develop a new adhesion promoter for plastic-metal hybrids that can be used in lightweight construction applications, where they reduce weight by 20 percent (p. 6 ff). And working in close cooperation with machine manu-facturers and customers, we are also accelerating the pace of developing new label systems that need no liners at all—a boon to sustainability and cost-effectiveness alike (p. 24 ff).

For all of these projects, we have bundled internal and external compe-tencies throughout the entire value-added chain to form powerful teams. Add to that a long-term strategy, a clear objective, and the ability to learn from setbacks, and a company—like the German national soccer team—is certain to win many titles. We just have to keep our eyes on the ball.

dr. Peter naglerChief Innovation Officer Evonik Industries AG


4 news

Christian Kullmann appointed to Evonik’s Executive Board Evonik’s Supervisory Board appointed Christian Kullmann (45) to the Executive Board of Evonik Indus-tries AG effective July 1, 2014. As Chief Strategic Officer, Kullmann will be responsible for the Corporate Strategy & Corporate Performance, Legal & Compliance, Corporate Affairs, and Corporate Security Divisions.

Klaus Engel, Chairman of Evonik’s Executive Board: “The Executive Board is gaining a long-standing, competent, and experienced manager. As a close colleague of mine, Christian Kullmann played a trusted and decisive role in repositioning the Group as a specialty chemicals company and in shaping Evonik’s stock exchange listing. We look forward to continuing to work with him as a member of the Executive Board.”

On December 1, 2003 Christian Kullmann became head of Communications & Board Office at the former RAG, from which Evonik was formed in 2007. Prior to that he was Director of Public Relations and Public Affairs at Dresdner Bank. Evonik’s Supervisory Board appointed him Executive Vice President effective April 1, 2013.

New hydrogen peroxide plant officially opened in JilinIn July Evonik Industries formally commenced operations at a new hydrogen peroxide plant in Jilin (China). The new production plant has an annual capacity of 230,000 metric tons. Evonik has invested over €100 million in the site, there by raising its current global capacity for hydrogen peroxide production to more than 900,000 metric tons per annum.

“This investment further con-solidates our market leadership

for hydrogen peroxide and sees us resolutely pursuing our growth strategy in Asia,” said Klaus Engel, Chairman of the Executive Board of Evonik Industries, at the official opening ceremony in Jilin.

Evonik supplies H2O2 from Jilin straight to the neighboring propylene oxide plant run by Jishen Chemical Industry Co., Ltd., which has likewise been newly erected.Jishen uses the hydrogen peroxide to manufacture propylene oxide

on the basis of the HPPO process. Propylene oxide is used predom-inantly to make the polyurethane intermediates that are used in the manufacture of products such as upholstery for car seats and furni-ture or insulation material for the construction and refrigeration industry.

“We are registering a great deal of demand around the world for our efficient HPPO process,” says Gregor Hetzke, head of the

The event was attended by high- ranking representatives from politics and the business community

Advanced Intermediates Business Unit at Evonik. “The Jilin plant represents another milestone on the way to establishing hydrogen peroxide as an eco-friendly oxi-dant for the process of chemical synthesis.”

To date, hydrogen peroxide has been used mainly as a bleach-ing agent by the textile and pulp industry. The HPPO process now allows this eco-friendly oxidant to also be employed in the direct chemical synthesis of propylene oxide. The benefits of the new method are that it requires much lower investment costs, has high production efficiency, and has excellent environmental compat-ibility.

duction facilities,” said Patrik Wohlhauser, member of the Evonik Indus-tries Executive Board and Chief Operating Officer.

Evonik has more than fifty years of experience with isophorone chemistry and is the only company worldwide to cover the entire value chain for isophorone and its derivatives. So far products based on iso-phorone (crosslinkers) were being manufactured in Antwerp (Belgium), Marl and Herne (Germany), and in Mobile (Alabama, USA).

In addition to the new production complex, Evonik built an appli-cation technology service center with state-of-the-art laboratories

New isophorone facilities in China onstream Evonik has commenced an integrated production complex for isopho-rone and isophorone diamine in Shanghai (China). The company has invested over €100 million in the facilities, which will have an annual output capacity of 50,000 metric tons. Evonik primarily plans to use the new capacities to serve customers in the coatings and paint, con-struction, adhesives, and composite industry in Asia.

“The new plant continues our successful growth story in isopho-rone chemistry. We are now represented in the three major economic zones, Europe, NAFTA, and Asia, with fully backwards integrated pro- 333


5news

successfully processed to pipes and tested. Samples for customer tests will be available soon. The process offers several advantages: 100 per-cent renewable raw materials as a basis for polyamide 12, identical product properties, and a simpler production process.

Further results from the pilot plant, which has been operating for over a year, will be the basis for the selection of the process for the next capacity expansion of polyamide 12.

On the market, the name VESTAMID® refers to the structural mate-rial polyamide 12, and VESTOSINT® for the coating powder from Evonik.

Evonik Industries has expanded its polyamide 12 production capacity at Marl Chemical Park by 5,000 metric tons, thereby increasing the sup-ply security of its VESTAMID® high-performance polymer material. In addition, preparations have begun for increasing the production of VESTOSINT® polyamide powder.

For nearly 50 years, Evonik has operated a fully backward integrated plant for production of polyamide 12 at Marl Chemical Park, starting from butadiene, all the way through all precursors to the polymer. Orig-inally a batch operation, the production facility was expanded to include continuous plants in the year 2000.

“VESTAMID® is a sought-after material on the market. Substitutes, which were needed following the temporary outage of the cyclodo-decatriene plant, have done well only in niche markets. We view it as our obligation to offer our core markets—above all, the automotive industry—the greatest possible supply security,” says Dr. Michael Pack, the new head of Performance Polymers Business Unit at Evonik.

The growth strategy is also underscored by the development of various technologies for the precursors of polyamide 12. On the one hand, Evonik now has a production-ready conventional route based on improved processes for an independent C12 line all the way to the polymer.

On the other hand, the biosynthetic route based on palm kernel oil—free from butadiene and cyclododecatriene (CDT)—is far advanced. The process results in ω-amino lauric acid, an alternative to petro-leum-based laurolactam, and yields an identical polyamide 12. The initial batches of polyamide from this precursor have already been

Evonik sets the course for polyamide 12

The first VESTAMID® pipes made from 100% renewable raw materials have passed internal tests successfully

Financing available for Biolys® plant in VolgodonskThe issuance of a construction permit by the Russian authorities and the signing of a credit agreement with the Russian Agricultural Bank represent two important milestones for the project to build a Biolys® plant in Volgodonsk by the OOO DonBioTech joint venture. Evonik In-dustries and Russia’s Varshavsky Group are shareholders in the joint venture.

The plant will have an annual capacity of roughly 100,000 metric tons. It will strengthen the position of Evonik on the Russian market and help make pork and poultry production in Russia more efficient and sustainable.

Biolys® is considered to be an extremely effective source of lysine in animal feed for pigs and poultry. It is to be manufactured in Vol-godonsk using modern fermentation technology from Evonik. Wheat from the Rostov region will be used as a raw material, and the joint venture will process this itself.

at the Xinzhuang site in Shanghai. The custom-tailored isophorone solutions will strength en the competitiveness of Asian customers.

The global market for isophorone and its derivatives grows at a stronger annual rate than global gross domestic product, with Asia showing above-average growth, predominantly in the area of compos-ites. They are used in lightweight construction for automobiles as well as in highly durable wind power stations.

In addition, isophorone chemistry prolongs the life expectancy of heav-ily used surfaces, which reduces maintenance cost and often makes renovations superfluous. Examples include floor coverings in parking garages, facades exposed to demanding climatic conditions, or ships operating in salty ocean water. Growth projections are also high for environmentally friendly coating technologies, such as UV-curing sys-tems or solvent-free powder coatings.

333


6 Plastic-Metal Hybrids

How light can lightweight construction get? In a project supported by the BMBF (the German Federal Ministry of Education and Research), the Performance Polymers Business Unit and partners have developed a novel adhesion promoter system for the coil-coating process. As a result of full-faced bonding, metal and plastic are especially strongly and reliably connected, so that automotive hybrid components can be made with up to 20 percent less material.

[ text Dr. Karl Kuhmann, Martin Risthaus ]

For car ManuFacturers, every kilogram saved is of immense value. Higher safety and comfort levels and more equipment in cars result in additional weight that must be saved elsewhere—otherwise the industry would be unable to meet its fuel consump-tion regulations or the EU’s CO2 fleet targets. This means that in the future components must be even lighter, materials used more efficiently, and compos-ites more intelligently designed.

Automotive components—including doors, instru-ment panel supports, front-end systems, and under-carriage components—consist increasingly of light-weight hybrid structures made from different mate-rials. Automotive plastic-metal hybrid components often consist of thin galvanized steel plate over-molded with fiber-reinforced plastics such as poly-amide 6. Reinforcement of three-dimensional met-al-sheet structures with plastic ribs allows production of relatively lightweight automotive components with high mechanical load capacity.

Metal and plastic are extremely different chemi-cally and physically, and bonding them together strongly and durably is a challenging task. Designers often use mechanical anchoring (form fit) for this purpose: metal edges are encased with plastic, for example, or rivet-like plastic sections are used as

bonding elements. Under load, high stress peaks and elongations may occur at precisely these bonding points, leading to failure of the component.

Adhesive bonding replaces mechanical anchoringA highly promising alternative has recently become available for lightweight automotive components. Un-der the BMBF-supported HYLIGHT project, a team led by Evonik’s Performance Polymers Business Unit has successfully developed an adhesion promoter sys-tem that allows full-area, rather than point-wise or local, bonding between metal and plastic. The tran-sition from the conventional form fit to adhesive bonding brings a number of advantages: The plastic- metal bonds are mechanically durable because force transmission and distribution change. Stress peaks are avoided and force absorption is more uniform. Best of all, hybrid components of this design are even more lightweight thanks to the wide-area bond. This is because molded form-fit areas can be replaced in the adhesive bond concept, and both metal and plas-tic components designed—depending on application and load—to be more thin-walled and with more eco-nomical use of material (fig. 1). The use of the novel

Paring down lightweight construction New adhesion promoter for plastic-metal hybrids:


7Plastic-Metal Hybrids

adhesion promoter ultimately allows savings of up to 20 percent on material.

But putting this concept into practice is not as sim-ple as it sounds. Fabrication of composite components for the automotive industry requires a reproducible process with very low error tolerances. Moreover, the supply chain for the complete component involves many different players including plastic and metal producers, metal refiners, and metal processors.

