Creating Chemistry For a sustainable future Issue two 2012

A role model for sustainable Also in this issue: 8 Rethinking our future: How smart and visionary technologies might energy use? help power the cities of tomorrow. 28 Hungry for change: Two experts present their differing strategies on how to Director of tackle malnutrition. Dr. Nawal Al-Hosany (photo) 36 Let there be light: An introduction to the illuminating world of OLED technology. presents the ambitious Masdar 42 Pick of the packs: Packaging ideas from around the globe. City energy-saving project. 50 value: How precious metals from electrical can help Interview on page 16 conserve limited resources. Contents

Information Innovation 4 The world in figures 26 New discoveries The key numbers from this issue’s topics. Smart ideas that might enrich our lives.

Inspiration From two perspectives: For & Against 6 Staging a green revolution 28 Better nourishment for all? How Hollywood star Cate Blanchett is transforming M. G. Venkatesh Mannar from the Micronutrient the Sydney Theatre Company’s home into a Initiative and Frank Braßel from Oxfam explain their showpiece for sustainable building. differing strategies for combating malnutrition.

Viewpoint BASF Our journey towards the energy 34 The best investment in human development 8 supply of the future. Walter Dissinger, President of the Nutrition & Health division at BASF, reveals how BASF contributes to Cover story fighting malnutrition. Feature: Quality of life The issue 36 The reinvention of light 8 Towards a new future for sustainable Organic light-emitting diodes (OLEDs) have energy use the potential to revolutionize the lighting market. Energy efficiency is at the top of the sustainability agenda. Some innovative and unconventional Insight ideas give a glimpse of what our energy future 42 A glimpse around the globe: packaging might look like. Packaging might seem inconspicuous but it’s an essential part of our lives. We explore some The graphic creative packaging ideas from around the world. 14 Energy harvesting How can we fight malnutrition? In the future, city-dwellers could be generating Feature: Food and nutrition 28 Two perspectives. energy without even noticing it thanks to the 44 Boxing clever harvesting of small amounts of ambient energy. Not just an empty box: Innovations ensure that food packaging is affordable, sustainable and safe. The expert 16 The diplomat for sustainability Feature: Resources, environment and climate Dr. Nawal Al-Hosany, Director of Sustainability 50 From trash to treasure at Masdar City in , explains how this There could soon be a shortage of raw materials ambitious energy-saving project works. for important future technologies. We examine how electrical waste recycling can help preserve The reality these resources. 20 The BASF Verbund Since its founding, BASF has continued to Invention demonstrate how intelligent systems can increase 56 Pioneering thinker – then and now energy efficiency. We take a look behind German chemist Justus von Liebig is seen as the the scenes. founder of organic chemistry. Today, Professor Organic light-emitting diodes (OLEDs) Dr. Junji Kido from Japan is following in his footsteps. 36 are reinventing artificial light. The science 24 Winds of change Ingenuity The technology to generate power from the wind 58 Chemistry around us has been around for 125 years. We examine its How does a shirt become non-iron? history more closely. A short explanation of an everyday solution.

CO2 22 A look behind the scenes emissions of the BASF Verbund

Natural gas Incineration Power plant system

2 | Creating Chemistry Welcome

How can we use energy efficiently?

Everybody needs energy – to keep our homes cool in the summer and warm in the winter, to keep our economy going and to connect with each other worldwide. Our needs are growing daily: By 2050, humanity will consume two to three times more energy than it does today.

Energy efficiency is the focus of this issue of Creating Chemistry. This was the concern mentioned most frequently in our last reader survey. Of course, we are very keen to hear your views this time, too. Please let us know what you think of this issue at www.basf.com/creatingchemistry.

For BASF, energy efficiency is crucial. We require lots of energy, and it costs money. This is why we have been striving for decades to manage resources carefully. For example, we use the heat produced as a by-product from one plant to provide energy for another (page 20).

But energy efficiency has another dimension for us. We are working on solutions that help you save energy, too. For example, we are researching organic LEDs that are not only economical to use but also completely reinvent artificial light (page 36).

Renewable energy demands innovations from the chemical industry. Our products can be found in wind turbines (page 24) and solar installations. There are many other ideas and methods of producing energy, as well: In , for example, excess pressure in the drinking water system is being converted into (page 10).

We need progress of this kind because our planet’s resources are limited. The breakthroughs we are seeing now are just the beginning. I am convinced that in five or ten years, we will be able to find other answers and ways of doing things even better.

