elements33 Quarterly Science Newsletter Issue 4 | 2010

Health & Nutrition Greater efficiency in the trough Professional protection for aging skin

Coating & Bonding Technologies The smart adhesive

02 contents

neWS 08 4 0 Dr. Klaus Engel appointed new president of VCI 04 Evonik is planning a new methionine plant in Singapore 05 Collaborating with the most ambitious university in the world 06 Debuting PLEXIGLAS® car windshields from Evonik 07 Decision to divest the global carbon blacks business 07 Fascinating effects with PLEXIGLAS® Textured Sheet RADIANT

L HEA TH & NUTRITION 8 0 Amino acids diet makes pig feed more favorable for the environment and climate: Greater efficiency in the trough 14 Professional protection for aging skin 22 neWS 20 Bachelor work at Evonik awarded by Max Buchner Research Foundation 21 Evonik Meets Science China 2010 21 Evonik to expand TAA production capacities in China

m No inated for the Evonik Innovation Award 2010 new Products/New System Solutions category 22 Bringing the power of meat back into feed: CreAMINO® for animal nutrition 23 SAVOSILTM brings light to new markets 24 New viscosity improvers reduce fuel consumption 36 No ew r Improved Processes category 25 Siridion® HCDS 500 E: a new raw material for the semiconductor industry 26 A new pathway to ultrapure isobutene 27 New biotechnology platform makes LOLA a winner

PR Ocess TECHNOLOGY 28 Self-learning programs: The EU INFER Project develops adaptive soft sensors 30 Professor conference: concentrated process and technology expertise

neWS 34 Coating materials with VESTOSINT® gleam at Durban’s airport 34 Significant capacity expansion for precipitated silicas 35 LEDs shine brightly for longer 35 PLEXIGLAS® façade for meteorological tower

COG ATIN & BONDING TECHNOLOGIES 36 Release coating made from UV-cured silicone: the smart adhesive

NEWS 43 Geothermal energy used even more efficiently

43 Credits

elements33 Issue 4|2010 oEdit rIAL 03

And the winner is ...

Second place, as in “they came in only second,” is an often neglected honor. Indeed, it is easy to overlook the tremendous achievement that second and third place re- present. To remedy this, we are now modeling our Innovation Award, which we have traditionally presented in December, on the Oscars: For the first time, we have nominated three teams each for the New Products and New Processes categories, and will not decide the first-prize winners in each category until the day we present the award. And it looks like the decision will be as difficult for us as ever this year, since our researchers have submitted so many innovative projects. Page 22 ff. of this issue will give you an idea of their work. The new nomination process is our way of drawing greater attention to the teams finishing second and third, because a win for them is a win for Evonik. We are also clear winners when it comes to DL-Methionine, an amino acid that Patrik Wohlhauser is particularly vital as an additive in poultry feed. Already the world‘s largest pro­ Chairman of the Board of Management of ducer, we are planning to expand our position by building a new plant in Singapore. Evonik Degussa GmbH When the committees concerned have given their approval to the construction of the plant, we will have, as early as 2014, a total capacity of 580,000 metric tons of DL-Methionine, on an investment in the mid triple-digit million euro range. This is money well spent, given that the market for methionine has been growing for years. First, consumer behavior is changing worldwide, and meat is appearing more and more on the tables of developing countries. In the prosperous regions, the growing trend toward healthy foods is driving greater consumption of low-fat poul- try instead of pork or beef. Second, the growing world population must be supplied with high-quality and safe food—and this is possible only with highly productive agricultural processes that take account of the scarcity of fertile soil and water. Innovative feed concepts that include our amino acids as additives, instead of protein-rich soy or rapeseed meal, are making a key contribution in this regard—as we have scientifically proven in our life cycle assessment. As a rule of thumb, if the vegetable protein in the feed is reduced by 1 percent, then the nitrogen content in the manure drops by ten percent, the am- monia emissions to the air fall by ten percent, and water consumption is reduced by three percent. And the 580,000 metric tons of methionine that we will be supplying the market beginning in 2014 will save 11.6 million hectares of arable land that can be put to such uses as growing food. A win-win situation for everyone.

elements33 Issue 4|2010 04N ews

­

Dr. Klaus Engel appointed new president of VCI

The general meeting of Germany’s vision for a growing world population chemical industry association, VCI, in and the provision of health care for an Dresden on September 24 elected Dr. aging population. It must be our shared Klaus Engel, Chairman of the Executive concern to have the innovations needed Board of Evonik Industries AG, as its pres­ to meet these challenges developed and i ­dent. Engel has been a member of the produced here in Germany. And for that association’s presidential council since we require an internationally competitive 2008. environment for our enterprises. I will Upon his election to the post, Engel seek to enter dialog with the political said: „As VCI President, I will act to en- community, the trade unions and society sure good prospects for chemicals com- at large on how we can create the ideal panies in Germany and for industry em- framework conditions conducive to that ployees. The coming years will see the aim.“ chemical industry’s products and inno- VCI stands for more than 90 percent vations more in demand than ever before. of the German chemical industry. In There will be challenges surrounding 2009, the German chemical industry re- energy and resource efficiency in build­ alized sales of about €145 billion and em- ing construction and mobility, food pro- ployed more than 416,000 people.

Evonik is planning a new methionine plant in Singapore

uct to 580,000 metric tons p.a. Evonik’s currently produces this amino acid at four Executive Board has now approved the plants in Wesseling (Germany), Mobile conceptual and basic engineering for (USA) and Antwerp (Belgium). In re­ Singapore’s petrochemicals site Jurong Is- sponse to the robust development of land. The approval of the Supervisory demand, the present facilities are being Board is still pending. expanded successively to raise total capac­ “Methionine is an Evonik core busi- ity to 430,000 metric tons p.a. by 2013. ness. The market is growing steadily and Backward integration to include cri­t­ has proven very robust, even in the eco- ical intermediates is a major advantage: nomic crisis. The planned new facility in “It means we can maximize delivery re­ Asia, which will be the most important liability and competitiveness for our cus- market in the future, is designed to tomers. That is shown by the experience strengthen our market leadership,” ex­ at our other sites, which also have a high plained Klaus Engel, Chairman of the Exe- degree of backward integration.” More­ cutive Board of Evonik Industries AG, over, the facility in Singapore will be the commenting on the approval of the engi- most advanced of its kind. “Our success as neering budget. The final investment sum market leader is built to a large extent on will be in the mid triple-digit millions our technological edge,” said Beste. “The Evonik Industries intends to build a new range and still has to be approved by the new complex in Singapore will be further production complex for the amino acid Supervisory Board. proof of that.” DL-Methionine for animal feeds in Singa- “The facility in Singapore is the next Preparations for the new complex are pore. This backward integrated complex step in the creation of Evonik’s global pro- already advanced. “That is attributable to will produce DL-Methionine and all stra- duction network for methionine,” com- the excellent support we have received tegically important intermediates. The in- mented Dr. Reiner Beste, who heads the from the authorities and our partners in tegrated production complex with a capac­ Health & Nutrition Business Unit. “We Singapore,” stressed Beste. That, together ity of 150,000 metric tons p. a. is expected will then have a presence in all major re- with the excellent access to petrochemical to come on stream in 2014. Evonik is al- gions—Europe, the USA, Latin America raw materials in Singapore, was the main ready today the global market leader in and Asia—and will be able to supply our reason for the choice of site. methionine and the new facility will raise customers in the feed industry directly DL-Methionine is an essential amino its total production capacity for this prod­ from local production facilities.” Evonik acid for healthy and environmentally-sus-

elements33 Issue 4|2010 News 05

tainable nutrition of farm animals, espe- tion of meat will rise from 37.4 kg per per- of animal nutrition. New feeding concepts cially pigs and poultry. Demand for methio­ son per year at present to 52 kg by 2050. that ensure more balanced animal nutri- nine has risen continuously in recent At the same time, growing health aware- tion while optimizing the use of resources years. This is partly because increasing ness in the more affluent countries is lead­ and environmental impact are gaining prosperity in populous emerging markets ing to an above-average rise in consump- ground. Evonik can demonstrate the sus- such as China is changing consumption tion of low-fat poultry compared with tainability benefits of such concepts patterns and increasing demand for meat. other types of meat. Other growth drivers through a lifecycle analysis that has now The FAO forecasts that global consump- for amino acids are innovations in the field been validated by TÜV Rheinland.

Collaborating with the most ambitious university in the world

Thirty-six square kilometers in size, built might become a leading technology cen- Saudi Arabia has already shown that it not at a cost of USD 12 million, world-class ter, and to benefit from it,“ notes Dr. Peter only has abundant gas and oil resources, technical and financial resources—with the Nagler, head of Innovation Management but it also has what it takes to create a lea- new King Abdullah University of Science Chemicals & Creavis (IMC), who visited ding university: King Fahd University of and Technology (KAUST), at which 2,000 the university in October together with Petroleum and Minerals (KFUPM) in students are to be educated in the future, Dr. Bernhard Schleich, also from IMC, and Dhahran, founded in 1963. This technical Saudi Arabia has set its sights on an ambi- colleagues from Process Technology. university focuses on educating around tious goal. The university, which started The company has already established 8,200 students. And has done this success- operations in 2009, hopes to attract the best initial points of contact. For example, in fully: The petroleum industry and down­ researchers in the world and be one of the Prof. Dr. Jean Marie Basset KAUST has at- stream sectors in the region recruit a ma- best universities in the world for science tracted a renowned catalysis expert with jority of their new talent in the sciences and technology by 2020. Reason enough whom Evonik already has a relationship, from KFUPM. And this is the reason why for Evonik to establish contact with KAUST which has been nurtured through the this university was also on the itinerary. and to pave the way for collaborative ven- „Evonik Meets Science“ scientific forum. „If we want to establish ourselves in the tures, especially because the company Basset has now returned the favor and in- region with our own production opera- now also wants to get a foothold in Saudi vited Evonik to the opening of the Cataly- tions, naturally we will also need an access Arabia with production and to take part sis Research Center at KAUST at the end to an excellent local hiring pool,“ explains in a joint venture manufacturing superab- of the year. Currently 60 researchers Tilmann Ehret, who, as Evonik‘s Regional sorbers: „We have the opportunity to play work there; in the coming months this President Middle East/North Africa, ac- an active role in the formation of what number is supposed to go up to 120. companied his colleagues to the university.

Sea view from the King Abdullah University of Science and Technology

elements33 Issue 4|2010 06N ews

Debuting PLEXIGLAS® car windshields from Evonik

A car windshield made of polymethyl meth­ acrylate (PMMA) developed by Evonik In- dustries is now making its debut in racing. The company sells its PMMA prod­ ucts under the PLEXIGLAS® trademark. Following a trial phase in a racing car, the material is designed for series production later on. “The requirements in motor sports,” says Rudolf Blass, responsible for automotive and surface design in Evonik’s Acrylic Polymers Business Line, “are so high that it is the ideal training field for new developments.” For instance, a windshield that will stand up to racing must be optically perfect in order to give the driver a clear view for maximum safety. High resistance to stone chips is also es- sential. The specialists at Evonik have mas­ tered these two key requirements—and successfully, according to Blass: “The stone chip resistance, for example, is much better than in a comparable wind­ shield made of glass.” What is more, The Lotus Exige with a car PMMA reduces the weight of the wind­ windshield made of PLEXIGLAS® from Evonik shield in RED Motorsport’s Lotus Exige For Evonik, motor sports is the acid test race car sponsored by Evonik by as much for other uses in everyday life, because as 40 percent, from eleven kilograms to what works on the race track generally six kilograms. has what it takes to be used in a produc- While weight is extremely important tion model. This is the reason Evonik took in racing, says the head of Evonik’s Auto- North Rhine-Westphalia, underlining the the next logical step: joining forces with motive Industry Team (AIT) Klaus Hed- importance of lightweight structures in sports car maker Lotus in Hethel, United rich, PLEXIGLAS® offers “additional, im- cars. This is the case for his Lotus Exige Kingdom, to develop a very special, street- pressive advantages.” Other characteris- race car—refined and made lighter with legal Lotus Exige demonstrating all tics of this material are its pronounced parts from Evonik Industries. Lightweight Evonik’s lightweight design solutions, and rigidity, excellent transparency, good design is a priority for the Group’s auto- a lot of other advantages. “The prototype acoustic properties and high UV and motive specialists. Body parts made of was our RED Motorsport racing car,” said weath ­ering resistance—all of which con- CFK and ROHACELL® structural foam AIT head Klaus Hedrich, “with which we tribute to a long life. What is more, the were produced for the lightweight racing celebrated numerous racing successes in material has a lower infrared transmission car, for example. It was also the first time the past in the Dutch Super Car Challenge than glass, so the passenger compartment that plastic charge air ducts were fitted in and came first in our class in 24-hour stays cooler. For some time now, PMMA the car engine, these being only half as racing in Silverstone 2008.” side windows have also been installed in heavy as the metal parts used up to now. The concept behind: The car’s low the Brit Racer, though the windshield and On the cold side, they consist of sintered weight has a positive effect on many of its side windows are just one aspect of polyamide 12 powder and, on the hot side, key characteristics—fuel consumption, Evonik’s glazing strategy. The developers VESTAMID® HTplus polyphthalamide, acceleration, braking, and cornering. The have their eye on further applications which withstands temperatures of up to task of the fast car with the number plate such as the glass for rear windows or pa- 180° Celsius. Evonik products are also used is to show how racing-tested lightweight noramic roof panels, which may be ready in the engine: RohMax® oil additives im- design solutions can be applied in serial for series production shortly. prove the friction properties of lubricants, vehicles, plus the secondary aspect of how “Potential weight savings of between generating higher performance with lower attractive real slimming down can look. 40 and 50 percent for one component fuel consumption. The power for the The result: the Evonik Light Weight make the heart of any racing engineer beat start ­er motor is generated by a lithium-ion Design (LWD) Lotus, which weighs stunn­ faster,” says Martin Roos, the owner of battery, which is only a third of the weight ing 75 kilograms less than the already very Mettmann-based RED Motorsport in of conventional lead batteries. light Lotus Exige S.

elements33 Issue 4|2010 News 07

Decision to divest the global carbon blacks business

Evonik Industries has decided to divest its utilizing the opportunities offered by this fore decided to concentrate investment on carbon blacks business. Dr. Klaus Engel, strong position to open up new perspec- areas with above-average growth poten- Chairman of the Executive Board of Evo- tives for the carbon black activities. Now tial. Given this, together with the increas­ nik Industries AG, said: „Our declared aim is the right time to extend and secure their ing consolidation of the sector and the is to find a solution that is equally convinc­ global presence through a change of own­ ris­ing significance of Asian markets, ing for customers, employees and business ership,“ said Engel. Evonik sees better perspectives for the partners. The decision to divest this busi- About 80 percent of Evonik‘s chemicals carbon blacks business outside the Group. ness provides the best basis for sustained business ranks among the market leaders. The carbon black activities are no longer investment in carbon blacks, new growth The Group adopted a new strategic focus defined as part of Evonik Industries’ core prospects and for securing future-ori­ at the end of 2009, and has announced that business and have already been carved out ent ­ed jobs in the long-term.“ it will be further streamlining its portfolio to a separate legal entity. Evonik‘s carbon blacks business ranks and focusing investment even more Evonik manufactures and markets car- second in the world and has strong and clearly on key growth markets. Strategic bon blacks for the rubber and tire indus- established brands. It has 1,700 employees portfolio development is aligned to the tries and pigment blacks for applications in­ in twelve countries and sales of around three global megatrends: resource effi­ cluding coatings, plastics, printing inks and €1 billion. Carbon black is an attractive ciency, health & nutrition, and globaliza- toners. Since the start of this year Evonik business. Following the sharp market tion of technologies. In this way, Evonik has been intensively examining the op- downturn during the crisis in 2009, this aims to sharpen its profile as one of the tions for the value-oriented development year earnings will rebound to the good world‘s leading specialty chemicals cor- of this business. It has now engaged an in- level registered in 2008. „We are actively porations. The Executive Board has there- vestment bank to prepare the divestment.