In the HYLIGHT project, therefore, eight partners shared the work and the costs (fig. 2). Evonik and Lanxess supplied the adhesion promoter and poly-mers, while Kirchhoff Automotive realized the metal processing and forming. Montaplast GmbH contrib-uted its injection molding expertise and Hühoco Metalloberflächenveredelung GmbH developed the new coating system jointly with Evonik. With sup-port from Lanxess and Evonik, the Institut für Kunst-stoffverarbeitung (Institute of Plastics Processing) at RWTH Aachen University developed a simulation tool for computation of adhesive-bonded hybrid com-ponents. The Lehrstuhl für Kunststofftechnik (Insti-tute of Polymer Technology) at Friedrich-Alexan-der-Universität Erlangen-Nürnberg, in conjunction with carmaker Ford, was responsible for mechanical testing and analysis of test specimens; Ford also pro-vided the necessary technical specifications.

Paring down lightweight construction

333

Figure 1

Adhesive bonding based on the new adhesion promoter concept makes plastic-metal hybrid components up to 20 percent lighter

Figure 2

Representatives from the entire value chain participated in the BMBF’s HYLIGHT project

Form-fit concept

Overmolding (clasp)

Metal inlayThrough-molding (rivet)

Plastic Plastic

Metal inlayAdhesion promoter

Local force transmission: molded form-fit connections

Large-area force transmission allows additional weight-saving potential

†

Adhesive bonding based on the new adhesion promoter concept

Academic partners: Institute of Polymer Technology (Lehrstuhl für Kunststofftechnik) at Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute of Plastics Processing (Institut für Kunststoffverabeitung) at RWTH Aachen University

EvonikProduction of polymers

HühocoCoating pro-duction and application

KirchhoffMetal forming

LanxessProduction of polymers

MontaplastInjection molding

FordOEM



Figure 3Under the BMBF-supported HYLIGHT project, a demon-strator based on adhesive- bonded components was used for the front-end system of the Ford C-MAx

Front end of the Ford C-MAx as referenceA front-end system of the Ford C-MAx, which has been in large-scale production for many years, served as a reference. Front-end systems are located at the front end of the body frame and serve to support the bumper, radiator, and headlights, among other com-ponents. HYLIGHT’s aim was to work out the funda-mentals for the materials of this component and to develop tools for simulation of adhesive-bonded com-ponents. Another essential goal was to show by means of a demonstrator that the adhesion promoter is suit-able for current manufacturing processes and real components (fig. 3).

Coil-coating is an important coating process in in-dustry. Long metal strips up to 1 meter in width are coated with, for example, liquid corrosion inhibitors in large, fully automated systems. These metal strips are then formed into the required shape and over-molded with plastic. The BMBF project focused on coil-coating as the coating method and on formula-tion of a suitable adhesion promoter as the coating system (fig. 4).

Between 2011 and 2014 the project participants focused essentially on the following three questions: What kind of adhesion promoter is needed for dura-ble and reproducible adhesive bonding of metal and plastic? How can adhesive-bonded hybrid compo-nents be simulated? Could component suppliers and car manufacturers integrate the new adhesion system into their processes and systems without the need for major changes?

adHesion ProMoter For tHree-diMensional Metal coMPonents

VESTAMELT® powder coating already in series application

In addition to the strategy followed in the HYLIGHT project of wide-area coil-coating of semifinished metal sheet with coating systems, three- dimensional metal components and profiles can also be powder-coated by electrostatic spray coat methods. A VESTAMELT® Hylink powder system is already being successfully used in automotive mass production: Daimler has been using the adhesion promoter since 2012 for production of overmolded aluminum instrument panel supports in the current W176 (A-class) and W246 (B-class) lines.

The adhesion promoter technology does more than smooth the way for greater material efficiency in the automotive industry: It can advan-tageously be used wherever metals must be strongly and durably bonded to plastics, as for example in the IT sector, where components must be extremely small and light but also of high functionality.


Plastic-Metal Hybrids 9

In the search for a suitable starting product, Evonik had recourse to the proven VESTAMELT® family, a group of copolyamides used as hot-melt adhesives. The powder-form polymers are distinguished by high resistance to heat and chemical attack and excellent affinity to a very wide range of materials including metallic surfaces as well as polar substances. This combination of properties makes them the ideal adhesion promoter for composite materials.

Strong bonding by thermal crosslinking

For use in hybrid lightweight construction technol-ogy the adhesion promoter system had to be modified so as to bond strongly with metallic as well as poly-meric surfaces. Adaptation for the manufacturing processes of the component supplier industry, which occasionally use very high temperatures, was also a major consideration here. The newly developed sys-tem is therefore thermally crosslinkable and is acti-vated at temperatures above 200 °C.

The strong bond between metal and plastic is formed in two steps: In the process of coating the cleaned metal sheet the adhesion promoter first forms a durable bond to the metal surface. In the subsequent injection molding the hot plastic melt then comes into contact with this pre-crosslinked coat. This activates the coating, which finally forms a stable and highly durable bond with all contact surfaces.

In the coil-coating process, the copolyamide-based coating is applied across the surface. Three-dimen-sional components such as tubes and profiles may alternatively be coated with a powder variant of 333

Coil-coating plant of metal finishing company Hühoco Metalloberflächenveredelung GmbH for coating metal bands (above)

Figure 4

Process chain based on the coil-coating process for metal strips

Coil-coating: application of adhesion promoter system

Hühoco Metalloberflächenveredelung

Forming of the coated metal inlay after cutting

Insertion and overmolding

Hybrid component

The new VESTAMELT® basedadhesion promoter system bonds strongly to both metallic and polymeric surfaces (below)



VESTAMELT® using an electrostatic spray coat method (see box on p. 8).

Value chains in the automotive industry are dis-tinguished by the fact that processes and supply relationships are well established, tested, and usually planned for the long term. It was therefore crucial to develop a coating formulation in line with the para-meters of existing manufacturing processes. For example, the viscosity, adhesive potential, and pro-cessing behavior of the coating must be so adjusted that the coating can be used without any problem in conventional coil-coating, forming, and injec-tion-molding systems.

In searching for the optimal system, the specialists investigated powders of various particle distribution and composition in a wide range of coating formula-tions. These were then tested on real systems, with great success: At the end of the long test series a cus-tom-tailored coating system was obtained that allows fabrication of adhesive-bonded composite components for the automotive industry that meet the stringent requirements for the process chain described above. The coating system ensures homoge-neous and continuous application, as has been proven in extensive trials on coil-coating systems. The coat-ing serves for the necessary corrosion protection as well as for bonding, so that cathodic dip-coating of the metal sheet for corrosion control is not required.

Simultaneous simulation and component testingBefore a component is produced in the automotive industry, it is subjected to extensive simulation. Already at the computer design stage, designers develop a customized structure that is as light as pos-sible and at the same time adequately robust. The development of simulation tools was therefore an integral part of the HYLIGHT project schedule. In a number of studies, the simulation experts of the con-sortium showed that adhesive-bonded hybrid com-ponents satisfied the requirements prescribed in the functional specification. Moreover, simulated tensile loading, bending, shear, and torsion permitted com-

putation of how much lighter an adhesive-bonded reference component could become without nega-tively impacting its mechanical properties. The pro-grams developed allow simulation of simple as well as more complex components. Not least, they provide information on local failure of the adhesion promoter for the case of especially heavy loading.

Technical testing of components was performed simultaneously with simulation calculations, first, to validate the simulation model, and also because in the automotive industry every new or changed compo-nent must be thoroughly chemically and mechanically tested, thermally aged, and checked for corrosion resistance (fig. 5).

For the HYLIGHT testing program, the partici-pating universities initially used fairly small test spec-imens of various geometries to model relevant driv-ing loads; these included shear and tensile stresses in tensile shear, single rib, and torsion test specimens. In this way the technicians determined material parameters allowing assessment of the difference between form fit and adhesive bonding, and ultimately of the potential for application of the composites. The parameters were also used for the calibration of numerical models for simulation of the adhesive-bonded composites.

Trials were also performed on a hybrid beam (the so-called “Erlanger Träger”), now well established as a test specimen for hybrids (Fig. 6). The results pro-vided a base for simulation of an adhesive-bonded, weight-optimized front-end carrier for the Ford C-MAx. The reference component clearly demon-strates the enormous weight-saving potential of the adhesion promoter: While the conventional upper cross member of the carrier weighs 1.76 kg, the mod-ified variant, at only 1.39 kg, is a good 20 percent lighter.

The corrosion protection effect of the new coat-ing system has also been demonstrated. At the Ford testing ground a modified front end in the Ford C-MAx was exposed to harsh conditions in a climate testing chamber, alternating with driving cycles on a test track. The tests revealed no limitations in corro-sion protection.

333

Test specimen Model component Demonstrator Optimized demonstrator reduced weight

Figure 5

Various test specimens and increasingly complex components were chemically and mechanically tested in the course of development and optimization


11Plastic-Metal Hybrids

To summarize the BMBF project, the consortium has developed a new overall concept for adhesive-bonded injection-molded hybrid components that allows sig-nificant weight savings at no extra cost and can be implemented on mass-production lines. The use of the novel adhesion promoter system also opens up more freedom in the design of hybrid components.

The BMBF project was of great benefit to all the participating partners. Value chains in the automo-tive industry are complex. The HYLIGHT project suc-ceeded in bringing together the individual players and optimally pooling their individual fields of exper-tise toward a common goal that is becoming critically important in sustainable production: The intelligent mass production of components to perform a range of functions and meet high standards while ensuring maximum material efficiency and thus resource con-servation. 777

Martin risthaus has been Global Business Manager Lightweight Design in the High Performance Polymers Business Line since 2007. He completed an apprentice-ship as a chemical laboratory technician at the former Hüls AG and then studied chemical engineering at the FH Münster (Münster University of Applied Sciences). He has occupied posts in research and key account management in the High Performance Polymers Business Line. phone +49 2365 [email protected]

dr. Karl Kuhmann is responsible for processing technology and CAE in the Application Technology department at High Performance Polymers. He studied mechanical engineering, specializing in plastics tech-nology, at RWTH Aachen, and subsequently worked at Friedrich-Alexander-Universität Erlangen-Nürnberg, initially as a research assistant and then as senior engi-neer at the Institute of Polymer Technology. He then moved to Hengst, Münster, working in process devel-opment. In 2002 he joined the former Degussa AG. phone +49 2365 [email protected]

Final meeting of the project participants at the Ford test ground in Lommel

Figure 6

Loading tests and simulations were performed using a hybrid beam, now established as a test specimen for hybrids

Simulation model of the hybrid beam under torsional load (with adhesion promoter system)

Deformation of the hybrid beam under torsional load (no adhesion promoter system)

The authors would like to thank the German Federal Ministry of Education and Research (BMBF) for their financial support, and also Project Management Jülich (PJT) for managing the project with the abbreviation HYLIGHT (FKZ: 03X3030A). We would also like to thank our project partners—Ford Forschungszentrum Aachen GmbH, Hühoco Metalloberflächenveredelung GmbH, Kirchhoff Automotive Deutschland GmbH, Lanxess Deutschland GmbH, Montaplast GmbH as well as the Institute of Plastics Processing (Institut für Kunststoff verarbeitung) at RWTH Aachen University and the Institute of Polymer Technology (Lehrstuhl für Kunststoff-technik) at Friedrich-Alexander Universität Erlangen-Nürnberg.