Dr. Kurt Bock Chairman of the Board of Executive Directors BASF SE

Creating Chemistry | 3 Information

50 The The number of countries that require mandatory fortification of certain staple foods with specific nutrients to improve public health.1 world See Better nourishment for all? on page 28. in

Food and nutrition figures 30% Around one third of all the food produced worldwide – 1.3 billion metric tons – is lost or wasted every year.2

Resources, environment and climate $110* The amount that the average household could save every year by turning off electrical devices and lights when leaving a room.3

$4.4 billion The estimated value of the global market for energy harvesting by 2021.4 See Energy harvesting on page 14.

*In this issue the conversion of euros to U.S. dollars is based on the average exchange rate on December 31, 2011, when €1 cost $1.2939. The $ symbol always refers to U.S. dollars.

4 | Creating Chemistry Resources, environment and climate 40 million The number of metric tons of electronic waste that are produced worldwide each year.9 90% The percentage of the world’s Resources, rare earth deposits that are environment and climate found in China.10 100 252 meters The number of vehicles that would The predicted diameter of wind cause as much pollution as just one turbine rotor blades by 2020. In vehicle produced prior to 1974, thanks 1980, the average diameter of 11 $1 to today’s modern catalysts.6 rotor blades was 15 meters. The value of the gold typically Food and nutrition 5 found in a single cell phone. 25% of the world’s used iodized See From trash to treasure on page 50. salt in 1990. Now it is more than 70%.12

1990 25% 2012 70% 2 billion The number of people worldwide who suffer from malnutrition and other nutrition-related diseases.13 95 – 115 kg The amount of edible food per person that is thrown away each year in industrialized countries.14

Resources, environment and climate Quality of life 20% 100 How many times thinner Masdar City’s goal is to use the diameter of the organic just one-fifth of energy consumed layer in organic light- 8 by a similar sized city. emitting diodes (OLEDs) is 20C compared to a human hair.15 The reduction in average temperature in Masdar City (compared to outside of the city) possible through 20% The percentage of the 7 using traditional Arabic construction techniques. world’s consumption See The diplomat for sustainability on page 16. that is accounted for by generating light.16

1. www.foodinsight.org; 2. Food and Agriculture Organization of the United Nations (FAO): Statistical Yearbook 2012; 3. German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety; 4. IDTechEx: Energy Harvesting and Storage for Electronic Devices 2011-2021; 5. Jon Mooallem: The Afterlife of Cellphones, New York Times, 2008; 6. BASF Metals Recycling; 7. Masdar City; 8. Masdar City; 9. United Nations Environment Programme (UNEP); 10. European Commission; 11. European Wind Energy Association (EWEA); 12. Micronutrient Initiative; 13. World Health Organization (WHO); 14. Food and Agriculture Organization of the United Nations (FAO): Statistical Yearbook 2012; 15. www.oled-lights.org; 16. Dresden University of Technology

Creating Chemistry | 5 Inspiration

Staging a green revolution

November 26, 2010: Cate Blanchett stands on the roof of an old harbor building in Sydney known as “The Wharf,” the home of the Sydney Theatre Company. Immediately after becoming co-artistic directors of the theater, the Hollywood star and her husband set themselves the ambitious goal of transforming the heritage structure into a showcase for . Now, they are celebrating a major milestone with the installation of the second largest photovoltaic rooftop array in Australia. A lot has happened since then.