Fascinating effects with PLEXIGLAS® PLEXIGLAS® Textured Sheet RADIANT, the new prod­ uct that Evonik has been offering since September, is Textured Sheet RADIANT guaranteed to grab attention. For one thing, its textured surface diffuses light in an interesting way. For another, it creates colors that change according to the viewing angle, which is known as the RADIANT effect. Passersby see a colorful play of hues that is set off to particular ad- vantage by the surface texture. The special RADIANT surface coating is available on three different textures: Honeycomb, Ribbed and Pyra- mid. The combination of texture and color effects makes PLEXIGLAS® Textured Sheet RADIANT the center of attention, and equip the material for all applications that are meant to catch the eye, such as store fixtures and exhibition booths. The material also offers a diversity of options for interior design in bars, clubs and lounges. Designers and creative professionals make use of the material’s mirror-like reflections and scintillating colors. Lighting elements made from this new material in ceil­ ings and floors, or in lamps, are particularly striking. Ordinary daylight is usually enough to trigger the impressive rainbow effect, but the firework of colors is emphasized when the material is illuminated or backlit. Depending on the focus of the light source, this gives rise to a myriad of different shades. This effect is very popular. The existing PLEXIGLAS® RADIANT grade has already been installed in a large number of applications. A firework of colors with PLEXIGLAS® Textured The new product that has now been further developed Sheet RADIANT by the Acrylic Polymers Business Line at Evonik builds on this success.

elements33 Issue 4|2010 Amino acids diet makes pig feed more favorable for the environment and climate Greater efficiency in the trough

Modern livestock breeding and production supplies billions of people with vital protein. At the same time, it is one of the primary sources of greenhouse gases and environmental pollutants. A new life cycle assessment shows that high-efficiency and, therefore, resource- conserving feeding concepts are playing a key role in reducing livestock’s impact.

[ Text Dr. Michael Binder, Dr. Mark Redshaw ]

elements33 Issue 4|2010 HL EA TH & NUTRITION 09 ­ Livestock farming is one of the chief organism, eight to ten of these amino timal care of the animals. This method re- causes of damaging greenhouse gases—in acids—the “essentials”—have to be absorbed duces both the nitrogenous emissions and Europe alone, roughly 22 percent of green- through food. For proper protein synthe- the greenhouse gases of the feed. In prin- house gas emissions are attributable to sis in the body, the amino acids absorbed ciple, there are two ways to achieve this. milk and beef production. Animal feed through the feed have to be present in the Deficits of certain amino acids can be com- also generates high amounts of nitrate and proper ratio. This is the only way the or- pensated either by adding a higher per- ammonia, which pollute the air and water. ganism can form a sufficient quantity of centage of protein-rich feed components The farm operations themselves are not the numerous proteins it requires. such as oil seed meals, or by fortifying the the only sources of these emissions—feed­ feed with essential amino acids specially ing large populations of animals requires The right balance of amino produced by Evonik for this purpose. the importation of feed from emerging and developing countries, where natural acids is everything areas of great ecological value must give Conventional feed raw materials normally Customized supplementation way to the cultivation of soya and other display an unbalanced protein supply for Considering efficiency, the latter method animal feed. The problems will only get animal nutrition. Most of the time, the is better: selectively adding certain amino worse: the Food and Agriculture Organi- range of amino acids available does not acids to pig and poultry feed not only en- zation (FAO) estimates that worldwide meet the actual physiological needs of the sures a well-balanced diet for the animals consumption of meat, which is currently animals. Even a mixed feed consisting of but also conserves resources and protects 38 kilograms per head and year, will in- corn, wheat and soybean meal can lack the the environment. Evonik reached this crease to 52 kilograms in the year 2050. essential amino acids methionine, lysine, conclusion at the end of a life cycle assess- The environmental and climate issues threonine and tryptophan, depending on ment that compared the two options for associated with intensive livestock produc- the need and the purpose for which the optimizing animal feed. tion are well-known. But it is also an un- animals are being fed. Internationally, the life cycle assess- disputed fact that a steadily growing world Because conventional plant-based ani- ment (LCA) is the most recognized population has to be reliably fed over the mal feeds are always deficient in one or method for evaluating the environmental long term with safe, high-quality foods. more amino acids, the consequences are impact of a product or process, because it An optimal diet for humans and animals significant: the animals require more feed is the only method that can cover a broad includes amino acids, the building blocks because they utilize it poorly. They also, range of applications consistently and uni- of protein, hair and skin, part of muscles in turn, produce more manure, which pol- formly across nations. This tool describes and connective tissues. As components of lutes the groundwater with nitrate and the the entire life cycle of a product—from ex- hormones they control the body‘s vital air with ammonia. Not least, the livestock traction of raw materials, through the processes; as antibodies they fight off in- producer must pay more for his animal production process and then use by the fections; as carrier proteins they transport feed. consumer, to disposal. key substances through the body. The solution is clear: animal feed must Evonik is the only manufacturer of All organisms build their proteins from be formulated to offer a customized range amino acids for animal nutrition that has 21 different amino acids. Depending on the of amino acids and, therefore, ensure op- subjected its products— L-Threonine, 333

Evonik determines the amino acids composition of forage plants in the analytics laboratory in Hanau. This is necessary for optimizing the range of amino acids to meet Greater efficiency in the trough the needs of the animals

elements33 Issue 4|2010 10L HEA TH & NUTRITION

Figure 1 Option 1: Amino acids premix Representation of the functional unit for environmental 1.0kg Premix assessment of the individual options for feed mixtures in pig feed. All three options are based on the same mix- 0.10kg DL-Methionine ture of wheat and barley; Options 2 and 3 are each 0.67 kg L-Lysine shown in contrast to Option 1. For example, the amino 0.20 kg L-Threonine acids mixture from Option 1 corresponds to a mixture of 0.02 kg L-Tryptophan 29.1 soybean meal and 1.9 kg soya oil in Option 2. To ba- lance out the quantity and energy content, an additional Option 2: Soybean meal Option 3: Soybean meal/Rapeseed 4.6 kg of wheat, 17 kg of barley and 7.5 kg of corn- + 4.6 kg Wheat + 21.6 kg Wheat DDGS must be added to Option 1 to make it comparable + 17.0 kg Barley + 2.6 kg Barley to Option 2 + 7.5 kg Corn-DDGS + 7.5 kg Corn-DDGS + 1.0 kg Soya oil

– 29.1 kg Soybean meal – 27.9 kg Soybean meal – 1.9 kg Soya oil – 2.7 kg Rapeseed meal – 3.9 kg Rapeseed oil Figure 2 Representation of the individual life cycles for balancing deficient feed mixtures for pigs and poultry either with soya or amino acids produced by Evonik

Production Production Production Production Production Production Production rapeseed soybeans wheat barley premix sugar beets corn

Chemical Oil mill production of DL-Methionine

Biotechnological Feed mill production of Sugar refinery L-Threonine

Biotechnological Animal production production of L-Tryptophane

Biotechnological Corn Spreading production of processing manure Biolys®

Figure 3 Figure 4 Figure 5 Contribution of the individual options to the Contribution of the individual options in the Contribution of the individual options global warming potential (GWP) in the form of pig feed to the acidification potential (AP) in the pig feed to the eutrophication potential CO2 equivalents per functional unit [CO2e/fu] in the form of SO2 equivalents per functional in the form of PO4 equivalents per functional unit [SO2e/fu] unit [PO4e/fu] Option 1 Option 2 Option 3

GWP [kg CO2e/fu] AP [kg SO2e/fu] EP [kg PO4e/fu]

28 1.4 0.36

0.32 24 1.2 0.28 20 1.0 0.24

16 0.8 0.20

12 0.6 0.16 0.12 8 0.4 0.08 4 0.2 0.04

0 0 0

elements33 Issue 4|2010 Methionine plant in Antwerp. For every metric ton of CO2 emitted during synthesis of methionine, a total of 23 metric tons can be saved over the entire life cycle of the product. For ammonia, the sav­ings factor is 26, for nitrate, 7

333 L-Lysine (Biolys®), DL-Methionine, and „functional unit“ for the assessment, each emissions from the oilseed parts in the L-Tryptophan—to a comparative and com- of the feed mixtures also had to offer the feed and the production of manure as fer- plete life cycle assessment, and compared animals the same benefits. For this reason, tilizer are particularly responsible for the them with alternative raw materials like another wheat/barley/corn mixture of greater global warming potential of feed soybean meal or rapeseed meal. The life about 29.1 and 31.7 kilograms was added mixtures 2 and 3. cycle assessment was also certified by to the amino acids mixture (Option 1) to Acidification and eutrophication poten- TÜV Rheinland, a globally recognized in- align the energy content and weight of the tial are two factors that accelerate wide­ dependent auditor. The certificate proves mixtures (Fig. 1). spread damage to forests—known as “forest that the scientists have carefully and im- The environmental impact of the en- dieback.” Both indicators are primarily de- partially assessed all environmental con- tire life cycle was analyzed and evaluated, termined by nitrogen emissions from the sequences. including the cultivation of the plant based cultivation of the individual feed compo- raw materials, production of the amino nents. So it is not surprising that the in- acids, production of the mixed feed, as well crease in oil seeds in Options 2 and 3 car- Comparing feed mixtures as the practice of housing animals in con- ries a considerably higher acidification po- Evonik based its life cycle assessment on ventional agricultural operations found tential than with Option 1: the feed mix- a representative mixture of wheat and in Germany and Europe (Fig. 2). The ture with the supplemented amino acids barley that shows deficits of methionine, follow ­ing indicators were determined and has an acidification potential of only 0.1 kg

lysine, threonine and tryptophan. Evonik compared to each other as key factors for SO2e/fu (measured as the quantity of chose three methods for compensating for envi ­ronmental and climatic impact: glo­bal sulphur dioxide equivalent per functional these deficits: warm ­ing potential, acidification potential, unit) and is therefore lower than the two • Enrichment with the four amino acids eutrophication potential, primary energy oil-seed-rich alternatives by a factor of 12 from its own production (Option 1) demand, resource consumption, and and 13, respectively (Fig. 4). • Adding a mixture of soybean meal chang­ ­es in land use. The result is just as clear when it comes and soya oil (Option 2) to the eutrophication potential (Fig. 5). • Adding a mixture of soybean meal The components of fertilizers, such as ni- and rapeseed meal (Option 3) Results of the assessment trate and phosphate, are responsible for The greenhouse effect is primarily caused the overfertilization of bodies of water, These three options were compared to by the pollutant gases carbon dioxide which causes oxygen deficiencies and, in

each other in the life cycle assessment. (CO2), nitrous oxide (N2O), and methane the final stage, the death of plants and ani- The amino acids and soybean meal/oil or (CH4). For the pig feed scenarios we dis- mals in surface waters (eutrophication). soya/rapeseed meal were each added to cuss here, CO2 and N2O are the greatest With only 0.022 kg PO4e/fu (measured in the base mixture in the precise amount of concern. As a greenhouse gas, methane phosphate equivalent per functional unit), methionine, lysine, threonine and trypto- plays a particularly important role in Option 1 far outperforms Options 2 and 3,

phan that optimally covers the average cattle farming. Comparison of the three with 0.357 kg PO4e/fu. This means protein requirements of a pig. The use of feed mixtures shows that while Option 1 roughly 16 times the potential to reduce one kilogram of amino acids based mix- with added amino acids contributes only such pollution through supplementation

ture replaces about 31 kilograms of feed about 5 kg of CO2 equivalents per function­ with amino acids. mixture based on soybean meal, or about ­al unit (kg CO2e/fu) to the greenhouse The primary energy demand of the 34.5 kilograms of an alternative feed mix- effect, the emissions of Options 2 and 3 various options is a central indicator. But

ture for pigs based on soya/rapeseed. To (25 and 8 kg CO2e/fu), respectively, are here, the discrepancy in the results is not create a comparison of the systems, and a considerably higher (Fig. 3). Nitrous oxide as obvious. With 154 MJ/fu (measured 333

elements33 Issue 4|2010 12L HEA TH & NUTRITION

Figure 6 Figure 7 Figure 8 Contribution of the individual options Contribution of the individual options Influence of the change in land use on the in the pig feed to the primary in the pig feed to the resource requirement contributions to the greenhouse effect GWP energy demand (PED) in the form of consumption of crude oil equivalents Base scenario Option 1 Option 2 Option 3 Minimum Maximum

PED [MJ/fu] Resources [kg crude oil equiv./fu] GWP [kg CO2e/fu]