12 catalysis

Researchers and developers of the Catalysts Business Line have shown that amide acetals and iminium esters can be hydrogenated under very mild conditions with Noblyst® P-series hydrogenation catalysts. The process could represent an attractive alternative to producing amines for pharmaceutical ingredients. [ text Dr. Renat Kadyrov ]

aMines are iMPortant starting materials for a number of commercially produced products, such as colorants or poly-amides, but also for pharmacologically active substances. Cata-lytic hydrogenation of amides represents an attractive approach to supply amines. However, this process requires extremely high temperatures and pressures. In the past few years, significant improvements have been achieved with the use of bimetallic catalysts. A publication from 2013, for instance, described a bimetallic Pd/Re-based catalyst that made amide hydrogenations possible under milder conditions. However, the reaction was characterized by both over-reduction and non-selective over- hydrogenation of aromatic rings, alkenes and alkynes.

The goal of Evonik’s catalyst specialists was to develop an ac-tive and highly selective process using heterogeneous catalysts to produce amines for the fine chemicals and pharmaceuticals industries.

An intermediate step makes the path easier

Over the course of the reductive amination studies, it became clear that the reactions took place primarily via hydrogenoly-sis of the N,O-acetals formed as intermediates. The initial work-ing hypothesis was that hydrogenolysis of the amide acetals proceeds under significantly milder conditions than the direct hydrogenation of amides (fig. 1). The first experiments then showed that N,N-dimethylformamide and acetamide dimethyl acetals could both be efficiently converted to trimethylamine and dimethylamine using conventional palladium-based Noblyst® catalysts.

The general applicability of this approach was proven by the smooth hydrogenolysis of several different amide acetals and iminium esters under moderate conditions (5–40 bar H2 pres-sure, room temperature, reaction time of 10–60 minutes) with

various Noblyst® P-series catalysts, which differed in terms of their precious metal content and carrier material. For example, N-methyl-2,2-dimethoxypyrrolidine and 2-ethoxy-2-methyl- 3-benzyl-oxazolidine were quantitatively converted to N-meth-ylpyrrolidine and N-benzyl-2-(ethylamino)ethanol, respectively. The hydrogenation of ethyl N-phenyl-propionimidate and O-methylcaprolactam also yielded quantitative amounts of N-propylaniline and hexamethyleneimine, respectively.

From amide to amine problem-free

Several methods are known for the conversion of tertiary am-ides to amide acetals, as well as for the conversion of secondary and primary amides to iminium esters. Among them, O-alkyl-ation using known alkylation agents such as dimethylsulfate, triethyloxonium tetrafluoroborate, or chloroformic acid ethyl ester were of most interest because of their low cost, simple alkylation procedure, and high yields. In some cases, the imin-ium salts as primary products of O-alkylation could also be hydrogenated to amines. For successful hydrogenation to amines it was essential to free up the acetal by addition of a base together with the Noblyst® catalyst.

The method, which has now been optimized by the catalysts experts at Evonik, involves the hydrogenation of the amide acetal or the iminium ester that is formed from an iminium salt and a solid base (K2CO3) in an alcohol solvent. The table (fig. 2) shows selected application examples of the method described above.

In conclusion, it can be said that amide acetals and iminium esters can be hydrogenated with the use of various Noblyst® P-series catalysts from Evonik. The advantages of this method lie in the commercial availability of Noblyst® catalysts, and in the high selectivity and excellent yields achieved under extremely mild conditions. 777

Amines by a gentler process

Figure 1

Amide reduction via acetals vs. direct amide hydrogenation

Special catalyst, high T and H2 pressure, reaction time in h

Noblyst® P-series catalysts

OAlkOAlk OAlk

R NR’R’’ NR’R

NR’R’’RNR’R’’R

O

or

Amide acetate Iminium ester


13catalysis

dr. renat Kadyrov is responsible for synthesis plan -n ing, upscaling, and production of homogeneous catalysts in the Catalysts Business Line. He studied chemistry at Kazan Federal University in Russia, and received his PhD there in 1984. He worked in the fields of element-organic and metal-organic chemistry at the university in Kazan until 1994, and then spent five years at the University of Rostock in Germany. In 1999 he began working for Aventis as a catalyst expert. He and his group then moved to the former Degussa AG in 2001.phone +49 6181 59-8710, [email protected]

Noblyst® P-series catalysts

Noblyst® P2060 5 % PtO

NH NH

86

Noblyst® P1152 5 % Pd

Noblyst® P2081 5 % Pt

78

Noblyst® P3061 5 % Ru 63

Noblyst® P1084 5 % Pd 78

Noblyst® P3061 5 % Ru

Noblyst® P1159 5 % Pd

98


R = Me, Bn

BocHNCOOMe

N

O

R

NH COOMe

NR

EtO

O

R = Me, Bn

34 � 55�


Figure 2 Examples of the catalytic hydrogenation of in situ O-alkylated amides

Catalyst Amide Amine Isolated yield [%]


14 interview

Dr. Oenbrink, what exactly is a strategic partnership with a university?When we sign an agreement such as this, we more or less give the go-ahead for joint research activities with the university, also in the operational areas. For example, in Tokyo, it means that we will now organize regular meetings to get to know each other better so that we can share our knowledge and experiences and initiate joint research projects.

The partnership also includes Evonik’s participation in the students’ education: employees from Evonik hold lectures there, we sponsor students with scholarships, and have professors at the University of Tokyo advise us regarding research topics. These activities will help position Evonik as an attrac-tive employer at the partner universities.

By entering a strategic partnership, we create a defined framework in which activities such as this can be initiated easily and with no major bureaucratic effort.

Looking at the latest partnership with the University of Tokyo, does this mean that the work is only now really starting?(laughs) Yes and no. Anyone who has ever negotiated an agreement with a university knows the amount of work that goes into it before the underlying conditions are arranged so that both sides benefit from them. Dr. Masaharu Akiba, our technology scout in Japan, has done some outstanding work in this regard. But, of course, the real work is now commencing with our colleagues in the business units and in Creavis. Our objectives are to achieve regular contact and joint researchactivities.

At the universities, are you welcomed with open arms or do you need to be persuasive?We are definitely welcomed with open arms. Universities have a natural interest in getting external funding; in other words, research financing in addition to their own budget. This gives them more leeway because they can carry out more research and train more master students and doctoral candidates. And since we generally initiate projects that are interesting for the university and for us as a company, this is also very attractive for them from a scientific aspect. On top of this, we give the

Strategic partnerships with universitiesInterview with Dr. Georg Oenbrink, responsible for Innovation Networks & Communications (INC) at Evonik

Evonik and the University of Tokyo plan to work closely together in selected areas in the future and, for this purpose, have concluded a strategic partnership. Evonik now has four such partnerships—in addition to Tokyo, with the University of Minnesota, with Shanghai Jiao Tong University, and with the King Abdullah University of Science and Technology (KAUST). Evonik is also intensifying its partnership with the University of Duis-burg-Essen in Germany by sponsoring a junior professorship and ten doctoral candidate scholarships. In the fall of 2013, CI signed a memorandum of understand-ing regarding a strategic partnership with A*STAR, Singapore’s leading national agency for science, technology, and research. Dr. Georg Oenbrink, head of INC, explains why strategic partnerships are important.


15news

universities important advice regarding the relevance of re-search fields and enable rapid transfer of the research results into the society.

How far are you with the other partner universities?The business units have already started their first joint research projects with the universities in Minnesota, Shanghai, and Duisburg-Essen. In Duisburg-Essen, we have also awarded the first three scholarships to doctoral candidates and are in the phase of calling for submissions for the endowed professor-ship. Parallel to this, we organize regular meetings to discuss defined topics, and Evonik staff have held their first lectures at almost all the universities.

How long are the partnerships designed to last?The agreements usually last for between three and five years. At the end, we evaluate the results together with the univer-sity and make a joint decision on whether to go on with the partnership.

When does a university become interesting as a strategic partner?When it carries out research in fields that are relevant for Evonik. This can be chemistry, process engineering, biotech-nology, materials science but also economics or business administration. The university must also have recognizably high competences. And it must have a very good international reputation in teaching. Another important criterion is that we already have contact with the university—that the regions, the business units, HR, or Venture Capital has an interest and already has had first good experiences with the university.

In your view, what is the major advantage of a strategic partner-ship for Evonik?On the one hand, we are casting an anchor for our own re-search activities in every important world region—by doing so, we accelerate the internationalization of our own research. On the other hand, we discover more about research trends and projects in the respective regions and are able to respond more quickly. Moreover, the partnerships help us find talented young scientists for our sites in the regions. 777

Interview with Dr. Georg Oenbrink, responsible for Innovation Networks & Communications (INC) at Evonik

Stronger involvement of external partners in R&DIn June, Evonik invited selected scientists from various uni-versity faculties and research institutes to submit solutions to three predefined problems. Scientists have until the end of November to take part in this Evonik Call for Research Proposals (ECRP). With this new approach, Evonik hopes to gather creative ideas and proposals that, ideally, can result in a joint research project.

“In light of ever shorter innovation cycles and increas-ingly complex innovation topics, we are looking to strengthen the involvement of external partners in our own research and development work,” said Dr. Peter Nagler, Chief Innovation Officer of Evonik.

The specialty chemicals company gained its first expe-rience with this format in 2013. “For the most part, the feedback from the professors following the first ECRP was extremely positive. Almost all welcomed this new approach and expressed interest in taking part again,” says Dr. Georg Oenbrink, head of the Innovation Networks & Communi-cations department at Evonik. Three proposals on the topic of methionine synthesis without hydrogen cyanide as build-ing block were so good that the Health & Nutrition Busi-ness Unit intends to form a partnership with the professors involved.

The three current ECRPs focus on a new technology for masking the taste of pharmaceutical ingredients and dietary supplements; a donor-acceptor concept for the quantitative determination of fragments of oil additives that protect against wear, even under high pressure; and a tech-nology that can be used to create thin, transparent layers with extremely good barrier properties from the liquid

phase. Interested sci-entists from universi-ties and research in sti-tutes can request the call for proposals and rules of participation at [email protected].