hen Hollywood of Community Programs and the man directly to the landfill by the theater is BASF’s new North star Cate in charge of implementing Greening being reduced,” says Patrick McIntyre, American headquarters Blanchett and the Wharf. General Manager of the STC. The her husband, system had a positive impact almost Lowering the playwright and Shrinking the as soon as it was installed, with a of buildings is also an important director Andrew In 2010, the building project marked significant reduction in the amount goal for BASF. Its new North Upton,W became co-artistic directors its first major milestone: the rooftop of waste thrown away. American Headquarters in Florham of the Sydney Theatre Company installation of Australia’s second Promoting real changes in Park, New Jersey, which opened in (STC) four years ago, they not only largest photovoltaic rooftop array. behavior and attitude is one of the May 2012 and provides room for focused on the repertoire, but also The 1,906 solar panels now produce more challenging goals of Greening 1,400 employees, is one example of on the conversion of the heritage about 427,000 kilowatt hours of the Wharf. As Blanchett explains: BASF’s commitment in this regard. building housing the theater. With the electricity annually. To meet its water “One of the key roles of theater and More than 30 BASF products were “Greening the Wharf” project, they conservation targets, the theater the arts more broadly is to stimulate used during the construction of this wanted to combine their two great installed a sophisticated rainwater social change by bringing vision to 30,200 square meter (325,000 passions: art and climate protection. recycling system. A gigantic tank action through forum, experimentation square foot) building. It meets the “Theater is very much engaged in under the pier supplies all the and debate.” The STC has developed highest environmental standards the time and place in which it is non-drinkable water used by the STC a model that resonates far beyond and was designed to fulfill the made,” says Cate Blanchett, and its restaurant “The Bar at the End the walls of the old harbor building: requirements of the United States’ explaining her motivation for the of the Wharf”. Now, drinking water Not only does it aim to engage the Green Building Council’s Platinum project (www.greeningthewharf.com). is no longer flushed down the toilet. neighboring district of Barangaroo LEED® certification (Leadership in “And the greatest challenge facing us These easy-to-implement and create a modern wharf area Energy and ), as a species at the moment is climate measures have been highly effective, here, it also wants to inspire other which promotes sustainable change. We felt that, as a theater reducing the STC’s carbon footprint by art and cultural organizations around construction techniques. company, if we did not engage 80%. With these results, the theater’s the world. One of the special features with this incredible challenge we management has demonstrated that of the headquarters is the efficient all face, then very quickly we would older heritage buildings can be Green Award use of natural resources through become irrelevant.” ecologically transformed. “We believe To make these goals possible, intelligent systems. In comparison Her goals are ambitious: to that change is possible without a around $5.6 million (€4.3 million) has to conventional buildings, this produce 70% of the electricity correlating loss of quality,” Blanchett been invested in Greening the Wharf, reduces water usage by at least required by the theater and its said at a recent panel discussion 40% and energy consumption restaurant onsite and to save called “Creating a Climate for Change”. by more than 20%. Furthermore, 11.3 million liters of water each at least 20% of the materials used year – enough to fill four Olympic- Waste is turned into come from recycled components. size swimming pools. To achieve Their drive for innovation did not end This is even true for the furniture: this, the Greening the Wharf project with the theater; Blanchett and Upton chairs were partly crafted from team focuses on measures such as also investigated how to make the old plastic bottles, with each seat an automated energy management restaurant more environmentally containing 111 recycled items system for heating, ventilation and friendly. Today, organic waste from of packaging. and energy-efficient the restaurant kitchen is converted stage lighting. “The project is into energy and fertilizer, while other ambitious and broad in scope,” waste is turned into biogas. “We are Above The Histrionic by Thomas Bernhard is just explains Paul O’Byrne, STC’s Director thrilled that the level of waste sent one of many plays on the theater’s 2012 program.

6 | Creating Chemistry Left On the roof of Sydney Theatre Company in Walsh Bay: Cate Blanchett (right) and her husband, Andrew Upton (left), together with the chairman of Suntech, Dr. Zhengrong Shi, and his wife, Vivienne, inaugurate one of the largest solar rooftop arrays in Australia. This project was enabled by a donation from the chairman’s family foundation.

All images courtesy of Sydney Theatre Company provided by private donors as well as partners from politics, business and academia. The project was also supported by the Australian government’s “Green Precincts Program”. For project manager O’Byrne, the money is well invested: “The full project impact will require a few more years’ data, but we know that the investment is already significantly reducing the financial burden that increasing utility costs add to our annual budget.” Greening the Wharf has provided the theater with an even more promising future ecologically, economically and socially. This achievement has recently been publicly recognized: Greening the Wharf has seen Cate Blanchett – already the recipient of an Oscar and two Golden Globes – honored further. Along with Andrew Upton, she was awarded two Green Globe Awards in 2010, one for Sustainability Excellence and one for Community Sustainability.

Cate Blanchett

Hollywood star and Academy Award winner Cate Blanchett takes a hands-on role in climate protection. Her declared goal is to reduce her personal carbon footprint by 13,300 kilograms. To that end, she and her husband Andrew Upton have not only carried out green renovations at the Sydney Theatre Company, but also at their home near Sydney. To promote climate protection more widely, the Australian actress has taken to the political stage. As a prominent advocate, she got involved in the emotional 2011 debate about the introduction of a carbon tax in Australia. Since 2007, she has also been Patron of SolarAid, an international NGO bringing to developing countries.

To find out more, visit: www.greeningthewharf.com

Creating Chemistry | 7 Cover story: The issue

Towards a new future for use

Experts worldwide are developing innovative and visionary energy concepts for the future. Their aims are to find ways to use existing energy sources more efficiently and to improve the viability of alternative sources of power. The desired outcome is to take the pressure off more conventional means of producing energy while still meeting growing global demand. Some cities are beginning to establish themselves as pioneers of this new approach, but how successful are they?

A special train these rotor blades to their destination – a new station in Australia.