300 3,2 36

2,8 32 250 28 2,4 200 24 2,0 20 150 1,6 16 1,2 100 12

0,8 8 50 0,4 4

0 0 0 Option 1 Option 2 Option 3

333 in megajoules per functional unit), the portion of the carbon stored in the soil and ronment than adding protein-rich soya or energy demand of Option 1 is almost as biomasses is released as CO2 with these rapeseed: emissions of nitrogen compounds high as for Option 2, at 148 MJ/fu. Option methods. To quantify and evaluate these and greenhouse gases drop, acidification 3 contains a higher proportion of rapeseed effects, Evonik’s life cycle assessment for and eutrophication are significantly re­ oil in the feed mixture—this is reflected in the first time also recorded the influence duced, ecologically valuable natural areas the higher energy requirement of 281 MJ/ of a “change in land use“. are preserved, and not least, the livestock fu, since extracting oil from rapeseed is The effects of the change in land use owner saves money because the pigs uti- relatively energy-intensive (Fig. 6). The are clear when we examine the cultivation lize feed supplemented with amino acids high primary energy demand for Option of soya, for example. In this example, the far more efficiently. 1 is mainly a result of the high quality of baseline scenario corresponds to the green­ This leads us to ask: is intensive live- biotechnologically produced amino acids house gas potential of the relevant feed stock farming sustainable? And the answer in the feed mixture. Production of the sugar mix ­ture. The minimum values stand for is yes—if the interactions between live- sources used in the fermentation proces- a halving of the proportion of soya asso- stock and the environment are under- ses requires relatively high amounts of ciated with the change in land use, the stood, and if the knowledge we gain is energy. maxi ­mum values for a doubling. Because incorporated into growth scenarios and Adding amino acids to feed mixtures Option 1 contains no soybean meal, the feeding practice. In livestock production, replaces plant based resources and, there- value remains unchanged in comparison advanced protein nutrition plays a key fore, reduces the need for cultivation with the baseline scenario. Option 2 has role. Because cultivation of feed ingre- areas. In addition, less energy has to be the largest share of soybean meal in the dients and the production of feed itself of- used for preparing and providing the re- mixture, and therefore also shows the ten take place far apart from each other in

quired raw materials. These factors are widest fluctuation—from 18 kg CO2e/fu to our globalized world, it is no longer enough expressed in crude oil equivalents per 33 kg CO2e/fu compared to the reference to focus our attention on national con­ functional unit (crude oil equiv/fu). Ac- in the baseline scenario (25 kg CO2e/fu). ditions alone. cording to the life cycle assessment, the In Option 3, some of the soybean meal and On the contrary: social, environmental resource consumption of Option 2 (2.2 kg oil is replaced by rapeseed meal and oil, and commercial dimensions must be ana-

crude oil equiv/fu) is nearly twice as high and so the minimum values (2 kg CO2e/ lyzed and evaluated across all boundaries. as that of Option 1. The discrepancy is fu) are more favorable than in Option 1 To this end, the life cycle assessment is an even greater between Option 1 and Option (Fig. 8). important internationally standardized 3, which posted 3.05 kg crude oil equiv/ tool that allows a comparison between fu (Fig. 7). Innovative feed concept to worldwide material and production Ecologically valuable natural areas are chains. It also provides insight into areas often cleared to meet the growing demand promote sustainability of weakness, where science and industry for raw materials for feed. Such changes Summarizing, we can say that selectively can selectively apply their expertise to in land use affect climate-relevant emis­ supplementing conventional pig feed with develop environmentally safer, more sions primarily through deforestation and amino acids has significantly fewer nega- efficient and, in the final analysis, more slash-and-burn cultivation—a large pro- tive effects on the climate and the envi- sustainable products. 777

elements33 Issue 4|2010 HL EA TH & NUTRITION 13

LIE F CycLE ASSESSMENT of AMINO Acids for chicken feed

Chickens on a diet

The world’s appetite for meat—poultry meat, in particular—is and threonine, or by enriching the feed with high-protein soya or growing rapidly. The Food and Agriculture Organization (FAO) rapeseed meal and vegetable oil. estimates that the use of poultry meat will climb from the current The results speak as clearly as those of the life cycle assessment 88 million metric tons to over 140 million metric tons in the year for pig feed (see article above): the feed mixture supplemented

2030. The increase will occur primarily in Asia, Eastern Europe, with amino acids (Option 1) contributes about 4 kg CO2 equiva- and South America, where the FAO expects growth rates of five lents per functional unit to the greenhouse effect, while the alter-

to ten percent per year. natives supplemented with 48 and 34 kg CO2e/fu, respectively, are To limit the environmental impact of poultry feeding, it is vitally significantly higher. Even the acidification potential of the soya/ important that the animal feed is optimized to meet the physiol­ rapeseed mixtures is higher by a factor of 80 and 60 than with an ogical needs of the animals. Chicken feed is deficient in the amino amino acids diet. Compared to the production of soybean meal, the acid methionine. If an animal is given this kind of deficient feed, primary energy demand for the production of the added amino it cannot utilize other building blocks in the feed, and they are ex­ acids is relatively low, and the consumption of natural resources for creted with the animal‘s manure. But through supplementation a feed mixture with a high percentage of soya and rapeseed is al- with methionine, lysine and threonine, the essential amino acids most ten times greater than that of Option 1. determine how efficiently chickens can physiologically utilize the So the feed concept based on a reduced protein supply is a feed. win-win situation: a balanced range of amino acids guarantees op- This is why Evonik included chicken feed in its areas of focus in timal growth for the chickens and considerably less pollution for a study of the most logical method of balancing out the deficit in the environment, and the livestock owner benefits from lower feed the amino acid spectrum: by adding a mixture of methionine, lysine costs.

D r. Michael Binder is responsible for product D r. Mark Redshaw is responsible in the Health & authorization of amino acids for animal nutrition in Nutrition Business Unit for the development and pro- the Health & Nutrition Business Unit. After studying vision of new customer services. He studied agricul- technical biology and receiving his doctorate at the ture at the University of Reading and obtained a PhD in University of Stuttgart, he began his career at Evonik animal nutrition at the University of Nottingham, both in 1997 in the biotechnological research and develop- in the UK. He joined Evonik (Degussa Limited) as a ment of feed additives. In 2005, following another Technical Service Manager within the feed additives stint in application technology for feed additives, he business, moving later to Germany responsibly for moved to the Product Quality and Regulatory Affairs business within the region Africa and Middle East. In department, where he began working in his current 2005 he assumed responsibility for the Animal Nutrition capacity in 2007. Binder also represents the Health & Services group providing analytical handling and nutri- Nutrition Business Unit in the Arbeitsgemeinschaft tional services to customers globally, before taking Wirkstoffe in der Tierernährung (AWT) and the EU over his current responsibility in September 2010. Association of Specialty Feed Ingredients and their +49 61 81 59-6788, [email protected] Mixtures (FEFANA), where he heads the Sustainable Agriculture and Fermentation task forces. +49 6181 59-3404, [email protected]

elements33 Issue 4|2010 14L HEA TH & NUTRITION

Professional protection for aging skin Cosmedis®: Optimally customized skin care formulations for the health care industry

The number of people requiring nursing care in their senior years is growing. Until now, little thought was given that older people may need special protection for their skin, which is sensitive and often severely stressed. The specialists from Evonik’s Consumer Specialties Business Unit at the Krefeld site have developed a new product line that makes care easier and provides ideal protection for stressed skin—for the well-being of those affected, as well as for the benefit of nursing staff and family members.

[ text Dr. Petra Allef, Andreas Klotz, Dr. Thomas Mangen ]

More and more people are becoming older, and the products, basing their tests on current scientific the number of people who have only limited mobility knowledge. External institutes are also involved in and depend on periodic or full-time nursing care is developing and testing. In a Code of Practice, Evonik growing year after year. According to the German is committed to setting the highest standards—stan- Federal Statistical Office, there are currently already dards that go beyond legal regulations—when select­ some 2.4 million long-term care patients in Germany ing raw materials as regards their dermatological, alone, and in ten years time this number could grow ecological, and cosmetic aspects. This includes vol­ to 3 million. Approximately 700,000 senior citizens untarily forgoing the use of particular perfumes or today live in rest homes or nursing homes and receive preservatives that are frequently responsible for al- round-the-clock care. Staffing is tight in these kinds lergic reactions to the skin. of facilities, and the time provided for nursing care is short. Professional skin care must therefore meet two How the skin changes with age criteria: It must be tailored to the physiological needs As our skin ages, several changes occur. The epider- of aging skin and protect it effectively—even when mis becomes thinner, the connective tissue weakens, the skin has been affected by incontinence. At the and the skin loses its elasticity and moisture. The same time, it should be simple to use, so that family sweat and sebaceous glands slow down production, members and nursing staff can save time. and natural regeneration of the epidermis slows Evonik has developed the Cosmedis® product line down. Incidentally, this does not necessarily occur to protect, cleanse, and care for aging skin as well as only in old age. How fast the skin ages varies from to protect against skin problems, such as those expe- individual to individual. Aging skin is partly genetic rienced by people with incontinence troubles. The (intrinsic factors); however, extrinsic factors, such Consumer Specialties experts used their particular as exposure to UV-rays, smoking, and nutrition, play professional skin care expertise, which they have ac- a major role, too. Even 50 year-olds can have aging quired over decades as one of the leading European skin. manufacturers of protective, cleansing, and care prod­ In aging skin, the epidermal and dermal layers of ucts for occupationally stressed skin. A team of chem­ the skin separate more easily. The result is that me- ists, microbiologists, and engineers develop and test chanical stress, pressure, and friction leave their

elements33 Issue 4|2010

marks. The combination of pressure and stress re- one hand? Use of the product in conjunction with in- stricts the flow of blood to the affected area, toxins continence products is also particularly important. accumulate in the tissue, and cells die. Lying down Evonik’s Krefeld site is known for its superabsor- for long periods damages the local skin and tissues. bents—granular polymers that form a gel and absorb In extreme cases, bedsores, also known as decubitus and store up to 500 times their own weight in liquid. or pressure ulcers, will appear. In addition, inconti- The developers of Evonik’s new Cosmedis® product nence and swelling of the skin due to bandages or line therefore were always aware of ensuring that medical products severely stress the skin of people the new sprays, lotions, and creams would not under- requiring nursing care. mine the absorptive ability of incontinence products. Today’s skin care market offers an almost over- whelmingly broad range of products, but few are designed primarily for the skin of long-term care pa- Zinc paste is out tients. Among the few specialty products, several are Just to clarify matters, ordinary zinc pastes fail to based on old formulations, contain weak ingredients, meet these demands. The thick pastes cover wounds or are poorly, or not at all, documented as to their ef- and reddened areas. They are difficult to spread on fectiveness. the skin and can be removed only by vigorous rub- Professional care of aging skin takes a different bing. They also seal the surface of the diaper, thus approach and explicitly asks the following questions: interfering with the absorption of fluids. It is there- What type of ingredients and formulations are most fore obvious that these types of pastes are unsuitable effective in protecting irritated and stressed skin? To for the skin of elderly and long-term care patients. what specific stresses is the skin of long-term care Even advanced formulations specifically designed for patients subjected, and how can the stresses be miti- stressed, aging skin fail to prevent bedsores or delay gated? What type of tests can explicitly and transpar­ the aging process. They do, however, offer maximum ently document the effects? protection against excess friction, pressure, and The following are important questions, too: stress and mitigate the effects of harsh substances in Which formulations will make it easier to care for the human secretions. skin? How should the packaging be designed to pre- Documenting their effects was the key to develop­ vent injury and make the product easy to use with ing the Cosmedis® products. What sounds simple 333

elements33 Issue 4|2010 333 is in practice an extremely significant issue. There are no standard tests for cosmetic products as there are for medical products. The experts at Evonik therefore relied on proven methods, partly devel­oped within their own organization, which they used to determine a range of important parameters, such as germ prevention, skin compatibility, alkaline skin irritation, and cleansing efficiency. For this project, their long-time experience in developing skin pro- tection products for the occupational environment came in handy. Products for the skin must not cause irritation, even after long-term exposure, and must also be con- sistently well tolerated for regular and intensive use. To assess the general compatibility of Cosmedis® on the skin, small amounts of the undiluted product test samples were applied to the undersides of volunteers’ forearms, where the skin is relatively thin, and were covered with an aluminum cap. Due to the occlusion, moisture was trapped, resulting in swelling of the subcorneous layer and strengthening the effect of the applied substances. The length of application varied, depending on the product. In extreme cases, the prod­ uct was applied every 24 hours over 3 consecutive days. The results of these tests indicated that Cosme- Forearm test to deter­ mine general skin compatibility. Covering the skin with an alu­ minum cap strengthens the effect of the applied substances Figure 1 Figure 2 Test for skin compatibility. Effective skin protection against Vaseline is the standard ammonia solution

Cosmedis® skin protection creme Cosmedis® skin protection creme Standard Cosmedis® skin protection spray without skin protection

Skin damage after three-hour irritation Skin damage Maximal application time [h] with 0.5% NH3

4.0 70 0.9

3.5 0.8 60

0.7 3.0 50 0.6 2.5

40 0.5 2.0

30 0.4 1.5 0.3 20 1.0 0.2

10 0.5 0.1

0 0 0

elements33 Issue 4|2010 HL EA TH & NUTRITION 17

dis® products provided nearly consistently good and found in the stools of many people. In people with excellent skin compatibility properties (Fig. 1). immunodeficiencies, the fungi multiply uncontrolled, To evaluate the protective effects of the products, forming what is known as candidosis. Unfortunately, researchers first subjected the skin to irritation for this is a frequent problem in the health care field. three hours, using 0.5 percent ammonia diluted in Moreover, fungi release enzymes, particularly water, since ammonia is one of the main causes of di- proteases. Together with proteases, which are ex­ aper dermatitis. Visual assessment of the different creted in stools, they break down proteins in the skin test patches indicated that it was possible to reduce and thereby assault it. Lipases, which are found every­ the redness and drying of the skin caused by the am- where in and outside of the body, break down fat into monia by applying the Cosmedis® protective products unpleasant smelling, short-chain fatty acids. (Fig. 2). The activities of all these germs and enzymes therefore lead to decomposition products that irri- Active ingredients against tate, or even damage, the skin. Cosmedis® skin pro- tection spray therefore contains inhibitors such as damaging enzymes zinc salicylate, which blocks enzyme activity and When developing the new skin care line, the specia- inhibits fungal growth. Tests conducted in Evonik’s lists first concentrated on various types of irritation toxicology and ecology lab have demonstrated that caused by enzymes, which are particularly harsh to the spray deactivates ureases for a period of twelve weakened aging skin. Human secretions contain a hours and prevents the release of ammonia from urea variety of enzymes: proteases, lipases, and ureases. (Fig. 3). Proteases are also deactivated. Fluorescein- Ureases break down the urea contained in the urine labeled casein was used for this test. The protective into ammonia, increasing the pH on the skin‘s surface spray almost completely inhibits its breakdown. The and resulting in deterioration of the skin‘s acid product also inhibited the germ growth of candida mantle. The alkaline environment promotes the albicans. The growth inhibitor test showed that as growth of fungi such as candida albicans, which is early as 20 minutes into testing, 99 percent of the 333

Figure 3 Figure 4 Figure 5 Urease activity, a measure of the Inhibiting the growth of candida albicans Inhibiting protease activity release of ammonia

Cosmedis® skin protection spray Cosmedis® skin protection spray Cosmedis® skin protection spray Control (fully distilled H2O) Control (fully distilled H2O) Control (fully distilled H2O)

ppm NH3 x h Concentration candida albicans [KBE/ml] Prevention [%]

1,600 106 100

90 1,400

105 80 1,200 70

1,000 104 60

800 50

103 40 600

30 400 102 29

200 10

0 10 0 0 2 4 6 8 10 12 0 20 40 60 80 100 120 140 160 180 Time [h] Time [h]

elements33 Issue 4|2010 Ammonia test in Evonik’s toxicology and ecology lab

germs were killed, and after an hour of exposure, no Figure 6 germs could be detected (Figs. 4 and 5). Schematic diagram of a water- in-oil-in-water emulsion Gingko extracts are also added to many products (W/O/W), the basis for the in the Cosmedis® product line and contain flavonoids Cosmedis® skin protection cream and terpenoids, which can produce a pharmaceutical effect. For example, they improve blood flow and mi- Microscopic photograph of a crocirculation and guard against oxidative stress W/O/W formulation caused by free radicals.