Masking the taste of active ingredients is one of the current ECRP topics


16 designing witH PolyMers

Few industries place higher demands on the materials they use than the aviation industry. In the Performance Polymers Business Unit, developers were successful in modifying ROHACELL® structural foam so that it has improved ability to withstand even extreme changes in temperature and high mechanical stress. This gives the lightweight material distinct competitive advantages for complex aircraft components, where safety is always important.

[ text Dr. Kay Bernhard, Blake Juhl, Uwe Lang ]

Ready for takeoff!Structural foam for the aviation industry:


17designing witH PolyMers

wHetHer tHey are designing automobiles or airplanes, sports equipment or machines today, virtually every designer aims to reduce weight wher-ever possible. Lightweight construction reduces the consumption of resources and energy, fulfills de-manding mechanical requirements with less weight and, because of this, is an important driver of inno-vation. Playing a major role in this area are sandwich structures that combine a lightweight core with two thin layers of fiber-reinforced composite material. The top layers, separated by the core, give the com-ponent the required strength and rigidity. The result is a lightweight structural part that provides the high-est mechanical performance with minimum weight.

Sandwich composites are particularly suitable for the aviation industry, where reducing weight is a top priority. Over the average service life of an airplane component, each extra kilogram of weight increases jet fuel costs by about €300.

With ROHACELL®, Evonik has been well posi-tioned in this market for many years. The polymeth-acrylimide (PMI) structural foam is not only very light, but is also firm, strong, and resistant to pres-sure. PMI is the only foam that can withstand the processing conditions involved in manufacturing sandwich components at temperatures of up to 180 °C and pressures of up to 7 bar. Structural foams from Evonik can be found in virtually all helicopter rotor blades and in landing flaps, winglets, and fair-ings on airplanes. PMI also reduces the weight of For-mula 1 cars and supercars, cross-country skis, and hockey sticks. Used as a core material in x-ray tables for medical applications, the specialty foam not only enables the construction of a very lightweight table that is easy for medical personnel to move into posi-tion, but also helps ensure that radiation doses to pa-tients are kept to a minimum.

Although ROHACELL® has been used successfully in many different areas of an aircraft, in the past there have been limitations for the structural foam in applications where it is subjected to extreme tem-perature fluctuations and high levels of mechanical stress—such as in certain components on the exterior of an aircraft. At altitudes of up to 10,000 meters, temperatures can fall below minus 55 °C. The poly-mers must exhibit high elongation at break even at these extreme temperatures in order to withstand the resulting stress. However, if damage occurs, for safety reasons this must be very obvious and easy to detect visually on components such as wings, landing gear doors, antenna fairings, or rudders.

Damage can be caused, for example, by a bird strike or by foreign objects being hurled up from the runway. To make it visible, the tough, elastic 333

New application potential with high elongation at break performance

ROHACELL® structural foams from Evonik have proven their worth in many applications in a variety of industries, from aviation and automotive to sports equipment and wind turbines



core of structural foam has to support the outer layer in the event of an impact and to hold it firmly in place if plastic deformation occurs causing a dent to form.

The experts in the Performance Polymers Busi-ness Unit accepted this challenge. Their objective was to modify ROHACELL® in such a way as to increase robustness without having an adverse effect on strength. Not an easy task. At the same time, the homogeneous fine cell structure and the high tem-perature stability of the material was to remain unchanged. If it could satisfy these requirements, the specialty foam could be used in more commercial aviation components. Until now, applications in especially sensitive external areas have used a hon-eycomb structure. Problems in production and ser-vice of honeycomb structures were less important than ensuring that damage was visible.

With a honeycomb structure the supporting core, made of paper, polymer or metal, is arranged in a honeycomb shape and then bonded to the outer lay-ers of fiber-reinforced plastic or thin aluminum sheets. But these materials have several disadvan-tages. There are limits in regard to the complexity of the parts that can be made with the relatively coarse honeycomb. In addition, water can penetrate through the porous outer layers or microcracks form, which can result in corrosion and even cause the outer layers of the component to separate. Production of a honeycomb composite is very energy intensive, especially the two-phase curing process. Neverthe-less, because of the lack of composite materials with a similar level of damage tolerance, until now exposed lightweight components have generally been made from honeycomb panels.

While the developers were working on producing a competitive ROHACELL® structural foam for avia-tion, they had to resolve a contradiction: to make damage visible, the foam core must be softer and more elastic, as this is the only way it can absorb external mechanical and thermal effects without suf-fering too much damage. However, a soft core cannot withstand extremely high mechanical stress.

During their experiments, the foam experts at Performance Polymers trialed various fillers and plas-ticizers. While the plasticizer improved the ductility of the foam, it had a negative effect on its mechanical properties and temperature stability. Therefore, they had to take a different approach. The chemists changed the polymerization process and the process conditions for manufacturing the foam.

The starting materials for polymethacrylimide are methacrylic acid and methacrylonitrile, which poly-merize in special chambers with various additives,

A solution for two apparently contradictory requirements

333



catalysts, and blowing agents. The next step is foam-ing, which is carried out within a few hours at tem-peratures between 180 and 250 °C. The pore size and foam density are controlled by the choice of blowing and curing agents.

The developers’ idea was to find an optimum com-position of curing agents and plasticizers in order to form an additional network within the foam to enable the material to absorb and cushion external forces better. This would make the material softer and more elastic. The effectiveness of different medium- and long-chain curing agents from the Group’s portfolio were tested in extensive laboratory experiments. Normally, curing agents inhibit foaming, as they link molecular chains with each other during polymeriza-tion and counteract the formation of pores. This effect was largely leveled out with suitable types and quantities of curing agent and through cleverly coordinated control of the processes and reactions.

Using what was learned, the experts were able to develop two new ROHACELL® variants with consid-erably higher damage tolerances. The SL type has twice the elongation at break of previous grades, and tensile strength and shear strength are also improved. ROHACELL® SL has been introduced successfully to European, Canadian, and Chinese customers. The new structural foam is used to make especially resil-ient and durable sports equipment, such as hockey sticks.

However, the elongation at break of SL was not high enough for the intended main market, the avia-tion industry. To improve this parameter, the devel-opers again varied the composition and quantities of curing agents and plasticizers and at last found suc-cess. Elongation at break of the new ROHACELL® HERO (HERO stands for High Elongation ROHACELL) was improved by a factor of three with only minor losses in some mechanical properties (fig. 1). The result was an innovative structural foam that now has a level of ductility suitable for applications in the aviation industry.

As well as damage visibility, damage tolerance also improved significantly. This was demonstrated in tests by one of Evonik’s customers that produces com-posite components for the aviation industry. Even after 2,000 temperature change cycles between plus 180 and minus 55 °C, a maintenance flap with a ROHACELL® HERO core exhibited no damage from inner stresses (fig. 2).

In extensive investigations carried out by the Fraunhofer Institute for Mechanics of Materials in Halle (Germany), HERO was able to withstand the same mechanical stress as similar honeycomb struc-tures in the range of 3 to 35 joules and at minus 333

Two bullseyes: ROHACELL® SL and ROHACELL® HERO

Figure 1

Elongation at break of ROHACELL® HERO is three times higher than with other ROHACELL® products

ROHACELL® HERO 9–10% Standard ROHACELL® products 3–4%

Tension

Elongation at break performance

Figure 3

ROHACELL® HERO is superior to honeycomb structures in many respects

ROHACELL® HERO Honeycomb structure

4 Superior3 Excellent2 Very good1 Good0 Unsuitable

4

3

2

1

0

Damage visibility

Water ingress

Part weight

Design freedom

Surface quality

Part cost

Figure 2

Ultrasound photo of a material sample after a temperature change test: ROHACELL® HERO was undamaged even after 2,000 cycles



55 °C. The depth of the dent, which is important for identifying damage, was almost identical on the comparative panels subjected to the impact test (fig. 4).

The scientists in Halle were also able to prove that the bonding of the top layers of ROHACELL® HERO is so good that damage caused by impact remains local and does not spread throughout the component.

To prove that the material can withstand a lifetime in an aircraft, fatigue tests had to be carried out. The core with the outer layers easily withstood five mil-lion bending and relief cycles with bending stress well in excess of the design limits, thus proving that the material is suitable for highly stressed components for the full service life of an airplane.

All signs point towards ROHACELL® HERO even-tually having a considerable market share of the aviation sector. The new structural foam promises not only lightweight, but also extremely sturdy and temperature-stable components. A direct comparison with honeycomb structures clearly shows that the foam absorbs much less resin during bonding and curing, which has a significant effect on the weight of the component. It has no cavities that water can penetrate and cause damage to the structure.

Of special interest, ROHACELL® HERO enables more cost- and energy-effective production than con-ventional honeycomb structures, a very important aspect for the aviation industry and its component suppliers. In spite of all the technical progress that has been made, lightweight construction still requires complicated and, in some cases, manual production processes that take a lot of time and lead to high costs. Structural foam now offers a way to make lightweight construction more efficient and easier to automate. The fine-pore material allows complex components to be produced much more easily and more accu-rately. The cores can be thermoformed or milled to almost any shape. In addition, parts do not require nearly as much reworking as honeycomb structures

333

An energy- and cost- effective alternative for the aviation industry

Figure 4

With the impact test, the Fraunhofer Institute for Mechanics of Materials in Halle (Germany) confirmed that ROHACELL® HERO can withstand the same impact stress as similar honeycomb structures in the range of 3 to 35 joules and at minus 55 °C

ROHACELL® HERO (75 kg/m3) Honeycomb structure (48 kg/m3)

Impact 10 J at 23 °C

Impact 35 J at –55 °C

ROHACELL® HERO (75 kg/m3) Honeycomb structure (48 kg/m3)



to obtain perfect aerodynamic surfaces. A weight and cost comparison that Evonik carried out together with an Airbus parts supplier and Airbus subsidiary, CTC, came to the conclusion that components made from the new structural foam are, on average, about 10 percent lighter and cost about 20 percent less to produce than honeycomb structures (fig. 3, p. 19).

Samples of ROHACELL® HERO were provided to all major aircraft builders and component suppliers. Evonik offers the material in four different types in varying densities. This range covers applications that are not subject to high stress, as well as weight-sensi-tive applications and parts that are subject to extreme mechanical stress.