8 | Creating Chemistry Creating Chemistry | 9 Cover story: The issue

he highways of Energy harvesting in everyday life An alternative market is emerging; City. A system of pipelines allows may soon be Using roads as mini power stations is U.S. market research companies water to flow into the center moved known not just for their a prime example of how new ways of estimate global revenues from by gravity alone, at a pressure that endless distances. A bill producing energy are being sought, energy harvesting at $663 million enables it to reach the upper floors recently adopted in the even in familiar areas of life. Energy (€512 million) a year. By 2021, this of the city’s highest U.S. state will transform harvesting, as it is known, describes should rise to $4.4 billion (€3.4 billion). without a . However, this high Troads into small power stations that the notion of producing small amounts But many of the novel devices used pressure becomes too much for will harness the vibrations from of energy and electricity from our to harvest energy have a problem: pipes to withstand once they reach moving cars. This phenomenon immediate environment in order to Compared to the cost of a people’s homes. A pressure regulator is called piezoelectricity; certain ultimately produce a significant conventional battery with the same is therefore used to reduce the minerals are deformed and become quantity of energy. From hybrid cars, power, they are still too expensive. pressure in the urban water pipelines electrically charged in response to to watches that charge themselves from more than 40 to just over 4 bars. applied mechanical stress. Sensors through motion, and electronic tea Water pipes producing energy In the future, the New York in the road convert this mechanical lights that convert heat into electricity The search for economic and company Rentricity wants to replace energy into electrical energy. On using a thermoelectric effect, there are intelligent approaches to alternative the pressure regulators with a a two-lane, half-mile section of opportunities to harvest energy forms of energy production is flow-to-wire element – a turbine that road, up to 44 megawatts can everywhere. Although these methods an important concern worldwide. will convert the excess pressure be produced, according to the are ridiculed by some as misguided, Countries and cities have long into electrical energy. Similar to wind proponents of this technology. others see this as a viable means of sought to out where new and solar power, this process does The total energy generated from producing energy in the future. energy infrastructure might be not produce any emissions. In the roads could be sufficient to supply The equipment used to harvest created – but there is also new U.S. state of New Hampshire, 30,000 households with electricity. energy works on a small scale in potential being discovered in existing Rentricity has already installed the Although it is questionable exactly the same way as large solar systems. In the area’s ‘green lung’ first such generator unit in the water whether these values can actually installations and wind turbines – even around 200 kilometers (125 miles) treatment plant for the city of Keene. be achieved, the basic idea of though it is not yet as efficient. It north of , the reservoirs of This mini power station has an output harnessing small energy packets in harnesses ambient energy that the Catskill Mountains store the water of 62 kilowatts and supplies the plant our everyday lives is widely accepted. would otherwise be lost. supply for the whole of New York with electricity.

10 | Creating Chemistry their annual coal consumption a self-sufficient by 17,000 metric tons. In around based on alternative energy sources, 15 years, the city will be complete is focusing on microgrids. These and will house a population low-voltage grids are to be trialled of 350,000. on the small island of Pulau Ubin, On a much smaller scale, but which will be a test site for green with similar environmental ambitions, energy technologies. Masdar City in the United Arab Microgrids are closed regional Emirates is also taking shape. energy systems integrating The energy supply for this model decentralized energy producers, city will come entirely from local, consumers, and sometimes storage renewable sources (see interview facilities. These relatively small grids on pages 16-19). operate intelligently. They can be linked up to the higher-level grid or Clever grids run separately from it, whereby the Cities and countries are also seeking connection can be opened or closed innovative ways of securing their according to needs. energy supply through measures Even if the central transmission involving their electricity grids. or distribution grid fails, the microgrid The city-state of Singapore, which continues to operate. The consumer does not have any raw material can then take electricity directly from reserves of its own and is promoting the decentralized generation units. >>

As far as sources are concerned, a clear strategy toward economic viability is needed – even if this requires a continued commitment to state aid over a number of years in Cities such as New York are focusing on innovative energy order to achieve it. concepts. It is planning to use Maria van der Hoeven, Executive Director of the International Energy Agency the excess pressure in its water pipes to produce energy.

Innovative urban planning Developers are building the city While cities such as New York are entirely according to the tenets of optimizing their existing structures, the efficient energy systems. Intelligent planning of new housing developments town planning ensures that distances often focuses on efficient energy use are kept short, and a sophisticated from the outset. This is demonstrated recycling system and environmentally by an example from Asia, where a new friendly local system are wave of enthusiasm for saving energy being developed. Desalinated has been building for some time. seawater and recycled water are fed In 2007, the Prime Ministers of into the water supply chain, covering China and Singapore signed a half of the city’s water needs. On framework agreement for the roofs, solar panels and rainwater construction of the “Tianjin Eco-city” utilization systems ensure the supply covering an area of 31 square of warm water. The energy for the kilometers (12 square miles). Several planned 240,000 square meters companies from China and (about 2,600,000 square feet) of Singapore have equal shares in this residential and office space is $9.7 billion (€7.5 billion) joint venture. produced by a small power station The city is being built 40 kilometers using solar cells and geothermal (25 miles) outside the port of Tianjin facilities. These renewable energy in Northern China. With an integrated sources will account for one-fifth of overall design, as well as the latest the urban . The rest will Above Maria van der Hoeven has been technology and incentives for be generated by coal, which is still Executive Director of the International Energy Agency since 2011. In this role, she represents behavior, used widely in China, but here too To find out more, visit: the major industrialized countries on energy www.iea.org the aim is to keep the energy the focus will be on efficiency. Thanks matters on the international stage. consumption of the city’s inhabitants to modern technology, the power www.tianjinecocity.gov.sg to a minimum. stations outside the city will reduce