Easier, faster, gentler care Professional protection requires more than just highly effective ingredients. Just as important, the skin must Figure 7 remain intact if the product is frequently used. That Cross-section of a 3D skin model is, you must be able to apply it and remove it again without pressing, rubbing, or pulling. Choosing the right type of emulsion is crucial. Water-in-oil emulsions (W/O) are often greasy and heavy and are not suitable for the requirements of low viscosity products that are quickly absorbed by the skin. Oil-in-water emulsions (O/W), however, Figure 8 are light and form a thin, albeit temporary, film on Cleaning efficiency in the leather cloth cleaning test the skin. To care for thin skin prone to sores, the Evo- Cosmedis® nik specialists developed a cooling foam that is par- skin cleansing foam ticularly easy to spread and based on a stable micro- Competitor‘s emulsion. The protective cream, however, is based skin cleansing foam on a water-in-oil-in-water emulsion (W/O/W) (Fig. Cosmedis® 3-in-1 6). It feels light and pleasant on the skin while at the skin cleansing lotion same time providing protection through a stable film. Competitor‘s In addition, the active ingredients released in the 3-in-1 product innermost phase are conveyed to the deeper skin 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 layers. Clean No cleaning effect The Cosmedis® skin protection cream is precisely this kind of W/O/W formula. Its effectiveness has

elements33 Issue 4|2010 HL EA TH & NUTRITION 19 been confirmed not only in vivo, but also ex vivo. To medis® line is particularly user-friendly as a result of confirm its protective properties, the researchers tes- using different color packaging to clearly separate ted the cream in a 3D skin model (Fig. 7). A 3D skin the skin protection, cleansing and care products. Each model is an artificial skin grown from cells collected product is based on its own formula, conforming to from a surgical procedure. With the same structure the des­ ired effect and type of application while at the as normal skin, it was possible to demonstrate the same time addressing the different customer prefer­ strength of the skin‘s barrier on the model. Cosme- ences. dis® therefore stimulates synthesis of the skin‘s own Health care is a growing market segment. Evonik barrier lipids like ceramide and cholesterol. has set out to achieve a goal of acquiring an appre­ ciable share of the nursing and health care market within the next five to ten years. In so doing, the No skin care without proper cleansing chem ­ists, microbiologists, engineers, and marketing When the Cosmedis® cleansing products were devel­ experts have been able to benefit from the company‘s oped, only gentle tensides were used, since the skin long-term expertise in professional skin care for the of long-term care patients must be cleaned several industrial and occupational environment, from close times a day. Moreover, the developers made sure to contacts with customers and suppliers and above all combine the high degree of cleaning efficiency with from an in-depth knowledge of customer needs and fast and easy application. The lotion does not require desires. 777 the use of water or any additional care after it is ap- plied. Cosmedis® Antibacterial Skin Cleansing Foam aids in general hygiene applications and helps to prevent infections. This is a particularly quick-acting anti- biotic foam. Influenza virus strains are inactivated D r. Petra Allef is the head of Innovation Manage­ after just 15 seconds, and bacteria such as staph­ ment, STOKO Skin Care, in the Consumer Specialties ylococcus and enterococcus are inactivated after 30 Business Line, where she is in charge of research, development, and technical service for the STOKO seconds. The antibacterial foam is particularly effec- Skin Care Product Line. Allef studied chemistry and tive against methicillin-resistant (antibiotic-resistant) completed her doctoral studies, which focused on staphylococcus aureus strains, also known as MRSA. natural product syntheses, as a member of Prof. Kunz’s research group at the University of Mainz, Germany. Even though the bacterium is widespread and approx­ She then went to Japan, where she spent a semester in imately one fourth of the world‘s population are car- Kyoto. In 2000, she began her professional career in riers, in certain cases it can cause skin infections and the Gillette (P&G) company’s research department. She joined the Evonik Care Specialties Business Unit in myopathies in people with compromised immune sys- 2002. In that capacity, she was in charge of a develop- tems. Because of its resistance to antibiotics, the ment group working on the synthesis of cosmetic raw treatment options are slim, meaning that the rate of materials before taking her current position in 2005. +49 2151 38-1399, [email protected] morbidity (illness) and mortality (death) is high. This germ is therefore particularly problematic in hospi- tals and nursing homes. D r. Thomas Mangen has been working as head of Artificial excrement was developed to attest the the Biophysical Methods group since 2009, which is in cleaning efficiency of the cleaning agent. It consists the department Innovation Management, STOKO Skin Care, of the STOKO Skin Care Product Line. There of two-thirds tap water, ten percent margarine, 15 he is in charge of developing and testing Cosmedis® percent starch, five percent cocoa, and small amounts products. He received a degree in chemistry and com- of gelatin, preservatives, and thickening agents. For pleted his doctoral studies at the University of Bonn, Germany, and then spent a semester in Madrid, Spain, the leather cloth cleaning test, as the test was called, before attending the National Taiwan Normal Univer­ small patches of the smoothly tanned leather were sity in Taipei for post-doctoral research work. He coated with 0.5 grams of artificial excrement. After started his professional career in 2007 when he joined Evonik’s Superabsorbers Business Unit as head of one hour drying time, the testers applied 0.6 grams technical service laboratory. of the cleaning product and washed the patches +49 2151 38-3441, [email protected] under running water for 35 seconds. The Cosmedis® products showed an equally good or improved cleaning efficiency compared to the market standard, Andreas Klotz has been working as the senior market­ ing manager for STOKO Skin Care since 2006, where although the Cosmedis products are particularly he is in charge of the conceptual design and market gentle to the skin (Fig. 8). launch of the Cosmedis® nursing care product range. Even in the health care sector, preferences for skin Klotz completed his training as a chemical laboratory assistant at the Symrise company and obtained his care products are as varied as the range of products degree, with an emphasis on cosmetics, from the Uni­ available. Cream or lotion? Greasy or light? With ver­sity of Applied Sciences of Lippe-Lemgo before or without perfume? The developers of Cosmedis® launching his professional career with Evonik as the head of quality testing of the STOKO Skin Care Product listened to these individual preferences by offering Line. He became head of the Biophysical Methods different forms within a single product range, includ­ group in 1998 and then switched to the Marketing ing a spray, a lotion, a cream, and a foam. The Cos- department in 2001. +49 2151 38-1406, [email protected]

elements33 Issue 4|2010 20N ews

Bachelor work at Evonik awarded by Max Buchner Research Foundation

Ms. Marina Richter, a chemistry student who performed her bachelor work at Evo- nik Industries, received the Max Buchner Research Foundation’s book prize for Chemical Technology at Universities for Applied Sciences. Having earned her bachelor’s degree at the Bonn-Rhein-Sieg University of Applied Science, the 23-year- old is now working on her master’s degree at the RWTH Aachen under the guidance of Prof. Wolfgang Fink. Her bachelor’s thesis dealt with the operando spectros­ copic investigation into the mechanism of hydroformylation of olefins. The main fea- tures of this reaction cycle had been pub- lished in 1961 in a pathbreaking paper by Richard Fred Heck, who, together with The autoclave pilot plant in Marl (Germany). Ei-ichi Negishi and Akira Suzuki, received Here, Marina Richter performed her studies the Nobel Prize for Chemistry this year with a basis for customizing hydroform­ for his work in the field of palladium- ylation catalysts to new products. catalyzed cross-couplings. Upon the recommendation of univer- “We are happy that Mrs. Richter got sity teachers the Max Buchner Research her well-deserved distinction!” says Dr. Foundation awards annually the best Dieter Hess, senior scientist for oxo re- theses in the fields of industrial chemistry search at Evonik’s C4 Chemistry Business and biotechnology in universities of Line who supervised her work for six applied sciences and for degree studies at months. “With great determination, Ms. polytechnical colleges. “The success of Richter forged ahead with her work and Ms. Richter confirms our efforts to partic­ gave us valuable suggestions for further ipate actively in university education and optimizing hydroformylation processes.” butadiene, 1-butene, isononanol, and iso- to give budding chemists the opportunity „Evonik made it possible for me to coop­ tridecanol. to gain practical experience in industry as erate actively and independently on a cur- State-of-the-art hydroformylation in- part of their thesis work,” emphasizes rent research topic. I got excellent support volves highly selective processes that use Hess. His unit has regularly been sponsor­ and equipment. To delve deeper into ca- rhodium catalysts modified with organo- ing the thesis work of university students, talysis, I chose this as the emphasis of my phosphorus ligands. Research in this area which usually takes between four to six master‘s degree,“ added Richter. is centered on tuning the ligands to im- months. Any intern or Diplom candidate Hydroformylation, also called “oxo prove the activity, selectivity, and stability may apply who has completed five semes- synthesis,” is used to produce aldehydes of the homogenous catalysts further. To ters toward a bachelor’s degree and, above

from olefins and synthesis gas (CO and 2H ) this end, Evonik combines molecular all, demonstrates a “joy for research,” says and is extremely important throughout modeling with in-situ NMR and in-situ IR Hess. The application may be submitted the world. Globally, the chemical industry under reaction conditions in order to illu- online at Evonik’s homepage, where it is produces 9 million metric tons of oxo pro- minate the complex mechanisms of the always available at the designated loca- ducts each year; hydroformylation is thus hydroformylation reaction (see elements tion. An offer that is gladly accepted: The a prime example of industrial homogen­ 27, p. 6 ff). With the aid of these advanced most recent candidate started her bach­ eous catalysis. Evonik uses it in its technol­ methods and the statistical design of ex- elor’s work at Evonik in Marl in mid-Au- ogically complex C4 integrated produc- periments, Richter was able to describe gust. tion network in Marl, Germany, where the kinetics with which the active catalyst crack C4 is converted into a large number forms out of rhodium and phosphor­ of substances step-by-step; examples are organic ligands, thereby providing Evonik F or more information: www.evonik.de/karriere

elements33 Issue 4|2010 News 21

Evonik Meets Science China 2010

For the sixth time in a row, Evonik invited aca ­demia plays such an important role in we have built up a strong network with Chinese scientists to a two-day sympo- our global innovation process—open inno- the Chinese scientific community that sium in Shanghai in September to discuss vation for short.” helps us drive Evonik‘s development in current research trends, make new con- Inorganic-polymeric hybrid materials China,“ explained Dr. Dahai Yu, president tacts and strengthen existing ones. The have properties that differ not only from of Evonik Degussa (China) Co., Ltd. “Close theme of this year’s Evonik Meets Sci­ence organic polymers but from the inorganic cooperation with both universities and China was inorganic-polymeric hybrid materials from which they are made. These customers here in the region across all materials. Professors and renowned ex- hybrid materials open up seemingly end- stages of development will open up addi- perts in this field from over ten top uni- less possibilities. “Evonik sees enormous tional innovation opportunities for us and versities and institutes in China at­tend­ed market potential in this technological shorten development times.” the event, including Prof. Charles Han of megatrend. By deftly combining the know- In China, as well as in Europe and the the Institute of Chemistry of the Chinese how of outstanding Chinese scientists United States, Evonik Meets Science is al- Academy of Sciences (ICCAS) in Beijing, with Evonik’s leading technology, we plan ready a tradition. Organized by Innovation who was keynote speaker, and Prof. Xiao­su to continue expanding our market position Management Greater China, and support­ed Yi of the Beijing Institute of Aeronautical here in the future,” said Dr. Jing Feng, head by colleagues in Germany, the symposium Materials. of Innovation Management for Evonik in was the sixth event of its kind since Evo- Recent technological breakthroughs the Greater China region. nik established its R&D center in China. and the desire for new functions have Evonik attaches great importance to The themes of the five previous events generated tremendous demand for novel dialogue and cooperation with Chinese were biorenewables, functional polymers, materials. “Our innovative capacity is our scientists, because partnerships are a key nanotechnology, biotechnology, and cata- strength,” said Dr. Thomas Haeberle, Board to success. “Over the past several years, lytic processes. Member of Evonik Degussa GmbH, in his opening remarks. „In the specialty chemi- Evonik meets Science cals sector in particular, a constant stream in Shanghai in September 2010 of highly sought new products and appli- cations is vital to ensure lasting success against the global competition. This is why sustainable knowledge exchange with