At Airbus, experts have been subjecting the opti-mized material to thorough tests for two years. At present, the aerospace group expects the first com-ponents made from ROHACELL® HERO to be pro-duced in series in 2015. The response from other com-panies has been positive. In the future, the high-per-formance structural foam will be the product of choice, especially for demanding geometries or in new aircraft parts where weight and production costs play an important role. Experts from the British firm Smithers Rapra, who conduct material tests for the plastics industry around the world, are already won over by the new lightweight composite. In May, Evonik received an Innovation Award for ROHACELL® HERO at the Blowing Agents & Foaming Processes Confer-ence, organized by Smithers Rapra. 777

dr. Kay bernhard is responsible for research and development of ROHACELL® at the Darmstadt site. After completing his chemistry studies, earning his doc-toral degree in the field of textile and fiber chemistry at the University of Stuttgart in Germany, and studying economics at FU Hagen (Germany), a distance learning university, he joined a well-known fiber producer in Southern Germany in 2005 as product developer for polyester fibers. In 2008, he joined Evonik in Darmstadt as head of the ROHACELL® R&D laboratory.phone +49 6151 [email protected]

blake Juhl is Director of Sales and Marketing for ROHACELL® in the Americas. Juhl has been working with composites since he earned his degree at California State University in Northridge (California, USA) in 1987. He has been involved in processing, sales, and marketing of advanced composite materials and related products for more than 25 years. He has been employed with Evonik since 2001 and most recently was appointed Global Launch Manager for the newly developed ROHACELL® HERO grade. phone +1 801 495 9403, [email protected]

uwe lang has been responsible for ROHACELL® sand-wich technology and regional manager for Germany in the High Performance Polymers Business Line since 2013. After completing his aerospace studies, specializ-ing in aircraft construction, at Aachen University of Applied Sciences (Germany), he joined AIK in Kassel (Germany), where he worked from 1991 to 1999— initially as a composites development engineer, then as product manager for composites parts. He has been with Evonik since 2000 and has held various positions for ROHACELL®, including manager of the aviation market segment, key account manager for Airbus Stade, and in Sales and Marketing.phone +49 6151 18-3570, [email protected]

An energy- and cost- effective alternative for the aviation industry

Floor panels

Pylon aft secondary structure, access panel

Empennage leading and trailing edges,VTP tip, VTP panels,dorsal fin

Main landing gear doors

Nose landing gear doors

Flap track fairings, wing leading and trailing edge panels,access panels

Spoilers/ailerons

With ROHACELL® HERO, Evonik can now offer an alternative to honeycomb composites for aircraft components where safety is a significant factor


22 corPorate resPonsibility

Evonik Industries has set new long-term environmental targets, which are published in the Sustainability Report 2013. Evonik publishes the report annually to underscore its commitment to ecological, economic, and societal sustainability. It is accessible online at www.evonik.com/responsibility.

Sustainability Report 2013

10metric tons represents the volume of products Evonik produced in the year 2013—four percent more than in the previous year.

29million € were invested by Evonik in 2013 to further improve environmental protection (previous year: €39 million).

percent is the amount by which Evonik plans to cut back on specific water con-sumption by 2020 (compared to reference base 2012). It indicates water consumption in relation to production output.10

12percent less specific greenhouse gas emissions compared to the level of 2012 in relation to production output, in accor-dance with the Greenhouse Gas Protocol—that’s what Evonik aims to achieve by 2020. The indicator includes all direct greenhouse gas emissions as well as indirect net emissions from the purchase and sale of energy.


23corPorate resPonsibility

86 petajoules is the amount of energy used by Evonik in 2013. This is four percent less than in the previous year, although production increased by four percent in the same period. That represents a decoupling of growth and energy consumption.

10percent of total production input in 2013 came from renewable resources; in total, Evonik used 8.23 million metric tons of raw materials. Most of the renewable resources comprised dextrose and sucrose for the fermentative production of amino acids. Natural fats and oils and their derivatives are used to produce precursors for the cosmetics, detergents and cleaning agents industry, and in technical processing aids.

250million € represents the operating costs for environ-mental protection in 2013.

23young scientists benefited from support from the Evonik Foundation in 2013. The Foundation supports students and doctoral candidates with their research, and its work goes well beyond providing financial assistance. Evonik employees support the young researchers as mentors during their scholarship and give them insights into the company and a chance to build valuable contacts.

2 years ahead of schedule: This is when Evonik achieved its long-term environ-mental targets for the period 2004 to 2014—that is, in 2012.

earths is what we will need in the year 2030 to keep up with the consumption of resources, according to the prognoses of the WWF Living Planet Report 2012 on the health of the earth.

2


24 coating & bonding tecHnologies

UV-curing silicones from Evonik have been found to work well in release coatings for all manner of self-adhesive products. Working in close cooperation with machine manufacturers and customers, the Consumer Specialties Business Unit has accelerated the pace of development of new label systems that need no liners at all—an advantage to sustainability and cost-effectiveness alike.

[ text Dr. Winfried Hamann, Georg Michels, Liz Patterson, Jürgen Pomorin, Dr. Stefan Stadtmüller ]

adHesives MaKe liFe simple—a maxim that applies in many technical applications just as it does in ev-eryday life. In this case, however, “simple” refers only to the handling: self-adhesive products such as labels are actually sophisticated, multilayer systems. In ad-dition to the adhesive and the label itself, a laminated label also includes a backing—also known as a release liner—made of paper, plastic, or other materials. If the label is to work properly, however, an invisible yet crucial fourth layer also comes into play: thanks to this silicone layer, adhesive products can be peeled off of backings quickly and without leaving residue. Applications for these silicones other than labels in-clude adhesive tape, and release papers and films used in the home and in industry.

The global market for self-adhesive products is grow ing at a rate of four to five percent each year. Volume currently amounts to roughly 40 billion square meters of material a year, which equates to several billion US dollars in sales worldwide—30 percent of which is now generated in Asia. Growth in demand for modern labeling systems has been especially great in emerging markets, where the market for consumer goods is growing rapidly. Packaging applications play

a particularly important role here. According to the German Packaging Institute, 180 billion packages are produced each year in Germany alone. Most of these require one or more labels bearing important logistics, commercial, and consumer information.

The release coating is the deciding factor when it comes to how self-adhesive products work and how they are applied. While traditional label systems in-corporate thermally cured silicones, a critical disad-vantage of these materials is their highly energy-in-tensive curing process—crosslinking does not proceed until temperatures reach 100 °C or more. Plus, ther-mally curing release coatings are not suitable for the growing thermal paper market, as the elevated tem-peratures of the curing process render the thermally sensitive paper unusable.

UV-curing release coatings save energy

Release liners made of radiation-curing (RC) silicones therefore represent a superior alternative. It is UV-C radiation rather than heat that causes the silicone pre-polymers in these products to crosslink and thus to cure, a process that takes place in a fraction of a

Linerless labels: adhesives with nothing underneath


25coating & bonding tecHnologies

second using the medium-pressure mercury-vapor lamps commonly used in industry. RC silicones allow manufacturers to make flexible, versatile backings not only from paper, but also from temperature- sensitive plastics. Radiation curing also requires less energy than its thermal counterpart.

Evonik leads the global market for RC silicones. The TEGO® line of RC silicones has been put to the test for many years now to determine whether it perfectly meets customers’ sophisticated technical demands, as well as their commercial and environmental expecta-tions. RC silicones fall into two different groups based on their chemistry. The first are the silicone acrylates: Because substances in this group must be in an oxy-gen-free environment to undergo free-radical curing, Evonik has developed a special nitrogen purge that keeps residual oxygen content below 50 ppm. The sec-ond group is made up of epoxy silicones, which un-dergo cationic polymerization and, as a result, do not require the reaction chamber to be flushed with nitrogen. Over the past several years, Evonik special-ists have developed around a dozen different radia-tion-curing silicones, each with different release values tailored to customers’ specific requirements.

Disposing of 1.2 million metric tons of glassine paperIt remains an undisputed fact that traditional self-ad-hesive products have been perfected and have stood the test of time. They do, however, have one serious disadvantage: The backings used in traditional sys-tems are the source of roughly 40 percent of these systems’ material costs and weight. In standard prod-ucts, the backing is made of glassine paper, a high-quality and, as such, relatively expensive spe-cialty paper—and after the labeling process, it be-comes expensive garbage. Roughly 400,000 metric tons of glassine paper are disposed of each year in the EU alone, a figure that rises to around 1.2 million met-ric tons worldwide.

To put it another way, each year more than one million metric tons of high-quality cellulose paper is simply thrown away, most of it burned or ending up in landfills. Attempts at reducing costs and waste have consisted of making the release paper thinner, or switching over to other types of paper or recyclable plastics. At best, however, these approaches can lessen the waste problem, but not eliminate it. 333

Self-adhesive products with release liner are currently a major compo-nent of paper waste



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Systems that use no backing at all—known as liner-l ess technologies—are far more sustainable. Evonik’s Consumer Specialties Business Unit has been work-ing with machine manufacturers and printing firms to press ahead with bringing these alternatives to market. With linerless products, labels are no longer fixed to a paper or plastic backing (release liner), but are instead wound up much like a roll of tape. The role that RC silicones play in linerless labels is like-wise to ensure that, prior to processing or dispensing, the layers peel off of each other quickly, cleanly, and without leaving a residue. The key difference here, however, is that the release coating is applied directly onto the face of the previously printed label, or soon to be printed thermal image label (fig. 1).

Omitting liners for greater sustainability

The advantages are obvious: for customers, doing away with this layer eliminates the costs of the paper or plastic liner, reduces the costs of materials and dis-posal, and prevents considerable amounts of waste. Storage and logistics expenses decrease as well. And last but not least, linerless applications represent a more compact way of dispensing labels, saving space, and making production more efficient.

Lower costs and improved efficiency are not the only factors that are boosting the popularity of linerless systems. Issues such as sustainability, waste preven-tion, and recycling are now playing a significant role for more and more companies. A recent survey con-ducted by market researchers at AWA (Alexander Watson Associates) of the Netherlands revealed that roughly half of the manufacturers of self-adhesive products feel that environmental considerations are already relevant to their business. A similar number anticipate that sustainability will have a direct impact on their own business in the coming five years.

Our linerless method has already become estab-lished for thermal labels, which are commonly used in the food, transport, and logistics industries. Pro-duction of linerless thermal labels is currently the industry’s fastest growing market segment and has become the standard for new thermal printers. Cus-tomers especially appreciate how easy to use, light-weight, and compact linerless labels are.

Linerless systems are also part of a clear trend that has been emerging on the market over the past several years: more and more printing firms are using machines that siliconize material immediately after printing. This in-house siliconization process liberates printing firms from label laminate manufacturers and

333

Figure 1Whereas traditional self-adhesive labels consist of four layers—the paper or plastic liner, the RC silicone release film, the adhe-sive, and the label itself (see diagram above)—labels made using liner-less technology omit the liner altogether. In this case the release film is applied directly onto the face of the printed label

Pressure-sensitive adhesive

Facestock

Release liner = waste

Silicone

Pressure-sensitive adhesive

Silicone

Facestock



adds value to printers’ processes. Linerless application is also on the rise in the packaging sector, with Evonik supplying raw materials in close cooperation with other players in the value-added chain. Foremost among these players are machine manufacturers, who develop equipment such as label applicators, and sili-cone application and curing systems.