Creating Chemistry | 11 Cover story: The issue

Energy-saving tips Shale gas is mixing up the energy market Turn down the heating: Replace traditional bulbs: Lowering the temperature in the Fluorescent tubes and energy-saving Renewable energy sources alone home by just 1.8F (1C) reduces lamps use around a quarter of the will not be able to secure our energy costs by 6%. energy of traditional bulbs. The U.S. energy supply in the foreseeable Department of Energy claims future. Fossil will also still be Unplug appliances and that simply changing every bulb in required to provide the base load – switch off lights: Don’t leave the United States to an energy-saving the amount of energy that must be

electronic devices such as TVs, model would cut CO2 emissions by available around the clock to supply computers and stereos in stand-by 400 million metric tons a year. all homes, businesses and public mode, and turn lights off when institutions with electricity. But leaving the room. This can save the Insulate wherever possible: resources are limited. Alongside average household around $110 Ensure that windows and doors around the development of new energy (€85) per year. the home are fully sealed. Use a lit concepts, major efforts are being candle to test for drafts by observing made to find unconventional Get economical in the whether the flame is blown out or deposits and innovative extraction kitchen: The kitchen offers flutters when close to window or door methods for raw materials. numerous ways to save energy. frames. Check how walls and roofs can Shale gas is a particularly hot Only fill your kettle with as much be better insulated – infrared thermal topic at present. In the United water as you need to boil, and place imaging shows where energy is being States, it’s undergoing a real boom; a lid over saucepans to conserve lost. According to the German Energy the widespread extraction of shale energy while cooking. Use the Agency, the right insulation can lead gas has led prices to right-sized hob or burner, and to savings of up to 80%. fall by up to 80% over the last few regularly defrost the fridge-freezer – years. Shale gas is found in thick ideally twice a year. clay and shale formations at depths of up to 4,000 meters (2.5 miles), Source: German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety (BMU) where it is trapped in small pores. Special techniques are required for extraction, such as hydraulic Although they are less efficient in the cycle and reused, thus saving sources and nuclear power. “As far fracturing – or “fracking”. Here, a producing electricity than central resources (see diagram on pages as renewable energy sources are mixture of water and quartz sand, installations, they ensure that a local 22 and 23). concerned, a clear strategy toward containing 0.5% to 2% supply is guaranteed in the “By increasing energy efficiency, economic viability is needed – even if additives, is pumped into the rock event of disruptions to the central grid. it might be possible to ensure that this requires a continued commitment at high pressure, to create fissures. These decentralized microgrids demand for energy does not rise at to state aid over a number of years The gas can then escape via these situated close to consumers enable the same pace as economic growth,” in order to achieve it,” she stresses. fissures, and funnel through the the electricity grid to be stabilized says Maria van der Hoeven, Executive If politics and business work borehole at the surface. The quartz when electricity needs rise. Director of the International Energy effectively together, a growing share sand remains in the rock, and acts Together with a further expansion of Agency (IEA). of renewable energy sources in as a support material to keep the central grids, microgrids can help in Van der Hoeven is also convinced overall supply can become more than cracks open. The additives prevent achieving the transition to a new that “we must not only try to use less just a nice-sounding idea. That said, the fissures from becoming energy era. and less in the way of old energy experts are divided on how quickly blocked, and thus increase the gas sources, but also guarantee that the and to what extent this vision can output. Critics claim the technology Corporate energy sustainability costs of new energy sources reflect become reality. For example, the could be harmful to the In the past few years, more and more the true costs.” This means boosting German Advisory Council on the environment; however, it has been companies have started meeting their efficiency, but also phasing out Environment is convinced, according used without any problems in oil energy demands with their own wind fossil subsidies and pricing in to a 2010 report, that will and gas extraction for decades. parks and photovoltaic and biogas externalities (such as through carbon be able to supply all its energy needs The American shale gas boom installations. In addition, many firms pricing) to make renewable energy from renewable sources by 2050. has had a big impact on the U.S. are attempting to increase their sources marketable and competitive. However, this report uses model economy. As a result, energy- efficiency by producing more energy calculations and working hypotheses intensive industries can operate from fewer resources, and saving The political vision based on technologies that are at lower costs due to reduced both money and energy by keeping According to van der Hoeven, currently not ready for the market, energy prices, and thus enjoy heat losses to a minimum. One governments can make a major such as geothermal energy and competitive advantages. example is the LED factory of contribution to the development compressed air storage. Critics Siemens subsidiary Osram in and deployment of clean energy therefore doubt whether this scenario Regensburg, Germany. Its design technologies and new energy will truly be realistic by 2050. enables incidental heat produced sources “by giving greater support Fossil fuels are still an essential by machinery to be captured and to research in this area and creating source right now and will continue fed into other production equipment. attractive underlying conditions for to play an important role in energy According to Siemens, this saves innovation and private investment.” supply in the future. New potential the company around $1.2 million She sees the optimal energy mix of is offered by unconventional deposits, (€900,000) in energy costs each year. the future as a more efficient and such as shale gas stored in porous The BASF Verbund system also cleaner use of fossil fuels in rocks up to 4,000 meters (2.5 miles) shows how energy can be kept within combination with renewable energy below the Earth’s surface, which can