Evonik to expand TAA production capacities in China

Demand for triacetonamine derivatives (TAA derivatives) has kept rising for several years. Evonik Industries is taking advantage of the economic opportunities afforded by this situation and is considerably expanding its production capacities for these derivatives in China. The foundations for a new plant will be laid as early as this year. Currently, Evonik produces the derivatives in the joint venture Evonik Tianda (Liaoyang) Chemical Additive Co., Ltd. at the Liaoyang site in northeastern China. The existing production capacities are to be moved within the Liaoyang region to the Aromatic Site (LAS), one of the country‘s largest petrochemical sites, and will also be signifi- cantly increased. Full production is scheduled to commence in the fourth quarter of 2011. Apart from the plant in Liaoyang, Evonik has further production capacities at Marl Chemical Park in Germany. The company is already one of the world‘s leading suppliers of TAA derivatives. These are essential intermediates for the production of hindered amine light stabilizers H.A.L.S. The stabilizers improve the properties of plastics TAA derivatives are intermediates for hindered amine light stabilizers that are that are subject to intensive light radiation. The main applications are used in agricultural films among others in the automotive and construction industries as well as agricultural films

elements33 Issue 4|2010 22Nm o inated for the Evonik Innovation Award 2010

NP ew roducts/New System Solutions category

A steadily increasing number of farm animals must be fed with an ever increas­ Bringing the power ing amount of vegetarian feed—because the world population continues to grow, and so does the need for meat, milk and eggs. Consumption of vegeta­ of meat back into bles, rice and potatoes is also rising. But the arable land is limited, and there are limits to the expansion of food and feed production. Innovative feeding con- feed: CreAMINO® cepts offer a solution to this problem. Optimizing the animals‘ feed conversion helps to feed more animals on a balanced diet with the same amount of feed. for animal nutrition The Health & Nutrition Business Unit, already a leading supplier of amino acids supporting this effort (see also p. 8ff), has now identified another means for sustainable animal nutrition: guanidinoacetic acid (GAA), marketed under the trademark CreAMINO®. The body uses GAA to produce creatine, which plays an important role in the body‘s energy balance: it helps supply the muscle cells of humans and ani- mals with the energy they need. Even though the body can produce creatine itself, it relies on external meat sources when the requirement is high, such as in times of high stress or in the growth phase. Chickens are not vegetarians by Dr. Ernst Krämer nature. They were fed diets containing meat and bone meal until a few years Ricardo Gobbi ago. But since BSE, such feed is prohibited in the EU. And in other countries, Dr. Andreas Lemme the meat meal is heated to such high temperatures for hygienic reasons that the Dr. Michael Binder creatine is destroyed. As a result, poultry cannot optimally utilize the vegetarian Dr. Alfred Petri feed. Dr. Thomas Kaufmann The nutrition experts at Evonik have not only identified this problem, but Health & Nutrition are now the first to solve it—with CreAMINO®. Adding about 600 g CreAMINO® Business Unit to one metric ton of pure vegetable feed can compensate for the creatine de­ ficiency. The product, which AlzChem GmbH produces in Trostberg for Evonik, has already been approved for use in the EU. Approval in other regions, such as Asia, the United States, and Latin America is on the way, and the first metric tons have already been sold. An international commission of experts elected by DLG (Deutsche Landwirtschafts-Gesellschaft) is also impressed with CreAMINO®: it has now awarded the product a silver medal in the EuroTier 2010 competition. Once again, Evonik has proven its expertise in sustainable animal nutrition.

elements33 Issue 4|2010 Nmo inated for the Evonik Innovation Award 2010 23

NP ew roducts/New System Solutions category

SAVOSILTM lenses for LED

TM Light-emitting diodes (LED) generate a lot of light from little electricity, which SAVOSIL brings is why they are increasingly used in a wide variety of lighting applications. They can already be found in the blinkers and tail lights of cars, in traffic lights, light to new markets bedside lamps and table lamps, in scanners, and in the background lighting of flat-screen monitors. Evonik is now entering this market thanks to SAVOSILTM, the trademark of high-purity glass lenses produced by eco-friendly technology that can create virtually any shape, and that is behind the brand concept: “cus- tomized solution”. Cristal Materials Corporation, the joint venture Evonik for- med specifically for the new product, has developed and produced the lenses since the end of 2009, and has created a rapidly evolving market share prac­ tically overnight. Production of the new glass lenses is based on Evonik‘s own patented SiVARATM sol-gel technology, which the company honored with the Inno­vation Award as early as 2005. In this process, an aqueous AEROSIL® disper­sion is cast in a mould where it gels and afterwards is sintered in an oven where it turns in high-purity silica glass after several processing steps. Whether Dr. Daniele Fregonese it is a tailored solution or complex design—creativity is allowed free reign. Dr. Iordanis Savvopoulos Evonik has produced the SAVOSILTM product family from this technology, Glen Marston whose energy efficiency surpasses that of conventional glass production, Fulvio Costa and secured a leading position in the value-added chain, gearing its efforts to Junglin Tsai the end customer. Inorganic Materials In addition to the LED, the developers have long set their sights on a new, Business Unit future-oriented application: concentrating photovoltaics. This young technol­ ogy is attractive for its high efficiency, because it uses lenses to bundle sunlight and focus it on solar cells. This not only strengthens the sunlight but also saves material in the production of the solar cells. Evonik is currently introducing SAVOSILTM lenses to the market for concentrating photovoltaics.

●

elements33 Issue 4|2010 24Nm o inated for the Evonik Innovation Award 2010

NP ew roducts/New System Solutions category

Lubricants have several important functions in the automotive industry, one New viscosity of them being to reduce fuel consumption. The less friction there is between vehicle components, the less energy is lost. To reduce internal friction, the improvers reduce lubricant should have the lowest possible viscosity at low temperatures. For decades, polyalkyl methacrylates (PAMA) and polyolefins have been used as fuel consumption the most important basic materials for the formulation of viscosity improvers. Back in the early 1990s, Evonik’s Lubricant Additives Business Line, which is part of Coatings & Additives, began acquiring experience in producing comb polymers from PAMA and polyolefin chemicals. Comb polymers consist of a linear PAMA main chain with longer polyolefin side chains of mostly the same length branching off in more or less regular distances. The comb polymer project, however, was discontinued due to a lack of commercially available raw materials and the viscometric properties, which in those days were still „un- spectacular.“ Knowing that the viscometric properties of a polymer can be changed sig­ nificantly by the polymer’s architecture, employees revived the idea of comb Dr. Torsten Stöhr polymers ten years later and developed high-performance viscosity improvers Boris Eisenberg whose viscosity indices and thickening properties by far surpass the current Dr. Michael Müller wholly PAMA-based products with the same shear stability. Dieter Janßen In a series of performance tests—conducted both internally and externally— Dr. Thorsten Bartels as well as in a field test with three vehicles, the researchers demon­strated the Roland Schweder superior properties of the comb polymers to the team: Using these polymers, Miriam Stihulka fuel consumption can be reduced by 1.5 percent. The new products can make Coatings & Additives a contribution of over 10 percent to the European Union’s goal of cutting

Business Unit automakers’ fleet emissions by a further 20g of CO2 per kilometer by 2015. Industrial quantities of the new viscosity improvers marketed in the VISCOPLEX® product portfolio have already been delivered to the first customer, and proj­ ects are being implemented for a large number of other customers.

elements33 Issue 4|2010 Nmo inated for the Evonik Innovation Award 2010 25

Noew r Improved Processes category

Siridion® HCDS 500 E: a new raw material for the semiconductor industry

Small, shockproof, and currently available with a storage capacity of up to 64 gigabytes per chip: flash memories are the ideal way to carry data when traveling. They can be found in smart phones, di- gital cameras and MP3 players, in USB sticks, and tablet PCs, and represent an attractive growth market, driven by consumers’ desire to store increasingly larger amounts of information in the smallest amount of space. To meet this demand, however, the structures on the chip will have to be made smaller to accommodate tighter place­ ment of the transistors. Current state-of-the-art production proc­ esses for mass production of flash memories are already working with structural sizes of 25 nanometers (approximately 3,000 times smaller than the diameter of a human hair). But new generations with even finer structural widths are already in the pipelines of the major memory chip manufacturers. Evonik is well-equipped for this technological leap: with Siridion® HCDS 500 E (hexachlorodisilane). This silicon-based raw material can be used to produce the ultra-thin, functional layers necessary for these fine structures through chemical vapor depo­ sition. Compared to established silicon-based raw materials, HCDS displays outstanding properties that enable low-temperature depo- sition of uniform and dense films. This is possible thanks to a new plasma-based and patented manufacturing process that supplies an ultra-pure form of HCDS. In September 2010 in Rheinfelden, Evonik commissioned the first pilot plant in Rheinfelden, which supplies 1,000 kg of Siridion® Siridion® HCDS 500 E HCDS 500 E per year. And because the pilot plant is working to is a key raw material full capacity, there are already plans to expand production by for production of the Dr. Christian Götz flash memory devices another 5,000 kg annually—a relatively easy matter for the team Dr. Harald Klein used in mobile elec­ nominated for the Innovation Award, which has developed an ex­ Dr. Ekkehard Müh tronic equipment tremely robust and easily scalable production process. Here, they Dr. Hartwig Rauleder fully leveraged the advantages of flexible process development Inorganic Materials in the modular container plant. Negotiations for the sale of these Business Unit additional quantities are well underway. The growth chances are excellent, because the growing markets for swift flash memories Dr. Jürgen Lang include not only mobile devices but computers: increasingly, Process Technology & computers are using solid state drives, which also consist of flash Engineering memory chips, instead of conventional hard drives. Siridion® HCDS Service Unit 500 E, therefore, fits seamlessly into the enormously successful Siridion® family of products, under which Evonik offers key raw materials for the production of solar silicon, optical glass fibers, semiconductors, and flat screen monitors.

elements33 Issue 4|2010 26Nm o inated for the Evonik Innovation Award 2010

Noew r Improved Processes category

A new pathway to ultrapure isobutene

Shanghai (China), September 2009: Startup of the integrated production facility for methyl methacrylate (MMA). Antwerp (Belgium), October 2010: Startup of isobutene production. At first glance these success stories from two different Evonik business units appear to have little in common. Nevertheless, the link is the production of isobutene by decomposition of MTBE (methyl ter­ tiary butyl ether) in a new process invented by Evonik in both cases. The new process consumes less energy than the established processes and also produces less waste. In Antwerp, the isobutene is sold directly in ultrapure form, while in Shanghai it serves as a raw material for MMA production. The startup of two commercial- scale facilities only a year apart in two different business units and on two different continents was the climax of a process develop- ment that originated in an idea from the C4 Chemistry Business Line. Using its globally unique integrated production systems in Marl and Antwerp, C4 Chemistry utilizes all components of crude C4— a hydrocarbon cut that is a by-product in ethylene and propylene production—and converts them into marketable products, which also include MTBE. However, due to the fact that isobutene, a raw material for MMA and other chemical products such as butyl rubber and polyisobutene, has higher added value, the team’s chemists, engineers and technicians met the challenge of developing a cost- effective and ecologically attractive decomposition process. The road to success from the initial idea to industrial production was a long one: Starting with known materials of defined structure, many different catalysts with various substrates, active components, and doping were systematically optimized and, supported by high- throughput methods, tested in more than 1,500 experiments. More­ The new isobutene over, catalyst preparation methods had to be adapted to commercial plant in Antwerp scale, the process had to be developed and a pilot reactor had to be Dr. Christian Böing designed. But the team achieved all this in just two-and-a-half years Reiner Bukohl, Helmut Kamps by combining state-of-the-art experimental technology with com­ Dr. Dietrich Maschmeyer puter simulations. This made it possible to run all the steps, from the Peter Nothhaft, Dr. Udo Peters search for the catalyst to the design of the pilot reactor, virtually Dr. Dirk Röttger, Arnd Schade concurrently. Equally important was the interdisciplinary approach: Dr. Markus Winterberg For every problem faced, whether in catalysis, reactor design, separ­ C4 Chemistry Business Line ation technology, process simulation or plant engineering, experts were available on the project team. Dr. Torsten Balduf, Dr. Wilfried Schmidt Methacrylates Business Line

Thomas Quandt Catalysts Business Line

Walter Luh, Dr. Armin Rix Dr. Horst-Werner Zanthoff Process Technology & Engineering Service Unit

elements33 Issue 4|2010 Nmo inated for the Evonik Innovation Award 2010 27

Noew r Improved Processes category

New biotechnology platform makes LOLA a winner

The amino acid L-ornithine and its derivatives, particularly LOLA (L-ornithine-L-aspartate), are the active ingredients of choice for treating patients with impaired liver function. The amino acid has so far been produced by chemical or enzymatic processes, both of which, however, have a key disadvantage: The workup of the L-ornithine produced and the derivatives obtained from it is complex and costly. The enzymatic process also uses an enzyme obtained from animal cells, a procedure that is becoming unaccep- table in the pharmaceutical industry. But these drawbacks are now history, because Evonik has developed a fermentative process in which bacteria produce L-ornithine directly from sugar. More­ over, the amino acid can be converted into highly pure derivatives from the fermentation broth without the need for complex workup. The key to the new process was supplied by a basic strain ob­ tained by classic mutagenesis, which the researchers analyzed using molecular biological methods and then optimized via targeted manipulation of the metabolic pathway. In this way they more than doubled the efficiency of the bacteria and also succeeded in elimin­ ating critical by-products. Because the fermentation process and the workup were simultaneously brought to production readiness, the entire development took only about two years. Since late 2009 L-ornithine and its derivatives have been produced on a commercial scale at Evonik Rexim SAS in Ham, France, in conjunction with the Slovakian Evonik subsidiary Fermas. They serve a highly attrac- tive market: Active ingredients based on L-ornithine currently register 10 percent annual growth. These active ingredients are used in the treatment of hepatic A glimpse into produc- encephalopathy. In this disorder the liver‘s capacity to detoxify the tion at Evonik Rexim ammonia formed in the body is no longer adequate. As a result, SAS where the Dr. Andreas Karau L-ornithine derivatives blood that is rich in ammonia reaches the brain and reduces brain Dr. Hans-Josef Ritzert are produced in colla­ function, which could lead to hepatic coma. Active ingredients Dr. Thomas Hermann boration with Fermas. based on L-ornithine counteract this by increasing the liver‘s detoxi- In addition to Rexim’s Dr. Robert Gerstmeir scientists, biotechnol­ fication capacity. With the new technology platform, therefore, Dr. Wilfried Claes ogists of the Health & Evonik is not only extending its range of high-quality pharmaceu­ Dr. Ulrich Becker Nutrition Busi­ness Unit tical amino acids, but also contributing toward improving the quali- in Halle-Künse­beck also Dr. Stefan Eils participated in the devel­ ty of life for patients with impaired liver function. Friedhelm Merz opment, which started Dr. Ingrid Dechamps off in Creavis‘s Science- to-Business Center Bio Christian Klus Erika Kohutovicova Jaroslav Sochor Health & Nutrition Business Unit

Christian Alt Process Technology & Engineering Service Unit

elements33 Issue 4|2010 28R P Ocess TECHNOLOGY

Self-learning programs

The EU INFER Project develops adaptive soft sensors

PIMS

Sensor data

Easy-to-measure data – input for soft sensor

Soft sensor

Adapt soft sensor

Soft sensor predictions of difficult-to-measure data Performance monitoring Laboratory analysis – difficult-to-measure data