This intense collaboration is crucial if the label application is to work flawlessly in modern, fully au-tomated plants. Using linerless systems, for instance, means having to modify process management for sil-iconization, as the face of the label has both printed and unprinted areas and can consist of a very wide variety of materials. As such, the silicones used must be compatible with the printing inks and adhesives involved, and they must cure and adhere well on printed and unprinted surfaces alike.

Introducing linerless alternatives also raises spe-cific questions: How do you die-cut labels with no liner—with no opposing surface? How do you apply the labels? How much flexibility do customers have in terms of label size and shape? Despite the techni-cal challenges involved, AWA has found that the use of this type of application has been increasing at an annual rate of 10 to 20 percent, making it the fastest-growing method on the market.

RC silicones and linerless systems go hand in handSeveral companies have in fact developed various technologies that offer answers to these questions. One of Evonik’s most important partners is the Brit-ish firm Ravenwood Packaging Ltd., which develops a variety of machine systems for linerless label production and use. Ravenwood systems apply the release coating and adhesive in thin, parallel strips, and an applicator uses a blade to cut individual sleeve labels from a continuous roll. This creates flexible la-beling options virtually regardless of the format of the packaged goods—an important benefit, especially in the rapidly growing market for meat, fish, and con-venience foods (fig. 2). Label rolls also offer signifi-cantly more room for information that industry and consumers need.

Ravenwood uses only Evonik RC silicones in its machines, as this is where the advantages of these silicones versus thermal curing release coatings come into play: RC silicones cure extraordinarily quickly, making them suitable for use in the inline process (adhesive coating), they do not react with printing inks, and system components are relatively inexpen-sive. More and more customers are recognizing

Supermarkets, which use thermal labels quite frequently for labeling perishables, have already gone linerless

333



the advantages of linerless systems. Ravenwood is currently expanding its business throughout Eu-rope, Asia, and the United States.

Evonik partner ETI is taking a different approach. For several years, this Canadian machine manufac-turer has been producing machines for in-house sil-iconization and has recently begun making label dis-pensers as well (fig. 3). These machines apply the la-bel using a process liner, which also serves as a con-veyor belt and as a substrate for die-cutting. The liner runs in a loop within the system and transports the labels many times—an approach that reduces waste and the use of liner material by roughly 90 percent over traditional application methods.

Another advantage to the customer is that these machines can be used for labels in a variety of shapes and sizes, thus combining the flexibility of traditional label laminates with the outstanding material effi-ciency of linerless applications.

Anytime linerless materials are used, manufactur-ers must pay special attention to producing labels that can be dispensed individually. Ravenwood applicators accomplish this using a cutter bar (guillotine) that cuts individual labels from the label roll. For thermal labels and manual application processes, this is done by hand using a sharp cutting edge.

The Catchpoint company has patented a concept of its own. Here the printer’s production machine in-cludes a special roller that creates microperforation lines on the label roll, and these lines serve as tearing points, making it much easier to detach labels from an automated dispenser. Existing labeling lines can be readily and reversibly converted to linerless ma-terials with Catchpoint perforations.

Linerless systems can also be used on old equipmentRadiation-curing silicones from Evonik are the ma-terial of choice for all linerless technologies thanks to their chemical and physical properties, which al-low these silicones to meet the demands of fully au-tomated production.

New labeling machines are not the only kind of equipment suitable for linerless labels—Evonik launched a pilot project in 2013 to determine whether TEGO® RC silicones could also be used on existing equipment. An application system at the Krefeld site was retooled to affix new linerless labels to soap bot-tles. Pilot operation lasted for two weeks and fully automated application worked perfectly during this time. The main aspect to take away from the project

333

Label rolls for conve-nience foods constitute one of the main applica-tions of Ravenwood technology using RC silicones from Evonik

Figure 2Ravenwood systems pro-vide flexible labeling options for packaging in virtually any size or shape

Landscape top

Landscape top and side

Landscape top and two side

Landscape C-wrap

Landscape full wrap

Wraparound



was that even existing labeling machines can be retooled quickly and economically, allowing manu-facturers to switch between normal labels and liner-less labels quickly. Linerless labels can be dispensed reliably and at the same rate as standard labels.

The Consumer Specialties Business Unit is work-ing with industrial partners to continue moving linerless technology forward. The importance of linerless systems will continue to grow insofar as they improve equipment efficiency and fully automate machinery, and as expectations of sustainability rise.

And last but not least, self-adhesive products—regard-less of how simple they appear at first glance—clearly show how important it has become to harmonize raw materials and production processes. Only by working together closely can the players involved secure markets for the future and ensure an inno-vation process that will lead to solutions meeting all of the customer’s needs: considerable leeway for design, highly efficient application, maximum label quality, and comprehensive preservation of our finite resources. 777

dr. winfried Hamann Technical Head Innovation Management RC Silicones EMEAphone +49 201 173-2452winfried.hamann @evonik.com

georg Michels Regional Product Line Manager Surface Technologies EMEA phone +49 201 [email protected]

liz Patterson Market Manager RC Silicones Americas phone +1 804 [email protected]

Jürgen PomorinTechnical Manager RC Silicones EMEA phone +49 201 173-1662juergen.pomorin @evonik.com

dr. stefan stadtmüllerGlobal Product Line Manager Surface Technologiesphone +49 201 173-3104stefan.stadtmueller @evonik.com

Figure 3The ETI system utilizes a liner within the label-ing system. This liner is run through a loop, significantly reducing paper consumption

Printed linerless label roll Matrix waste

Die cutting

Process linerless unwindReuse

Label dispenserContainers

Process liner rewind

Label dispenser

Label

Liner

Dispenser


30 news

New research center at Rheinfelden siteAt its Rheinfelden site Evonik is making an investment in the double-digit million euro range in a new research center. Starting at the beginning of 2016, up to 70 employees will conduct research into silanes in modern labo-ratories housed in a large new build with an area of 3,500 square meters. Silanes are used in the electronics industry, in the tire industry, for the production of adhesives and sealants as well as plastics, and in the construction indus-try. Application engineering, analytics, and

quality management will also be located in the research center in the future. The center fits in perfectly with the integrated silane chemical production network in Rheinfelden, which en-compasses research, development, application technology, and production.

Ralph Marquardt, head of Innovation in the Inorganic Materials Business Unit, explained the importance of silane research: “Evonik is the global market leader for functional silanes. We make target-oriented investments to build

on this position. In this context, first-class research and application engineering are a key factor for further positive development.”

The silanes that are being researched into and produced here make chips in smartphones faster and more efficient, protect buildings from corrosion and dirt, and enable fuel-saving tires or longer-lasting paints.

Evonik produces silanes at its sites in Rhein felden (Germany), Antwerp (Belgium), Rizhao (China), Mobile (USA), and Weston (USA). The specialty chemical company also operates laboratories for application technol-ogy support and regionally specialized research for silanes in China, India, Germany, and the United States. Evonik’s silane portfolio com-prises chlorosilanes and organo-functional silanes with an overall annual capacity of 300,000 metric tons.

New building for applied technology for tire and rubber inauguratedIn spring, Evonik inaugurated a new building to house precipitated silica applied technology for tire and rubber at its Wesseling site near Cologne. In doing so, the leading specialty chemicals company has added applied technol-ogy to the world’s largest facility for precipi-tated silica production and research. Evonik invested an amount in the low tens of millions of euros in the new building, where now more than 30 technicians and scientists are working.

A combination of precipitated silica and sulfur-functional silanes produced for the tire and rubber industry enables tire manufactures to reduce their products’ rolling resistance and improve their wet-grip. This can reduce fuel consumption by up to eight percent in com-parison to conventional tires.

Evonik supplies precipitated silica to the tire industry globally from Wesseling where silica production and research were previously located. Thus it made sense to relocate appli-cation engineering to the Wesseling site.

Innovative products for the rubber industry are being developed and tested in the new 2,500-square-meter building. Strict quality control, which is standardized worldwide, is applied to several thousand mixtures annually. The building itself is setting new standards for

resource efficiency. It is heated using waste heat from the plant’s silica production. To be closer to its worldwide customers and provide them with first-class products, Evonik has undertaken a robust worldwide capacity ex pan-sion. Evonik’s global silica production capacity will increase by approximately 30 percent over its 2010 capacity by the end of 2014.

Groundbreaking ceremony for the new research center: Represen-tatives from the country, the county, the city, and from Evonik get their shovels ready


31news

New Technology Center for Electronic Solutions in TaiwanEvonik has inaugurated its new Application Technology Center for Electronic Solutions in Hsinchu (Taiwan). The new Technology Center offers to the display industry not only technical advice but also customer-specific formulations, as well as new applications for the iXsenic® product line of the Coatings & Additives Busi-ness Unit. iXsenic® comprises semiconductors, dielectrics, etch-stop, and passivation materials that can be applied directly in solution. The materials are used in a broad range of current and future high-end displays: in LCD, OLED, touch-sensitive, flexible, and transparent screens, as well as printed electronics.

The use of a production line of the local research center ITRI also allows the Electronic Solutions team to test its solution-based semi-conductors in an industrial display production environment in order to improve material and process. Dr. Ralf Anselmann, Vice President

Russian joint venture OOO DESTEK celebrates ten years of successThe Russian joint venture OOO DESTEK, in which Evonik holds a majority interest, has suc-cessfully established itself on the market. The Acrylic Polymers Business Line of Evonik began producing extruded PLEXIGLAS® solid sheets in Russia ten years ago and has been signifi-cantly increasing its market share in the country ever since. “Having a presence in Russia was crucial if we were to strengthen and expand our business in this growth market,” said Michael Träxler, head of the Acrylic Polymers Business Line, on the occasion of the anniversary.

Investment in biotechnology company Evonik is investing in the technology start-up Algal Scientific Corporation (Northville, Mich-igan, USA). The company is part of an investors’ consortium that is investing more than US$3 million in Series A financing round. Under the trade name AlgamuneTM Algal markets 1,3--glucan, a polysaccharide that strengthens immune response. It is used as an additive in animal feeds and as a nutritional supplement as well as in pharmaceutical formulations.

This is the first time it has been possible to obtain -glucan from algae on an industrial scale. Algal has developed a new technology for this purpose and is currently in the process of starting up the first commercial production

plant in Michigan. -glucan is usually extracted from grain or produced using yeasts or fungi. Algal’s new biotechnological process needs fewer production steps and at the same time generates significantly higher yields.

In addition to the innovative production technology, the use of -glucan in a wide vari-ety of animal feed applications is of particular interest to Evonik. The immune-stimulating effect of -glucan results in healthier animals and efficient growth, thus contributing to resource-efficient nutrition of the global pop-ulation. -glucan is suitable for nutrition of pigs, poultry, and ruminants as well as for aquaculture.