12 | Creating Chemistry be extracted by means of a complex case – and it would no longer be technical process (see box on fed from the solar installation on the right). the roof into the grid. Many experts consider power-to- Without forgoing Intelligent electricity and steam gas to be another promising option for long-term electricity storage. things, it will not be Energy production is only one side of The power-to-gas concept involves possible in the long the coin; storage methods are crucial converting excess energy into too. Solar and wind energy output , which is then fed into term to achieve fluctuates, but electricity is used on the natural gas network. any political targets a continuous basis. Shortfalls in production or peaks in electricity Cost effectiveness relating to the consumption must therefore be Energy storage continues to face reduction of energy evened out using efficient storage a number of challenges. “All the new technology. This is the only way in storage solutions under discussion consumption. which goals such as those agreed are still a long way from crossing the to in Germany can be achieved; with threshold of cost effectiveness – plus, its reform package adopted in 2011, efficiency is still too low and the the country has set itself big targets conversion losses too high,” says A question to bring about a shift in its energy former head of the German Federal supply. It is aiming, by 2020, to Network Agency Matthias Kurth, of motivation produce more than 35% of the who is now a lecturer in energy electricity in its grid from renewable issues at the University of Bonn. Dr. Florian G. Kaiser, professor does not help just to live closer energy sources, but for that it needs “Things might improve in the coming of social psychology at the to nature. You also have to use the right storage facilities. Professor years, of course, but even then hardly University of Magdeburg, it for your personal recreation. Dr. Ulrich Wagner, Head of Energy anybody will get involved in major Germany, on social pressure to In Sweden and Norway, this use and Transport at the German projects unless funding is available save energy and the impact of of nature is truly impressive. A Aerospace Center in Cologne, once more.” one’s own experience of nature. relatively high proportion of leisure expects the need for such storage So when will the vision of U.S. time is spent on activities in a facilities to become increasingly economist Jeremy Rifkin become Creating Chemistry: Switching natural environment. There are also apparent in future and grow reality? The influential thinker whose off lights, pulling out plugs, indications from several research constantly over time. He stresses ideas have inspired energy reform avoiding waste – we know how groups that those who use nature that “we must therefore come up is not only demanding a complete to save resources. Why then for their active recreation tend with something new as far as storage shift to renewable energy but the do we often fail to do it? to be more motivated to behave technology is concerned.” dismantling of hierarchies between Professor Dr. Florian G. Kaiser: in a resource-efficient and Yet storing energy in the form producers and consumers as well: Because we are occupied with environmentally friendly manner. of electricity is not easy. Storage “This Third Industrial Revolution other things. The goal of saving requires conversion, which always will be driven by millions of people electricity and resources is not How can a person with only leads to some energy loss. worldwide who produce electricity in a primary concern like eating, limited environmental Pumped storage achieves a high their own homes and share surpluses drinking, and sleeping; it is, at awareness be encouraged efficiency. It enables energy to be via an intelligent network.” Rifkin is best, a secondary, learned one. to save energy? stored by pumping water into a vessel now 67. He still hopes to see his Not to mention that saving energy To get somebody to save energy, situated at a height. To produce vision come to fruition. ultimately means each of us will it is of course possible to raise electricity, the water is released to have to give up some personal the price of energy or apply social flow down to a lower vessel and thus benefits. The easiest way out for pressure to save energy. If, for drive a turbine. However, this system some is currently to buy an example, penalties are imposed can only be used in geographically energy-efficient fridge, an for throwing away paper in a public suitable locations, and many sites energy-efficient car, or a house space, then less paper will be have already been in service for a that uses minimal energy. We thrown away. Energy savings could long time. There is therefore very should begin broaching the subject also be achieved by each of us little expansion potential in Germany of doing without in the debate being a little more motivated to and the rest of Europe. about what form energy should consume a bit less. Looking at the Besides pumped storage power take, the shift to alternative energy unchanged figures for per capita stations, experts have identified sources, and energy consumption. energy consumption in Germany particular potential in electrochemical Without forgoing things, it will over the last 20 years, one storage devices in the form of not be possible in the long term unfortunately has to wonder batteries. These are able to store to achieve any political targets whether personal motivation or electricity temporarily and make relating to the reduction attitudes toward doing without are it available to the grid quickly and of energy consumption. changing at all. This means that very efficiently when needed. Private political energy-saving targets – households using might Why do some pay attention irrespective of where they are – soon be able to use such battery to resource-efficient behavior must convince people to reduce systems themselves. This would and others do not? consumption through personal allow self-generated electricity to There has barely been any conviction rather than only be used directly in one’s own home empirical research on this subject focusing on the question of which more often than is currently the yet. One thing we know is that it are the most efficient technologies.