Laboratory analysis

Predictions of adaptive soft sensor

Predictions of non-adaptive soft sensor

Adapt soft sensor

How an adaptive soft sensor works. The base consists of all accessible process data that are recorded by the process information management systems (PIMS). The soft sensor can thus predict process data that are not directly measurable. The adaptive soft sensor reacts to changes in the process. Comparison with analysis data from the laboratory shows that it predicts the situation in the reactor to a high degree of accuracy

elements33 Issue 4|2010 PR Ocess TECHNOLOGY 29

S-relf lea ning programs that reliably control a process, behavior of airline passengers if another airline suddenly floods even when the parameters suddenly change, are much in demand the market with cheap offers. In such cases the process models in the chemical industry. The airlines, which want to use them must be arduously retrained. to determine instantly the actual market value of their tickets, This is where INFER comes in, with the development of ad- seek them, too. Such broadly applicable programs, known as aptive soft sensors. In the future, these self-learning systems “adaptive soft sensors,” are still some way into the future, but will recognize even changing conditions and adapt independently that should change soon. INFER, an EU-supported project in the to the new situation, providing a prognostic tool that would be Seventh Framework Program, aims to develop a modular soft- valued not only by the chemical industry and airlines, but also ware platform with which adaptive soft sensors can be gener­ by a large number of other sectors like banking and telecommu- ated for a vast array of applications. INFER, which stands for nications. Evonik has the task of testing the algorithm to be de- Computational Intelligence Platform for Evolving and Robust veloped on processes that are well known, but hard to predict. Predictive Systems, is part of the EU‘s Marie Curie Industry- Academia Partnerships & Pathways (IAPP) program. Three partners are participating in the project, which was Breaking new ground in software development initiated in July 2010: the Smart Technology Research Centre of The project participants are breaking new ground. “There are Bournemouth University (UK), which focuses on machine learn­ at present no technical applications for adaptive soft sensors,” ing and automated intelligent systems; Evonik Industries AG, confirms Dudda. “Although there has been much scientific work acknowledged for its broad expertise in process technology; and on the subject, the methods described in the literature are very the Research & Engineering Centre (REC) in Poland, a highly specific. They are always adapted uniquely to the system in ques- innovative software development company. tion and cannot be transferred directly to other applications. For The partners have four years in which to realize their ambi- this reason, many companies are working on their own isolated tious goal. By June 2014, they intend to have developed the soft- solutions as we speak.” This is what the three INFER project ware platform to market readiness. The soft sensors thus pro- partners want to change, by providing a modular software plat- duced will be used in technical as well as commercial business form with which adaptive soft sensors can be developed rapidly processes as precise prognostic tools that immediately detect and flexibly for each specific application. changes in technical parameters, markets, or human behavior To this end, the 30 or so researchers involved, including six and iteratively adapt the underlying process model to the new process engineers from Evonik, will collaborate closely over the conditions. The project partners have a total of €1.55 million for next four years, moving between Germany, Poland, and the UK development at their disposal. and freely exchanging their knowledge. The expectations at- tached to the project are high: “We‘re looking at software with Prediction rather than measurement which we can control our processes more efficiently and, most importantly, use immediately for new plants so that we can de- after the event termine at what point we’re running optimally,” concludes Soft sensors—the word is coined from „software“ and „sensor“— Dudda. REC and Bournemouth University, on the other hand, are already in common use. “Evonik programs soft sensors, for plan to establish a spin-off to market the software platform, a example, to optimize chemical processes or provide routine sup- development that Evonik would welcome. “Marketing by a com- port to employees in process management,” explains Reinhard pany we‘ve established ourselves ensures that the adaptive soft Dudda, who is responsible for INFER at Evonik, where he heads sensors will continue to be developed even after the end of the the Quality Engineering group in the Process Technology & En- project. As users, we’d naturally benefit enormously from this,” gineering Service Unit. The soft sensors do not actually measure says Dudda. 777 physical quantities but estimate their “measured values” from all the accessible process data. They can thus predict the behav­ Reinhard Dudda heads the Quality ior of characteristics that are not directly measurable, such as Engineering group in the Process the resulting quality of products. “What‘s more, the soft sensors Technology & Engineering Service Unit deliver their results in real time, so you no longer have to wait and is responsible for INFER at Evonik. +49 2365 49-6233 for hours for analytical results,” says Dudda. [email protected] These empirical process models, however, currently have a disadvantage. They are unable to detect a change in the under- lying process and cannot predict, for example, the points of oper­ ation of a chemical plant if this is remodeled, or the booking

elements33 Issue 4|2010 30R P Ocess TECHNOLOGY

Process Technology/Chemical Engineering Professor Conference Concentrated process and technology expertise

In early autumn, renowned scientists met at the invitation of Evonik’s Process Technology & Engineering Service Unit for sharing knowledge between industry and academia.

For the forth time, the Process Tech- volume chemicals, but to precisely tailor and continued improvement of existing nology & Engineering Service Unit held products, which can open up completely ones, as well as development of processes the Conference of University Professors new applications, thanks to their above from an idea to a large scale production. on 27th and 28th September in Essen. average functionality. “It takes courage to Evonik generates about one-fifth of its Some 70 participants, amongst 44 scien- innovate in key technologies” pointed out sales with products that are no older than tists from throughout Germany, came to- Dr. Klaus Engel, chairman of the Executive five years. Last year, the company invest­ed gether to share their expertise in a field Board of Evonik Industries AG, at the con- €300 million in R&D, of which 85 percent that is playing a key role in Evonik’s com- ference. went to the decentralized projects of the mercial success. Chemical engineers and process tech- business units. The company has more It has always been a task of process en- nology engineers, with their process and than 260 research partnerships world- gineers to sustainably improve existing technology know-how, are uniquely posi- wide. “Courage to innovate, responsible systems and implement new processes on tioned to provide a critical leverage in this care, and sparing no effort are Evonik‘s the production scale. Moreover, in nowa- area. “We consider ourselves an integral core values,“ said Klaus Engel. The Che- days increasing market volatility, it is a part of the business units”, said Dr. Claas micals Business Area aims for an average matter of survival for speciality chemical Klasen, head of Process Technology & En- of 9 percent growth annually by 2014—pri- manufacturer like Evonik, to develop proj­ gineering. As a service unit, consisting of marily through organic growth, but also ects from the stage of idea to a commissi- integrated process technology and engi- through acquisitions. oned plant considerably faster and more neering, Evonik’s Process Technology & efficiently than in the past. For Evonik it Engineering works closely with business Innovation takes place at the is often not a matter of producing large units to assist in making new processes interfaces of the disciplines To reach this ambitious goal Evonik must involve its customers, business partners and partners in academia. The reason for this is, according to Dr. Volker Kerscher, head of Innovation Management in the Performance Polymers Business Unit, that “Nowadays innovations take place at the interfaces of the disciplines.“ An example presented Dr. Goetz Baum- garten, who is the former head of the Membrane Technology group of Process Technology & Engineering and currently is head of Business Development Mem­ branes in the Fibers & Membranes Business

Evonik uses the Segment of the High Performance Poly- Lotus Exige to show mers Business Line. He pointed out that how polymers Evonik made several partnerships with can reduce weight universities and research institutes in or- der to develop its membrane business.

elements33 Issue 4|2010 “The starting point was our expertise in experiments have shown that ligands mo- weight sports car together with Lotus and the intrinsic membrane properties of our dified with organically chemical, confor- other industrial partners. high-performance polymer family Poly- matively flexible moieties are not well But the industry must also recognize amide P84 and the successful application suit ­ed for separation in macroscopic pores. an innovation‘s potential early enough to of membranes in our own processes,“ said At the TU Eindhoven ligands which are be able to build up the required expertise Baumgarten. “The know-how for produc­ modified with polyhedral oligomeric silses­ in the companies or in the country. Prof. ing membranes and the module technol­ quioxanes (POSS) are prepared. The ho- Wilhelm Schabel pointed out that this has ogy came from our partners.” Evonik mogeneous catalysts synthesized by this not always been the case in Europe, and currently markets its newly developed method are large and „rigid“ enough to be he presented as an example optical films, modules in the area of fast-growing appli- separated with ultrafiltration membranes. which are currently essential in the pro- cations, such as in organic solvent nano- Together with the TU Eindhoven it was duction of LCDs. “This technology could filtration (OSN), a separation technology possible to identify a very promising have been developed ten years ago in Eu- used to separate various components in molecule and to prove its functionality in rope, because the competence was there organic solvents or in producing bio- a feasibility study. Franke and his colle- in the field of photographic films, but no natural gas from biogas. Membrane tech- agues now investigate this technology in one did it,“ said Schabel, Professor of Thin nology from Evonik stands out for its mar- lab and pilot scale together with the TU Film Technology at the Karlsruhe Institute ket-leading energy efficiency. Eind ­hoven as part of the EU research pro- for Technology (KIT). Dr. Robert Franke, head of Research & ject “F3 Factory”. He attributed this not only to wrong Innovation Hydroformylation in the In- judgements by the industry based on a dustrial Chemicals Business Unit, cited Going mobile with Open poor assessment of the future importance another example of a successful partner- of the technology, but also to a lack of co- ship—in this case with the Technical Uni- Innovation operation across disciplines and sectors. versity (TU) of Eindhoven. Franke and his Klaus Hedrich, head of the Automotive “And there was no promoter for this tech- colleagues are looking for homogeneous Industry team, illustrated what Open In- nology in Europe as there was in South­ catalysts that can easily be separated by a novation means for Evonik customers in east Asia with companies like Acer, Asus membrane filtration process. “Homogen­ the automotive industry by referring to and LG. To prevent entire value-chains eous catalysis has a number of advan­tages, his own team, a cross-BU working group from migrating to other regions in the but it is used in only about 15 percent of for innovative projects and new ideas. world, products have to be manufactured commercial-scale processes. This is pri- “We’re the interface to Tier 1 suppliers in Europe. And the value-adding proces- marily because it is extremely difficult to and OEMs in the automotive industry,” ses start with research and train­ing at uni- separate the catalyst from the reaction said Hedrich. versities,“ said Schabel. product,” said Franke. “We’re studying The team not only identifies trends, Schabel and his colleagues at KIT study ways of using ultrafiltration to separate but develops ideas for market concepts all the formation and processing of thin lay- the catalyst quite easily.“ the way to demonstrators as part of “in- ers, likewise they can make fluid flow in In principle this approach is feasible, novation clusters.” According to Hedrich, thin films, morphology and structure for- but in order to work, the homogeneous lightweight construction is a good exam­ mation visible in situ, as well as simulate catalysts must be modified to have a suf- ple: “Electric cars need lighter materials.“ them. This makes it possible for example ficiently high molar mass without chang­ With its in-house expertise in the field of to optimize coating tools, processes and ing its activity and selectivity compared polymers, Evonik has a lot to offer in this plants through the optimization of process to the standard systems. Simulations and field, and has already designed a light- parameters. 333

elements33 Issue 4|2010 32R P Ocess TECHNOLOGY

333 Prof. Michael Schlüter, head of the cess design. “We’re looking for an off-the- Institute of Multiphase Flows of the Tech- rack suit, so to speak, instead of a tailor- nical University of Hamburg-Harburg, made suit,“ said Schembecker. This meth­od studies the fundamentals of chemical re- would require a kit with modules, from actor design. Because of the complex in- laboratory equipment to plant design mod­ terrelationships of heat and mass transfer, ules and construction elements. Even the we are quite limited in our ability to de­ planning process would have to be modu- scribe multiphase flows in technical larized. “Then, a process engineer would re­c ­a ­tors. Therefore chemical engineers no longer design all pieces of equipment still have to spend a lot of effort to design of the plant in order to achieve the design equipment for multiphase flows. To change capacity accurately but he would work this situation on long-term, Schlüter’s within a corridor to become more effi­cient in ­stitute together with colleagues from and in the end more economic,“ said other Universities and research institutes Schembecker. are conducting experiments, developing Currently, Schembecker is working local models for the fluid flow and per­form­ with colleagues from the ProcessNet sec- ing numerical simulation studies on the tion “Process and Plant Engineering“ to complete system. “We’re trying to devel­op prepare an call for project applications for a multi-scale approach, from the nano­ a research program of the Federal Minis- meter to the meter scale,” said Schlüter. try of Research and Technology: „We‘re The problem is that, while integral me- trying to convince the Federal Ministry to thods allow calculation of variables such make shortening time-to-market in the as pressure loss, gas content, and mass process industry a funding priority with transfer, they do not calculate gas and con- an estimated volume of 50 million Euros.” centration distribution, or mass transfer limitations—in other words, no local infor- Process Technology as a mation. Schlüter hopes that local informa- tion gathered through experiments can career springboard enable the development of numerical A fact, that young engineers (and scien- mod ­els that can then point the way to ana- tists) in Process Technology and Engineer­ lytical models. “If we can define scope of ing have a chance to do more than inter­ application and, in turn, use them as the esting technological development, was starting point for new numerical simula- demonstrated by two following speakers tions, we can then verify integral models,” Markus Schulz, for example, now works explained Schlüter. in Corporate Development of Evonik Industries, where he develops and imple- Modularization for shortening ments the Group strategy for the Chemi- cals Business Area. “We assist strategic time-to-market development in business segments and In modern process technology, it is impor- develop proposals for corresponding re- tant not only to develop a functioning pro- source allocation,” said Schulz. cess but also to create the basis for short­ Dr. Andreas Hoff also holds a leading ening the time that has to be devoted to position in the company now. After recei- the planning, construction, and commis- ving his doctorate in 2002, he began his sioning of the production plant in which career in process technology as a project Prof. Dr. Wilhelm Schabel the new process is operated. “Because the engineer. He then became head of the Professor of Thin Film Technology at the time in which the product is launched into fluid separations laboratory and pilot plant Karlsruhe Institute of Technology (KIT) the market increasingly determines the unit in Marl in 2005, before moving to the Prof. Dr. Michael Schlüter Head of the Institute of Multiphase Flows economical success of a product” said Performance Polymers Business Unit to at the TU Hamburg-Harburg Prof. Gerhard Schembecker, head of the manage business development and market Prof. Dr. Gerhard Schembecker chair of Plant and Process Design at the intelligence for new PLEXIGLAS® prod­ Holder of the Chair for Plant and Process Technical University of Dortmund. ucts in 2008. In 2009, he became head of Design at the Technical University of Dortmund We have identified various approaches the global market segment Solar in the (from top to bottom) to dramatically reduce project execution Acrylic Polymers Business Line, before times. If they are applied in total they coming full circle this October: Hoff is could even help us to bring us close to our now head of Fluid Separations. “In this vision of a 50 percent reduction of project role, I have to work with all six chemicals execution time compared to the state of business units at Evonik,” he said. “A job the art. One approach that Schembecker at the interface of market and technol­ is studying is the modularization of pro- ogy.“ 777

elements33 Issue 4|2010

VEHRRFA ENSTECHNIK PROCESS TECHNOLOGY 33

INteRVIEW

“An engineer‘s job description has changed“

Evonik‘s Process Technology & Engineering Service Unit lives by the principle of Open Innovation—which also includes the regular Conferences of Professor in Chemical Engineering. Dr. Claas Klasen, head of the service unit, and Dr. Jörg Sauer, head of the Reaction Technology department and organizer of the conference, explain its objectives.