“Algal contributes toward sustainable animal nutrition,” says Dr. Bernhard Mohr, head of Evonik Venture Capital. “In view of the grow-ing global population and the subsequent increasing demand for animal protein, this is an interesting market with attractive growth poten tial.”

Also part of the consortium, in addition to specialty chemicals group Evonik, are the US venture capital firms Formation 8 (California), Independence Equity (Illinois), and Envy Cap-ital (Michigan), as well as regional funds and business development companies promoting the establishment and development of attrac-tive companies in Michigan.

DESTEK supplies the Russian market with sev-eral thousand metric tons of extruded PLEXI-GLAS® per year. Its main customers are from the illuminated advertising, noise protection, and furniture construction industries.

DESTEK has an outstanding distribution network that ensures supplies to the entire Russian market. In response to the strong demand for high-quality PLEXIGLAS® products, Evonik started to expand production capacity back in 2009. “In doing so, we advanced our growth strategy in Russia, further increased

the availability of our products, and shortened delivery times,” explained Andrey Ivanov, Director General of DESTEK. Currently, more than 30 employees in Podolsk manufacture solid extruded sheets. DESTEK also offers specialty PLEXIGLAS® products from other sites in the global production network of the Acrylic Poly-mers Business Line. To market these more effectively in Russia, Evonik opened a light stu-dio in Podolsk in 2013 in which customers can see all of the benefits of PLEXIGLAS® for themselves.

Measurement set-up for thin-film transistors

Electronic Solutions: “In the electronics indus-try, speed is what matters. Now we are ready to answer customer demand for support in an instant.”


32 catalysis

The new catalyst preparation laboratory will be based at the Xinzhuang site in Shanghai

witH tHe construction of a laboratory for cat-alyst preparation in Shanghai, Evonik’s Catalysts Busi-ness Line is taking an important first step toward in-dependent catalyst research and development in the Greater China region. This will consolidate the com-pany’s position in this important growth market.

The Catalysts Business Line has operated a pro-duction plant for precious-metal powder catalysts, including quality control, in China since 2010. A local team assists customers on-site in all catalyst-related questions. Technical consulting includes such ser-vices as recommending a catalyst and organizing a sample, answering questions regarding the use of the catalyst in the customer’s production process, and catalyst handling. It also includes resolving specific technical issues and solving problems in cooperation with the customer. Precious-metal management is also a component of the service.

Certain services, such as preparation of catalyst samples, adjustment and optimization of formulas based on specific customer requirements, and tech-nical consultation on quality issues for the Greater China region are currently handled almost exclusively in the R&D laboratories in Hanau (Germany). Addi-tional time must be allowed for sending the materials between Germany and China, which can be a major disadvantage, especially when requests are urgent. Strict rules governing the import and export of pre-cious metals in China also hamper movement by, for example, making it harder—or, in the case of precious metals, almost impossible—to use original raw mate-rials from China for catalyst preparation in laborato-ries in Germany. But with a laboratory in Shanghai, it will be possible to react faster than ever before to the respective local requirements.

The new laboratory will concentrate on precious metal powder catalysts for the Life Sciences & Fine Chemicals market segment, because it requires an especially high level of flexibility and speed. The catalysts are used primarily in discontinuous batch processes. Most of these are catalytic processes with relatively small production volumes, such as those in the pharmaceutical industry and agricultural chem-istry. For this segment, the catalyst specialists have several hundred products for a great variety of customers and applications in their portfolio.

The main tasks of the laboratory will be catalyst preparation on the lab scale—for customer sampling—and production on the pilot scale. The pilot plant will also assist technology transfer and scale-up to pro-duction. The laboratory will commence operation this fall with four employees. 777

Evonik consolidates catalyst research in China


33news

Evonik invests in specialist in biobased lubricantsEvonik has closed on an equity investment in Biosynthetic Technologies, LLC (BT), a spe-cialist in biobased lubricants headquartered in Irvine (California, USA). BT has developed and manufactures a new class of bio-based syn-thetic oils called estolides that are used primar-ily in the passenger car motor oil and industrial lubricant sectors.

Field trials have shown that the technical characteristics of the biobased synthetic oils made by BT are exceptionally good, and include the ability to combat soot buildup in engines, which helps keep fuel consumption low. In addition to Evonik, BP Ventures also partici-pated as a second strategic investor in this cur-rent funding round that focuses on growth. BP Ventures as well as Monsanto Company have already invested in previous financing rounds.

“Biosynthetic Technologies leads the way to high-quality sustainable lubricants,” says Dr. Bernhard Mohr, head of Evonik Venture Capital. “In view of the large automotive market and the strong trend towards fuel-econ-omy and sustainability, this is a growing market with a strong fit to Evonik’s oil additives busi-ness.”

For Biosynthetic Technologies, Evonik is attrac tive not only as an investor but because of its expertise in manufacturing, R&D, and sales and marketing. This support will allow Biosynthetic Technologies to expedite its commercialization process.

The benefits of biobased oils from BT include helping keep engines clean and fuel consumption low

the particular benefits the materials from Evonik bring to the vehicle,” explained Eckart Ruban, who heads the Automotive Industry Team at Evonik.

The race car is powered by a 360 hp tur-bocharged V6 engine with a CFRP (carbon- fiber-reinforced polymer) chassis and weighs approximately 1,050 kilograms in total. “The race car is therefore almost perfect for the race track,” Ruban confirmed. Other Evonik mate-rials will be used over the course of the season and will be tested under extreme racing con-ditions. ”These tests will also provide us with important knowledge about the performance and durability of our materials for the auto-motive industry.”

Specialists from various business units of Evonik are constantly developing innovative material solutions for the automobile sector in the fields of lightweight construction, fuel economy, and lighting and surface technol-ogies.

Testing products on the race track

Evonik has collaborated with Roding Co., a low-volume manufacturer from Bavaria, to de-sign an ultra-lightweight race car. The high-performance vehicle will be driven in this year’s DMV Touring Car Championship (DMV TCC), having premiered at the Hockenheim-ring race track in mid-June. The race car is based on the Roadster manufactured by Roding Automobile GmbH, a low-volume manufac-turer with outstanding expertise in lightweight design, composites and complete vehicle exper-tise.

Evonik is using the race car as a technology platform. Further innovative materials solu-

tions will be used from the specialist fields of lightweight design, fuel economy, and emis-sions reduction. For example, racing motor oil additives, VESTAMIN® resin for carbon- fiber-reinforced plastics (CFRPs), and the lightweight structural foam ROHACELL®, as well as PLEXIGLAS® for the screens, which saves around 50 percent in weight compared to customary glazing.

“This motorsports project strengthens Evonik’s expertise in producing automotive components based on specialty chemicals, and most of all it demonstrates to our partners in the automotive industry the practical use and

Premiere: New ultra-lightweight race car made with Evonik materials


34 corPorate ForesigHt

The world’s oceans are becoming increasingly important as a source of nutrition, a raw materials resource, and a transport route. The Creavis Corporate Foresight department investigated the potential of this development for Evonik for one year, focusing on the subject of marine economy.

[ text: Dr. Bernhard Schleich ]

Unearthing the oceans’ hidden treasures


35corPorate ForesigHt

More tHan two-tHirds of the Earth’s surface is covered by water, yet most human activities are car-ried out on land. For us humans, it is almost incon-ceivable that life on planet Earth began around 3.5 billion years ago in water and that the first amphibi-ans only emerged from the water about 400 million years ago. The deep ocean in particular has remained a largely unknown world for mankind.

In view of the continuously growing world pop-ulation and the increasing scarcity of resources on land, politicians and scientists are increasingly look-ing at the world’s oceans for a solution. Whether as a source of nutrition, a source of oil and gas from deeper and deeper reservoirs, a source of energy from wind, wave, and tidal power stations, or as a habitat—the sea offers many different opportunities. At the same time, there is a fear of upsetting this sensitive ecosystem and also of its power in the event that sea levels rise as a result of climate change. This would especially affect coastal regions, where many of the world’s large cities and industrial hubs are situated.

The Foresight team looks 10 to 15 years into the futureReason enough for Corporate Foresight, the Creavis department established to identify new growth areas as well as risks for Evonik, to make marine economy a focal topic for 2013. For twelve months, with the support of external experts, the in-house scientists investigated the opportunities that our oceans offer for Evonik within the next 10 to 15 years.

Seven clusters were formed in order to consider the subject from many different angles: Marine Transport, Marine Energy, Marine Raw Materials, Coastal Construction, Pollution, Security, and Leisure and Tourism (fig. 1). Within each cluster, the aim was to understand current developments better, to rec-ognize trends, and to identify topics that were rele-

vant for the future and that offer opportunities for value adding in the area of marine economy. Prom-ising innovation fields were then to be derived from the results of these investigations.

The ship of the future will be made from different materialsRight at the beginning of the investigations into ma-rine economy, the Foresight managers asked them-selves why Evonik has many activities in the auto-motive and construction sectors but almost none in the areas of ships and ports. It seems obvious that there are many starting points for specialty chemicals companies in this field—especially in regard to inno-vative materials and material design. For example, lightweight construction is not only a promising way to reduce transportation costs in the automotive sec-tor, but also in ship design, not least because of con-tinuously rising seaborne trade volumes (fig. 2). At present, when at sea, a large freighter consumes fuel to the value of US$250,000 every day. The maritime industry also sees a need for optimization in terms of material properties, such as temperature stability and fire resistance and regarding the environmental com-patibility of the paint used on the hull.

Selected representatives from Evonik’s business units were given insights into these topics during a workshop entitled Material Solutions for Future Ship-ping organized by Corporate Foresight in late 2013 in collaboration with the Maritime Cluster North Ger-many (MCN). MCN is a network of the German states of Hamburg, Lower Saxony, and Schleswig-Holstein for companies in the maritime industry. The work-shop was the starting point of an ongoing sharing of ideas and information between the business units, maritime research, industry, and politics. Some first concrete follow-up activities in the business units are already taking place. 333

Figure 1 The focal topic marine economy was investi-gated in seven clusters

Pollution Marine Transport

Marine Raw Materials

Marine Energy

Security

Leisure and Tourism

Coastal Construction



What happened to the topic of megacities?

Megacities were the focal topic of Corporate Foresight in 2011 and 2012. It was the first topic to be processed in this format in order to identify new growth areas for Evonik.

Megacities are cities with a population of more than ten million. There are already 20 of these worldwide and this number is certain to rise. In these densely populated megacities, newly arising problems become obvious sooner than elsewhere—such as difficulties in providing health care for the in habitants, providing them with sufficient food and water, and changing requirements in the areas of housing, energy, infrastructure, and mobility.