Creating Chemistry | 13 Cover story: The graphic

Nightclubs When miniature dynamos are fitted to nightclub dance floors, Energy the energy generated by dance movement can be converted to power the club’s lighting. Each reveler can generate up harvesting to 20 watts per hour in this way.

Energy harvesting taps ambient energy Roads by generating electricity from movement, Sensors allow roads to act as mini power plants. When fitted pressure and air streams. Developers from into the surfacing, they convert vibrations from cars into electricity for road signals and street lighting. The technology all around the world are working on is known as piezoelectricity. innovative pilot projects: In Israel, for instance, streets are producing electricity, while in the french city Toulouse as well as Sidewalks and subway steps in sidewalks are harvesting energy and Energy plates featuring piezoelectric (see above) fibers in subway stairways are generating in sidewalks and steps convert the pressure from pedestrians’ power. The yield from each individual initiative footsteps and movement into power. may indeed be small, but the overall potential of the technology is anything but – American market research firms estimate the global market will be worth $4.4 billion (€3.4 billion) by 2021, and even more in the years beyond.

Clothing Energy harvesting means cell phones can be powered via a T-shirt – special films placed under the fabric transform sound waves into electricity. The louder the ambient noise gets, the faster the battery recharges.

Shoes Scientists have developed a micro-generator made up of metal droplets, which convert energy from walking and jogging into electricity. When the foot touches the ground, the pressure moves the droplets, generating electricity that can be used for mobile devices.

Bags and backpacks With the help of a dynamo-like energy converter attached to a bag or backpack, every step taken by the wearer is This intersection in Tokyo’s Ginza district illustrates numerous transformed into electricity. One minute of walking is enough possibilities for energy harvesting. to power a smartphone for the same amount of time.

14 | Creating Chemistry Electric airplanes Exhaust pipes With the push of a button, the propeller transforms into an The waste heat produced by cars is also suitable for energy electric generator for the on-board battery either during the harvesting. Electric generators can produce up to 1 kilowatt plane’s descent or a sharp ascent. This would enable the hour of power in this way – almost enough to replace the plane to fly for the entire day. alternator completely, and cut fuel requirements by 5%.

Shock absorbers The vibrations from shock absorbers on buses or trucks can be harvested by power generators. Up to 400 watts per hour can be produced in this way.

Brakes In hybrid vehicles, the brakes are connected to a power generator. Simply bringing the vehicle to a halt at traffic lights is enough to power the car electrically for several hundred meters.

Cars and buses Tires The air streams generated by vehicles can be captured by Special generators are able to produce electricity using small wind turbines and converted into electricity to power the rotations of tires; this powers the sensors that measure illuminated information panels or weather stations on the side tire pressure. of the road.

Creating Chemistry | 15 Cover story: The expert The diplomat for sustainability

Situated in the desert of Abu Dhabi in the United Arab Emirates (UAE), Masdar City aspires to be one of the most sustainable cities in the world. As it takes shape, Dr. Nawal Al-Hosany, Director of Sustainability at Masdar, explains this ambitious energy-saving project, and how it could serve as a role model all over the globe.