S auer: The job description of the pro- cess engineer is becoming increasingly broader. Twenty years ago, the plant manager in the chemical industry was usually a chemist, the target position for engineers was plant engineer who often reported to the plant manager. The entire organization was managed primarily by chemists. That is not any more the case in many plants and instal­ la­tions are managed by engineers. More­ over at Evonik, engineers also work for example in applied technology, mar­ keting, and business development, or even in corporate controlling.

Why is that? Sauer: In the production plant, usually the fundamental chemistry of the pro- Dr. Jörg Sauer Dr. Claas Klasen cess has been investigated and under- Head of reaction engineering of the Process Head of Evonik‘s Process Technology & stood. For optimal performance of the Technology & Engineering Service Unit Engineering Service Unit plant it is crucial to consider both chemi- cal processes and equipment design as a whole. When it comes to applications of our products, Evonik works closely with engineers on the customer side—in the automotive and electronics indus­ Why does Process Technology hold S auer: An important objective for us is tries, for example. When engineers are a Conference of Professors? drastically shortening project run times on both sides they speak the same Klasen: We want to strengthen existing for the development and realization of language. contacts and make new ones. The event plants. In this regard we also rely on the also creates a space for developing new support of our partners in universities D o the figures reflect the growing ideas for future cooperation. We, on the and research institutes. importance of engineers? Evonik side, are also extremely interested Klasen: In the past ten years, the Pro- in finding out the current trends in re- Is there anything else you would like cess Technology & Engineering Service search and teaching from the scientists. the scientific community to know? Unit has trained and prepared more But we also want to convey to them our Klasen: Naturally, we also want to pro- than 300 employees for leading positions expectations and the development priori- mote ourselves to the professors as an in the Group. This figure should be ties we have set based on the current attractive employer, as they have many regarded in relation to the roughly 650 needs of the market. Process Technology young talents to offer. And engineering employees who work in this service can play an especially important role at is playing an increasingly important role unit. 777 the interface between process develop- in the chemical industry. This is chang­ ment for the manufacturing process of ing the engineer‘s job description—which specialty chemicals and application devel­ is opening up new career opportunities. opment. The universities need to know this.

elements33 Issue 4|2010 34N ews

Coating materials with VESTOSINT® gleam at Durban’s airport

Germany’s soccer team was not the only boasts a jetway for the new Airbus A380. modifiers fulfill the same role in many thing which drew a great deal of attention A total of 12,000 liters of coil coating ma- plastics, some of which would otherwise in Durban during the 2010 FIFA World terial in a modern and neutral shade of be brittle. Furthermore, VESTOSINT® Cup. The excellent quality of a coil coating gray were used in constructing the fine powder promotes excellent dirt re- for the new King Shaka Airport clearly airport‘s façades and roofs made of steel. pellency, which bears fruit particularly turned heads, as well. And that is thanks This coating material contains a unique with regard to outdoor architectural use. in no small part to a product from Evonik— additive: a polyamide 12 fine powder The coating’s resistance to abrasion is en- a polyamide 12 fine powder, VESTOSINT®. known as VESTOSINT®, which ensures a hanced because the polyamide particles— The new international airport in Dur- highly elastic structure resistant to abra- anchored in the coating by chemical ban, one of South Africa‘s ten World Cup sion. The polyamides are capable not only bonds—cannot be dislodged by friction. venues, was commissioned on May 1, 2010— of absorbing even those forces which im- In stoving paints, polyamides bring not long before the tournament began. pact a coating suddenly, but also protec- about uniformly fine surface structures, Designed for 7.5 million passengers, it also ting the coating against cracking. Impact which can be varied by means of the poly­ amide powder’s particle size distribution, as well as a mat surface gloss caused by the different refraction of coating resin and polyamide. The coatings contain no matt­ ing agents which could diminish weather resistance or elasticity. VESTOSINT® fine powders on offer vary as regards particle size and particle size distribution. They can be used individually or in a mixture to achieve the desired structure.

hwaites The façades and roofs of the new T King Shaka International Airport

ieron in Durban are well protected against : K abrasion, cracking and dirt by coil oto

PH coating with VESTOSINT®

Significant capacity expansion for precipitated silicas

Evonik Industries is planning to significantly increase its silica Thomas Hermann, head of Inorganic Materials, the business unit (precipitated silicic acids) production capacity over the next four covering silicas and other specialty chemicals. The move also years. „By 2014 we will have gradually expanded global capacity enables Evonik to continue ensuring the availability of its pre- at our existing plants by 25 percent, thus securing supply for our cipitated silicas in all regions. global customers,“ said Klaus Engel, chairman of the Executive Evonik‘s already strong market position is further reinforced Board of Evonik Industries. Investments to ensure this increase by product innovations: the specialty silicas SIPERNAT®288 and in production capacity will be in the mid double-digit million SIPERNAT®268 are designed for highly transparent silicone rub- euro range. Total capacity expansion is expected to be in the six- ber applications, such as keypads for cell phones, computers, and digit metric ton region and will be implemented mainly at remote controls. Other products for the tire industry and life Evonik‘s existing silica sites in Asia and Europe. In May 2010 science applications are being launched on the Asian market as Evonik had announced capacity expansion for precipitated sili- well. cas at its subsidiary INSILCO Ltd. in Gajraula (India). The application possibilities for precipitated silicas are di- These expansion plans back the Group‘s commitment to ac- verse and manifold. Silica, along with organosilane, is a crucial company its customers‘ growth as a strategic partner. „Evonik is component in low-rolling resistance tires. Silicas are also used the market leader in precipitated silicas. The market is expect­ed as carriers and free flow agents in the food and animal feed in- to grow substantially over the next few years. Through our ca­ dustries, and serve as additives in the paints and coatings indus- pac­ity expansion, we plan to satisfy the increasing demand and tries, or even as abrasives in toothpaste. Evonik produces pre- to achieve further growth along with the market,“ explained cipitated silica at 10 sites in 8 countries around the world.

elements33 Issue 4|2010 News 35

LEDs shine brightly for longer

Reflector sockets have a significant influence on the quality of LEDs. The whiter the reflector socket, the higher the reflectivity and the greater the luminous efficacy. Sockets made of VESTAMID® HTplus, a polyphthalamide PA10T developed by Evonik Industries remain pure white for a longer pe- riod, so the LED continues to shine brightly, gen­erating a consistently high light yield. This gives the LEDs a much longer life. In addition, VESTAMID® HTplus is particularly environmentally friendly because 50 percent of the polymer is based on renewable raw materials. Conventional reflector sockets turn yellow over time due to the effect of light and heat. As a consequence, the reflectivity and the luminous efficacy are continuously diminished until the light-emitting diode ultimately needs to be replaced. This is not the case for sockets made of VESTAMID® HTplus on ac- count of the very bright inherent color of the material coupled with its out- standing UV stability. Thanks to its low water absorption, VESTAMID® HTplus also boasts better dimensional stability, which makes it easier to process and makes it suitable for use in particularly small LEDs. The miniaturization trend

Size comparison: Even tiny LEDs can be produced with is also supported by the excellent adhesion to metal and silicon. reflector sockets made of VESTAMID® HTplus

PLEXIGLAS® façade for meteorological tower

A transparent façade that is made of which can stand up to all winds and weath­ PLEXIGLAS® sheets from Evonik envelo- ers. The façade also has another very spe- pes the new high-tech meteorological to- cific function: It serves as a projection wer at the Technische Universität Mün- screen, for example for weather data, chen (Munich University of Technology, news on campus life and scientific pic­ TUM) on its Garching campus. TUM’s tures. Text and images projected onto the new landmark was inaugurated in July af- surface from the inside can be clearly read ter three years of planning and construc- on the façade because the PLEXIGLAS® tion. “As a chemis­ t, I wanted a shell based elements in a whitish technical engineer­ on high-tech chemistry,” TUM’s presi- ing grade provide 88 percent light trans- dent, Professor Wolfgang A. Herrmann, mission. This makes the projections on the said in his speech at the opening cerem- material highly luminous. ony. “PLEXIGLAS® is the ideal solution.” Each of the 210 façade elements is The 50-meter-high Oskar-von-Miller- unique and has a different radius and cur- Turm collects meteorological data like vature due to the tower’s geometry. The temperature, solar radiation, and wind architects ventured into new territory speed using the latest technical equip- when installing the sheets. They devel­ ment. The architecture is also of the high- oped pointwise bearings so as not to im- est level. This was ensured by the material pair the material’s graceful optical im- mix of gentle-looking PLEXIGLAS® and pression by using aluminum bars as the tough steel and concrete. The reinforced supporting structure. The sheets are there- concrete structure can be seen through fore fixed by means of slim pointwise fas- the transparent vertical façade and reveals tening devices, which made it possible to the tower’s interior. reduce the butt joints between the To provide a glimpse behind the façade rings to an absolute minimum. scenes, the architects at the Munich office “The meteorological tower shows that of Deubzer König & Rimmel needed a PLEXIGLAS® offers completely new options The meteorological highly transparent façade material that for architects. They just have to use them,” tower at theTechnische was also resistant to weathering and UV said Thomas Ries, an architect in the Ac- Universität München light. That is why they chose PLEXIGLAS®, rylic Polymers Business Line at Evonik.

elements33 Issue 4|2010 Release coating made from UV-cured silicone The smart adhesive

Nothing is easier than gluing. And nothing is as complex as self-adhesive laminates that have to meet all the requirements of advanced com­mercial production processes. Evonik has spent the last 25 years developing UV-cured silicones for innovative release coatings that promise greater efficiency, profitability and sustainability.

[ text Dr. Winfried Hamann, Annegret Lange, Mikko Meyder ]

Hightech: the self-adhesive diaper fastener

elements33 Issue 4|2010 COG ATIN & BONDING TECHNOLOGIES 37

Wa h t do diaper fasteners, address stickers, graphic films and high temperatures, thermally curable silicones cannot be used carpet tape have in common? They are all self-adhesive. Day in for thermal paper or for extremely light and thin substrates made and day out, each of them plays a role in products with self-ad- from heat-sensitive plastics. hesive components. As in many other areas of technical innova- tion, however, what the end user experiences as simple, inex- Curing in a fraction of a second pensive and time-saving to use is actually based on complex composite materials that demand extensive know-how, compe- with UVC radiation tence and many years of experience. The better alternatives are release liners equipped with radia- Self-adhesive products are multi-layer systems. A label lami- tion-cured silicones (RC silicones), which are crosslinked with nate, for instance, consists of four layers: the release liner, the UVC radiation instead of heat. Using conventional mercury va- adhesive, the actual printable label, and an extremely thin sili- por lamps, this can be done in a fraction of a second, and is more cone-based release coating (Fig. 1). “Invisible, but essential to energy- and cost-efficient than the thermal variety. the function, this release coating ensures that the label releases A pioneer in this field is Evonik‘s Consumer Specialties Busi- easily and residue-free from its backing, the ‘release liner,’” says ness Unit in Essen, which developed TEGO® RC Silicone exactly Dr. Winfried Hamann, head of Application Technology for RC 25 years ago. Even back at the founding of the company in 1985, Silicones. it was clear to everyone involved that „the market for radiation- Self-adhesive laminates are hardly a new discovery. In stan- cured systems opens such great potential that we are setting a dard products, such as those used about 50 years ago, glassine sound milestone for the long-term.” paper—a smooth specialty paper produced under high pressure Indeed, the potential is enormous: the world market for self- and temperatures—was used as the release liner. The material, adhesive products amounts to about 32 billion square meters per which is usually blue- or yellow-colored, is normally coated with year, which corresponds to nearly one tenth of the surface area silicones that are then cured thermally. of Germany. Worldwide sales are roughly US$4.4 billion. At These systems have drawbacks. The glassine paper must be about 52 percent, self-adhesive labels of all kinds make up the completely wood fibre-free, and is therefore relatively expen- lion’s share of sales, with a solid one tenth going to adhesive sive. Also, thermal curing is an energy-intensive process, be- tapes for such products as packaging, and another eight percent cause the silicone is crosslinked at over 110° C (230° F). Even each to hygienic products such as diaper fasteners and industrial though there are formulations that cure at lower temperatures, applications such as floor coverings and protective films. The the chemical crosslinking takes significantly longer—and the coat­ rest is distributed to numerous products of daily life, such as en- ing line, in turn, has lower throughput. Finally, because of the velopes, stamps and wallpaper borders. 333

Figure 1 Structure of a label laminate Applications for self-adhesive materials. The twelve percent not shown ranges over countless products from everyday life, such as stamps or wallpaper borders. In all, the global market volume for paper and film release liners is about 32 billion square meters or US$4.4 billion

Label Adhesive

Label laminates Hygiene products standard labels, disposable diapers, Silicone clear labels feminine hygiene

Market share 52 % Market share 8 %

Construction industry & insulation Insulating materials, floor coverings, foams, bitumen Adhesive tapes Release liner automobile parts, Market share 8 % packaging, office supplies Market share 12 % Films Dust jackets, protective films, decorative films