The actual foresight process, using foresight methods, was carried out in 2011. At the end of this, the team had six growth areas that were potentially interesting for Evonik: medical technologies, advanced food ingredients, recovering potable water from the air, intensifying agriculture, thermal manage-ment, and urban technologies. In 2012, these were examined in more detail in terms of usability and were then focused further. Megacities were also a subject of the Evonik Meets Science conferences in Darmstadt in October 2012 and in Shanghai in November 2012 (see elements 42).

In the meantime, specific measures have evolved from five of the six topics: the involvement with medical products has resulted in the establishment of the Medical Devices Project House. How advanced food ingredients can contribute more to human health is currently being investigated as a project in the Health & Nutrition Business Unit. Concerning agricultural inten sification, the Advanced Intermediates Business Unit is

developing solutions to improve the supply of oxygen to plants. For thermal management of buildings, the Inorganic Materials Business Unit developed high-performance insulation materials that are now marketed under the CALOSTAT® brand.

Because the subject of urban technologies is so broad-based, the Foresight team initially focused on the construction industry and established an Urban Tech Team in Creavis in March 2012. Its task was to identify applications for Evonik in this area and to bring about innovation projects. The team observed the activi-ties of 13 different business lines in the construction sector and worked out what potential there could be if the competences were pooled. One of the main topics that were identified was the window of the future. Several business lines contributed to developing possible solutions. The results of this process were assessed in an open innovation event with key customers from the window industry and were supplemented with further inno-vation ideas.

In view of these promising results, the temporary Urban Tech Team was transferred to a permanent Construction Industry Expert Panel in spring this year. The task of the new team is to pool and position Evonik’s product and marketing competences in the construction industry across the different businesses. This will enable the company to offer new system solutions that are tailored exactly to the customers’ needs. The interdisciplin-ary team includes representatives from the Coatings & Additives, Consumer Specialties, Inorganic Materials, Performance Poly-mers business units, from Creavis, from Marketing & Sales Excellence, and from the Europe region.

Tokyo tops the list of megacities

FlasHbacK


37corPorate ForesigHt

An increasing number of ships sail with (and transport) liquefied natural gas The workshop also confirmed the importance of liquefied natural gas (LNG) from the Marine Energy cluster. LNG is created by cooling natural gas to about minus 160 °C. It has only around a 600th of the volume of gaseous natural gas. Because of this, it is not dependent on pipelines but can be transported by road, rail, and sea. This reduces dependency on indi-vidual natural gas suppliers. As a result, experts assume that global consumption of LNG will rise by about 20 percent by 2020. For example, Europe could buy liquefied natural gas from the USA or Saudi Arabia that would then be delivered in large oceangoing vessels.

However, since LNG has to be kept cooled, special storage and transportation containers are required. Suitable insulation materials, temperature-resistant coatings, and possibly composite materials are needed as an alternative to metals—interesting fields for the materials experts at Evonik.

But LNG is not only transported in ships. In the maritime industry, it is becoming increasingly im-portant as a fuel alternative to pollutive heavy oil. Sweden and Norway already have LNG plants where large ferries can refuel. According to a recent inter-national convention, ships should reduce their emis-sions (fig. 3) through fuel-saving measures by 20 per-cent by 2020 and by 50 percent by 2050. This may result in an increase in the use of LNG. The topic seems so promising for Evonik that Creavis will now analyze it in more detail under the heading “cryogenic insulation.” 333

90 percent of global goods traffic is by ship

LNG transporter ship

Figure 3

Increasing maritime trade is also reflected in the rise in CO2 emissions

Not including emissions reduction Including emissions reduction

Global CO2 emissions from shipping [million metric tons]

0

3,500

3,000

2,500

2,000

1,500

1,000

500

2010 2013 2020 2030 2040 2050

Source: Lloyd’s Register, 2011

Figure 2

The volume of freight shipped by sea has been increasing continuously for years

Freight [million metric tons]

10,0009,0008,0007,0006,0005,0004,0003,0002,0001,000

01970 1980 1990 2000 2005 2006 2007 2008 2009 2010 2011 2012

Source: UNCTAD/Clarkson Research Services



Methane hydrate could be an energy source of the futureIn the Marine Raw Materials cluster, the Foresight managers also looked at the sub-topic of methane hydrate—the enormous natural gas deposits that occur from the enclosure of methane on the seafloor (fig. 4). Methane hydrate is considered to be an energy source of the future. It is formed from water and methane gas at a pressure of about 20 bar and a water temperature of 2 to 4 °C.

Only last year companies from Japan and the USA started the first tests in the Pacific Ocean to recover methane hydrate from the seafloor. One of the diffi-culties is that methane hydrate becomes very unsta-ble when it is removed from an environment of high pressure and low temperatures.

With our present knowledge, only a small part of the methane hydrate deposits can be extracted eco-nomically. For example, the deposits must not be too far off the coast and not more than 200 meters below the seafloor. One of the extraction technologies is based on the use of chemicals to drive out the gas and then bring it to the surface of the sea. The Foresight team sees potential for Evonik here as well as in the area of flexible piping that is needed to transport the gas. However, it is not expected that methane hydrate will be recovered on a commercial scale before 2025.

Because of this, the team decided to put the subject on hold for now and will continue to observe the sit-uation.

Business units see potential for marine raw materials The investigations into each of the identified topics included in-house research and intensive sharing of information with experts from science and industry, such as scientists from the Geomar Helmholtz Center for Ocean Research in Kiel (Germany) and the Woods Hole Oceanographic Institution in Massachusetts (USA). Discussions were also held with experts from many industrial companies. Internal input also came from the Foresight Partners in the business units, from Process Technology & Engineering, Corporate Development, and the neighboring departments in Corporate Innovation Strategy & Management.

The sub-topics that were analyzed in the Marine Raw Materials cluster included aquaculture, which is booming throughout the world and which is already a successful area of business for Evonik (see elements 47). In addition to animal nutrition, the Foresight managers also identified other promising aspects, such as oxygen supply and water pollution control. These will now be processed further in the Advanced Intermediates Business Unit. The subject of macro-algae as a possible source of valuable compounds was also handed over to the Health & Nutrition Business Unit for assessment.

With two other topics that were investigated in more detail—port infrastructure (from the Coastal Construction cluster) and offshore wind power plants (from the Marine Energy cluster)—the evaluations have not yet been finalized. The Foresight team is currently working on transferring the many findings from these ranges of topics into promising innovation projects. Simultaneously, the next focal topic is being prepared. 777

dr. bernhard schleich has managed the Corporate Foresight department in Creavis since 2011. After earning his degree in physics, he joined the analy-tical department of the former Hüls AG in 1987. From 1996, he was a member of the screening committee that devel-oped new business options for the Group, which later led to the establish-ment of Creavis. There, he managed the Lotus-Effect project, and in 2004 he founded the Group’s first Science-to-Business Center, Nanotronics. Follow ing this, he held positions in the Liaison Office in Brussels (Belgium) and in Corporate Innovation Strategy & Man age ment.phone +49 2365 [email protected]

Figure 4 Deposits of methane hydrate have been discovered in the Arctic permafrost and on the seafloor at depths of 400 to 1,200 meters

Methane hydrate deposits

below seafloor

Faults provide conduits for methane seeps

Hydrate mounds on seafloor

Drill ship

Bottom of permafrost

Biogenic methane generated by

bacterial action in shallow sediments

Arctic methane hydrate deposits above and below

limit of permafrost

Drilling rig

Slow seepage of thermogenic methane from below


39news

Credits scientific advisory boardDr. Felix MüllerCorporate Innovation Strategy & Management [email protected]

editor in chiefDr. Karin Aßmann (responsible)[email protected] [email protected]

contributing editorChrista Friedl

PhotosDieter DeboUwe FeuerbachRolf van MelisFrank PreussBiosynthetic Technologies (p. 33 top)cycle4green Ltd (p. 25)Hühoco Metalloberflächen-veredelung GmbH (p. 9)Fotolia:del (cover)Gina Sanders (p. 5)lassedesignen (p. 6)Christian Müller (p. 30)EvrenKalinbacak (p. 35)SeanPavonePhoto (p. 36)

design Michael Stahl, Munich (Germany)

Printed bydruckservice duisburg medienfabrik GmbH & Co. KG(Germany)

Reproduction only with permission of the editorial office

Evonik Industries is a worldwide manufacturer of PMMA products sold under the PLEXIGLAS® trademark on the European, Asian, African, and Australian continents and under the ACRYLITE® trademark in the Americas

Publisherevonik industries agCorporate Innovation Strategy & Management

Rellinghauser Straße 1–1145128 EssenGermany

Evonik builds dispersant plant in EssenEvonik Industries is building a new production plant for polymer dispersants at the Gold-schmidtstrasse site in Essen (Germany). The specialty chemicals company is thus investing an amount in the double-digit million euro range and is tripling its global capacity for poly-mer dispersants. Plans call for start-up in the first quarter of 2015. Polymer dispersants are mainly used in water-based systems in paints and printing inks and in high-solid systems with a low proportion of solvent.

Dr. Ulrich Küsthardt, head of the Coatings & Additives Business Unit of Evonik:“The prod uct group of polymer dispersants is devel-oping in an extremely attractive way. With our expanded capacity, we want to serve this grow-ing market.”

Dispersants support the trend toward more environmentally friendly and efficient paint systems. They increase color intensity and colorant yield. Evonik markets the dispersants as additives under the name TEGO® Dispers. Because of their viscosity-lowering effect, the products permit economical production of paints and pigment concentrates by maximizing the pigment concen-tration during dispersion.

Investment in new silica plant in BrazilEvonik plans to build a plant to produce precipitated silicas in Ameri-cana (São Paulo, Brazil). The company is investing a mid-double-digit million euro amount; the plant is scheduled to go onstream in 2016. This will be the first production plant for highly dispersible (HD) silica in South America. This high-growth silica is used mainly for high-qual-ity low rolling resistance tires. In addition, by building this new silica production plant, Evonik is also catering for the needs of the growing regional business in attractive specialty segments in South America’s food, animal feed, and agricultural industries.

The tire industry profits from the growth in the automotive indus-try, which has recorded considerable increases in sales in South Amer-ica over the past years. The market for low rolling resistance tires and,

consequently, for HD silicas, has been growing much stronger than the market for conventional tires in South America. Evonik expects additional demand because of the planned labeling of the energy effi-ciency of tires in Brazil.

Evonik is expanding its silica capacities throughout the world: By the end of 2014, they will have grown by around 30 percent com-pared to 2010. In Chester (USA), a plant for precipitated silica with an annual capacity of about 20,000 metric tons is scheduled to begin oper-ations in 2014. The expansion in North and South America follows expansions that have already been completed in Europe and Asia. A production plant extension was completed in Thailand in March 2014, for example.

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