Market share 8 %

elements33 Issue 4|2010 38 coATING & BONDING TECHNOLOGIES

factors, largely determine the release value of the coating. The release value is the measure of the force required to release the The importance of adhesive label reliably and cleanly from the substrate in such applications as dispensing machines for the food or packaging industries. bonding processes is growing Chemically, the release value is determined by the chain length A whole host of trends in key segments of industry will further of the crosslinked silicones, through the position and number of increase the use of self-adhesive products. For example, adhe- the active groups in the molecule. But it is also determined by sive bonding processes are becoming increasingly important in the adhesive, the surface, and the substrate material. This is why technically demanding applications such as the automobile it takes a great deal of experience and the right expertise to de- industry, where adhesives are on a par with mechanical fas­teners velop the optimal formula. in many applications. Some applications—in the electronics in- dustry, for example—are not possible without adhesives. In ad- A choice between radical and dition, the increasing requirements for the labeling of packages could not be met without durable, secure and flexible labels. cationic crosslinking These include anti-counterfeiting labels for expensive cosmetics Inerting the reaction chamber with nitrogen is critically impor- and medicines, and thermolabels that can be coated with RC sili- tant for using RC silicone acrylates. Because the silicone acry­ cones directly and then no longer require substrates. lates crosslink via radicals, atmospheric oxygen would fill the What the silicon experts of the former Goldschmidt company active groups and prevent the reaction from occurring. This is could not foresee 25 years ago is that alternatives take time to why the specialists at Evonik developed a special nitrogen flush be implemented—investment in new technology always means or purge that ensures that the remaining oxygen in the curing not just opportunities but a certain amount of risk. Naturally, chamber stays below 50 ppm. This form of inerting is safe, harm- the willingness to invest is also largely dependent on the avail­ less, and generates very little added cost. Cationic crosslinking ability of lines based on the old technology. There is good reason of epoxy silicones offers an alternative. In this case, the reaction to feel confident about the future, however, because one thing chamber does not need to be flushed with nitrogen, but the is certain: TEGO® RC silicones have matured enough to meet catalysts are sensitive to poisoning by some substances that could the high technical, economic and environmental standards of be used as additives in the substrate material (Fig. 2). customers when it comes to release coatings for labels. TEGO® RC silicones have an array of important advantages In the past few years, the specialists at Evonik have devel­oped over conventional, thermally cured release coatings. Not least, a number of products and formulations specially designed for they are solvent-free. The curing units are also compact, since the requirements of customers—normally, producers of self-ad- heating, cooling and post-curing steps are not needed. In addi- hesive laminates and adhesive tapes. Most release coatings are tion, the curing process uses less energy, since high tempera­ made up of several components whose quantities, among other tures are not needed. 333

Saving space and energy: Following application by a multi-roller system (left), the silicone release coatings harden in a fraction of a second and close to ambient temperature in the UV chamber (middle), making them suitable for heat-sensitive substrates

elements33 Issue 4|2010 COG ATIN & BONDING TECHNOLOGIES coATING & BONDING TECHNOLOGIES 39

Figure 2 Evonik offers both radically cured silicone acrylates (above) and cationically require inertization with nitrogen. Cationically cured silicones do not require cured epoxy silicones (below) for radiation-cured release coatings. The inertization, and are therefore easier to handle. But they require post-curing, radically cured silicones can be used on any kind of substrate, harden quite as shown in the graph, and cannot be used on all substrates because they rapidly, and are therefore suitable for inline processes. However, they can be poisoned by additives in the substrate

Silicone acrylates Epoxy silicones

Relative intensities of characteristic bands in the infrared spectrum

1.0

0.8

0.6

0.4

0.2

0 1 2 3 4 5 6 7 8 9 10 Time [sec]

elements33 Issue 4|2010 The pilot plant in Essen (Germany) contains all the process stages essential to the manufacture of self-adhesive products: siliconization, adhesive coating/drying, lamination and cutting. Suitable for temperature-sensitive substrates It can be used for both inline and off- Biaxially oriented polypropylene film (BOPP) is a good example line production, and works at a speed of up to 100 meters per minute of a temperature-sensitive substrate. It is only 30 micrometers thick—only about half as thick as glassine. BOPP film makes the laminate about 20 percent thinner, on the whole, than laminates based on paper. So a roll of such laminate can contain one fifth more material. For production and processing, fewer roll changes mean savings in terms of transport volume, storage space and work time. Because the plastic film surface is also smoother and more closed compared to paper, BOPP substrates require about Figure 3 one fourth less silicone. Price comparison between glassine paper coated with thermally cured Innovations are expensive, and newly developed alternatives silicone, and a BOPP film coated with UV-cured silicone increase costs, right? But take a close look, and this wid­e­ly held

Glassine paper 55µm with thermal silicone view does not apply to TEGO® RC silicones (Fig. 3). Production Commodity BOPP 30µm with UV silicone may require a few more steps that roughly double the costs com- pared to thermally cured systems, but in evaluating cost effi­ ciency, the kilo price is not as important as the overall balance sheet. The important question is: how expensive is the release + 25 % coating per square meter of adhesive laminate?

Not just technical but commercial and environmental benefits Here, it becomes obvious that UV silicones are more cost-effec- tive than the thermal alternatives. A comparison of raw material 0 20 40 60 80 100 costs argues in favor of the plastic. While the economic crisis Relative raw material cost [%] has set raw material prices on a rollercoaster ride, BOPP film is still a less costly substrate than glassine paper, given the fact 333

elements33 Issue 4|2010 COG ATIN & BONDING TECHNOLOGIES 41

L cife Cy le assessment

thermally cured silicone, and one for BOPP film coated with UV-cured silicone. To this Plastic displays better life cycle assessment than paper end, they evaluated not only the materials themselves but their entire lifecycle—from Recyclables instead of waste extraction of the raw material, through processing, to disposal or recycling. The results of the study were clear: BOPP outperformed glassine in terms of greenhouse gas potential, as well as the use of biotic and abiotic raw materials. The differences between the two materials were also striking when it came to cumu­ lated energy demand. The manufacture of glassine takes a lot of energy, because the specialty paper has to be produced from fresh pulp so that it is completely wood- free. While BOPP film is produced from petroleum, the bottom line is that recy­ cling used film significantly reduces ener- gy consumption. Recycling reduces the Silicone-coated polypropylene film as a and thinner, would reduce the amount cumula­ ­tive energy required to produce substrate for self-adhesive products has of waste generated by half. Another bene- one square meter of the film by 80 percent technical and commercial advantages over fit is that the polymer is easily recycled: (Fig. a). conventional laminates on glassine paper. unmixed BOPP is a highly sought-after The pressure on the industry to devel­ But is changing from paper to plastic secondary raw material, from which recy­ op technical solutions for recycling release also environmentally smart? Would it not clers produce flower pots, winding tubes, liners is growing steadily. In some coun- amount to exchanging a favorable life and glazing blocks for installing windows. tries, disposal of glassine in landfill is no cycle assessment for an unfavorable one? With prices for fresh polypropylene again longer cheap. Also, the quantity of release The fact is that about 250,000 metric on the rise, the demand for used film is liners generated is considerable, and re- tons per year of silicon-coated glassine increasing dramatically right now. presents an interesting source of raw ma- paper is generated as waste material in The Wuppertal Institute for Climate, terials for recycling companies. “In a few Europe alone. Because the silicone makes Environment and Energy conducted an years, BOPP liners will be state-of-the-art recycling extraordinarily difficult, most of extensive comparison of paper and poly- in the label industry—coated with our the material is either deposited or burned, propylene on behalf of Evonik. Scientists TEGO RC silicones,“ says Mikko Meyder, which inevitably generates costs. Using from the Institute prepared a life cycle as- global marketing manager of the RC BOPP plastic, which is significantly lighter sessment for glassine paper coated with Silicones Busines­ s Segment.

Figure a Comparison of the waste generated by glassine paper and BOPP plastic Comparison of the cumulative amount of energy required to produce in kilograms per 1,000 square meters. Because the plastic is significantly one square meter each of BOPP and glassine paper. BOPP film lighter and thinner, the amount of waste is cut nearly in half does appreciably better here because the used film can be recycled— an impossibility with glassine paper Source: Wuppertal Institute for Climate, Environment and Energy

Glassine paper 55µm Commoditiy BOPP 30µm Glassine paper with incineration BOPP BOPP with recycling

– 55%

0 10 20 30 40 50 60 70 0 1 2 3 Waste [kg/1,000sqm] Energy demand [MJ/sqm]

elements33 Issue 4|2010 42 coATING & BONDING TECHNOLOGIES

333 that polypropylene is a standard plastic used for such ap­ LED UV lamp for silicone curing could be ready for use in just a plications as packaging films and heat sealing. The low price of few years. the film more than compensates for the increased price of UV Experts at Evonik are also setting their sights far beyond la- silicone. bels. “Silicones are chemical jack-of-all-trades. Thanks to their The economic and technical advantages are starting to make versatility, and the custom-tailored properties made possible by an impact on the market. One of the biggest laminate producers accumulated chemical know-how, UV-cured silicones would be in Europe has begun the transition from paper liners to films. suitable for completely new fields of application, such as coatings The new release coating even meets the needs of companies that for heat-sensitive technical textiles and membranes. With these value the sustainability of the materials they use: plastic release future potential applications, they create the basis for a valuable liners coated with RC silicones are lighter and, above all, envi- contribution to the sustainable growth of the Industrial Special- ronmentally safer because they reduce the volume of waste and ties Business Line,“ says Dr. Georg Feldmann-Krane, head of the can be recycled for high-quality production (see box on page 41). business line. 777 Demand is growing, particularly outside Germany. In emerg­ ing markets with strong economic growth, such as China and Brazil, there is high demand for consumer goods and, therefore, advanced labeling systems. The market for self-adhesive labels D r. Winfried Hamann is head of Application Tech­ is growing at a rate of about 15 percent per year in China alone. nology Radiation-Curing Silicones in Evonik‘s Indus­trial There, countless label manufacturers and printing houses are Specialties Business Line. After studying chemistry and earning his doctorate in inorganic chemistry at the looking for compact, durable equipment with relatively low in- University of Münster, he started his career in 1984 vestment requirements. It is also a country in which technology at Jackstädt GmbH, a manufacturer of pressure sensi­ „made in Germany“ has a particularly good image. In 2009, in tive laminate materials. In 1987, he became head of R&D Silicones, and held this position until he moved response to this development, Evonik opened the Competence to Evonik, the former Th. Goldschmidt AG, in 1992. Center Shanghai, where Asian customers can try out customized +49 201 173-2452, [email protected] RC formulations in a pilot coating plant and form their own im- pression of the benefits of radiation curing. Evonik also operates a similar Technology Center in Hope- Annegret Lange is responsible for the sale of RC well (Virginia, USA) and four mobile UV curing stations in Eu- silicones in the EMEA (Europe, Middle East, Africa) rope, Asia and South America, where market participants can region in the Industrial Specialties Business Line. experience radiation curing for themselves. In addition, since After an apprenticeship as an industrial business man­ ager at the former Th. Goldschmidt AG in Essen, she 2005, the RC pilot plant in Essen has offered customers the op- worked in various positions in silicone sales from 1977 portunity of testing a wide range of adhesives, substrate mate- to 1987. Beginning in 1987, Lange worked as Market rials and surfaces, and adapting them to their particular appli- Manager Western Europe for RC Silicones in Evonik‘s Industrial Specialties Business Line before moving to cations. The plant is able to coat a substrate with silicone, apply her current position in 2005. adhesives, and laminate a covering material, all in a single pass. +49 201 173-2574, [email protected] Development of RC silicones is continuing. Instead of con- ventional UV radiators, UV LEDs could be ready for use in just a few years. The advantages are clear: light-emitting diodes M ikko Meyder is head of Marketing RC Silicones in the Industrial Chemicals Business Line. After studying would turn the lamp into a geometrically shaped surface irradi- chemical engineering at the University of Dortmund, ator. The radiant energy can be precisely controlled by switching he began his career in 1998 at Wacker Chemie in Burg­ individual diodes on and off. Not least, LEDs are compact, have hausen and Nünchritz, first as Project Engineer Plant Construction, and later as Production Engineer. In 2002, a long life expectancy, and generate less waste heat than con- he moved to Evonik in Essen to become Project Engi­ ventional UV radiators. But LEDs are still unable to generate neer Plant Construction. Meyder held another position high-energy UVC radiation. Experts from Evonik are working as senior consultant in the Inhouse Consulting unit at Evonik before assuming his current responsibilities in together with engineers, substrate and adhesive manufacturers 2007. to coordinate LED technology and silicone chemistry. The first +49 201 173-2595, [email protected]

elements33 Issue 4|2010 News 43

Geothermal energy used even more efficiently

Geothermal energy is the most efficient form of heat­

ing. It generates 45 percent less CO2 than oil-based heating and 33 percent less than gas. What is more, the new direct heat exchanger technology using pro- pane increases the efficiency of this heating system by a further 10 percent as no brine needs to be pumped. Evonik Industries de­livers the plastic for the tubes required for this technology, which are driven some 100 meters deep into the ground. The material used is VESTAMID®, a polyamide 12 that provides a high barrier to permeation from propane which, unlike steel, can be processed from the reel and does not require corrosion protection. The conventional process for generating geother- mal energy uses a water-glycol brine for the heat ex- change that is pumped using polyethylene tubes. The new direct heat exchanger process instead uses the refrigerant R290 (propane), which is available in the tubes as a gas and a liquid. Because of the difference in temperature—at depths of 100 meters it is around 4 °C to 5 °C warmer than close to the surface—the propane circulates exclusively due to the physical ef- fect of the evaporation and condensation. This makes a pump unnecessary, which saves energy and conse- quently increases the heat generation efficiency by 10 percent. Polyethylene tubes cannot be used for this method, however, as they are permeable to propane gas. The alternatives are steel pipes, or pipes made of polyamide 12. The advantage of the latter is that they do not corrode and can be wound on rolls so that no on-site welding is required when the pipes are being laid. Tubes made of VESTAMID® modified especially for this application also have a rough inner surface that is indispensible for the development of falling film in the heat exchanger.

Direct heat exchanger technology using VESTAMID® polyamide 12 tubes improves the efficiency of geothermal energy production by a further 10 percent

S cientific Advisory Board Contribution Editors Printed by Credits Dr. Norbert Finke Christa Friedl Laupenmühlen Druck Evonik Degussa GmbH Michael Vogel GmbH & Co.KG Innovation Management Bochum (Germany) Publisher Chemicals & Creavis Design Evonik Degussa GmbH [email protected] Michael Stahl, Munich (Germany) Reproduction only with permission Innovation Management of the editorial office Chemicals & Creavis Editor in Chief Photos Rellinghauser Straße 1–11 Dr. Karin Aßmann Evonik Industries Evonik Industries is a worldwide 45128 Essen Evonik Services GmbH Karsten Bootmann manufacturer of PMMA prod- Germany Konzernredaktion Adrian Schmidt ucts sold under the PLEXIGLAS® [email protected] Stefan Wildhirt trademark on the European, Asian, Gina Sanders – Fotolia (p. 15) African, and Australian continents Stefan Richter – Fotolia (p. 24) and under the ACRYLITE® trade- Carlos Casariego – Getty Images (p. 25) mark in the America

elements33 Issue 4|2010 are no exception for us. forexception no are plastics insolutionsExceptional

www.evonik.com