Dr. Nawal Al-Hosany Creating Chemistry: Masdar City Is construction inside Masdar is growing fast. Your goal is to City progressing well? As the Director of Sustainability become a nearly zero-emissions Yes, it is. The first completed at Masdar, Dr. Nawal Al-Hosany city over the coming decades. neighborhood comprises the Masdar oversees the company’s corporate Can you give us a short update Institute and retail outlets including a sustainability programs. One of the on how successful your efforts bank, a grocery store and restaurants. company’s projects, Masdar City, have been so far? The City also has a number of is a new development being built Dr. Nawal Al-Hosany: Masdar City, ongoing pilot projects. Some of the in Abu Dhabi, United Arab Emirates an integrated unit of Masdar, is being projects, for instance, encourage (UAE). Al-Hosany leads a team built as the world’s most sustainable sustainable transportation and test responsible for developing urban development. Several the efficiency of electric vehicles, sustainability standards and measures are being taken to ensure including the driverless electrical policies in the area, which is that it remains a low-carbon, personal rapid transport system. intended to provide housing and low-waste city that can serve as a business opportunities for 40,000 commercially viable role model for Can you tell us more about residents and 50,000 commuters, cities across the world. Masdar takes the energy requirements of and generate minimal waste and a multifaceted approach to the entire Masdar City?

CO2 emissions. Al-Hosany grew value chain of renewable energy and The entire demand of Masdar City up in the UAE, where she also sustainability. Besides implementing is met by power generated through completed her engineering degree. energy efficiency measures, such as the 10-megawatt photovoltaic solar She obtained her doctorate from the use of recycled concrete in the power plant – the Middle East’s the University of Newcastle upon construction of Masdar City, we are largest grid-connected solar power Tyne, United Kingdom, and developing smart grids on several plant – and the rooftop photovoltaic attended Harvard Business School levels in partnership with global panels inside the city. Any excess in Cambridge, Massachusetts. cleantech leaders. power is fed back into the Abu Dhabi Before her role at Masdar, she was national grid. Masdar, the company the deputy director for planning at Do such systems offer an that initiated the Masdar City project, the Abu Dhabi Police Force – the opportunity for energy and has also developed other large-scale first women to hold this position – cost savings? commercial renewable energy and in 2008, received the Emirates They do in an enormous way, projects, both domestically Business Woman Award. Al-Hosany through an integrated grid that and internationally. In Abu Dhabi, tackles challenges in her private life tracks and influences energy the company is developing the as readily as she does in her work: consumption all the way from the 100-megawatt Shams One plant, Along with a friend, she was the utility down to the consumer level. one of the world’s largest first woman from the UAE to climb Smart appliances, meters, sensors, concentrated solar power (CSP) Mount Kilimanjaro. dashboards, building management plants, which is set for completion systems and distribution management by the end of 2012. When in systems are all part of the integrated operation, the plant will help save network. For example, Siemens’ approximately 175,000 metric tons of

Middle East headquarters, currently CO2 every year, equivalent to planting under construction in Masdar City, 1.5 million trees or taking 15,000 will meet the highest architectural cars off city roads. Internationally, and energy efficiency requirements – Masdar has developed the first potentially resulting in a 45% commercial-scale 19.9-megawatt reduction in energy consumption CSP plant in Southern , compared with the internationally Gemasolar, the world’s first solar acknowledged ASHRAE (American power plant capable of 24-hour Society of Heating, Refrigerating electricity generation. Masdar is now and Air Conditioning Engineers) developing the twin 50-megawatt standard and a 50% reduction CSP plants Valle 1 and 2 in in water consumption. partnership with the Spanish >>

16 | Creating Chemistry

Masdar City can serve as a commercially viable role model for cities across the world. Dr. Nawal Al-Hosany, Director of Sustainability at Masdar City

Creating Chemistry | 17 Cover story: The expert 20% Masdar City’s goal is to use just one-fifth of energy consumed by a similar sized city. 54% The reduction in water use in Masdar City compared to Abu Dhabi. 0 The number of cars with combustion engines that will be allowed in Masdar City. 2025 The year when Masdar City is due to be completed and ready to provide space for its 40,000 inhabitants. development and technology group how abundant they are. Let us take interest in Masdar City’s progress Above The cityscape of SENER. Besides solar power Masdar City: We have capitalized has steadily increased over the years. Masdar City is greatly influenced by traditional Arabic . projects, Masdar is also developing on the plentiful solar energy And we have already achieved many Thanks to the refined architecture one of the world’s largest planned available in Abu Dhabi by building milestones: Construction continues of the city, the buildings provide offshore wind farms, London Array, a 10-megawatt solar power plant inside Masdar City with the expansion shade for each other. This enables in a partnership with DONG Energy and rooftop photovoltaic panels. We of the Masdar Institute campus streets and houses to remain cool without the use of air conditioning. and E.ON. It is also spearheading also pursue an urban development expected to reach completion by several renewable energy projects approach with as little wastage and year-end. Extension of the campus Below left The Masdar Institute in developing countries such as CO2 emissions as possible. The will more than double the university’s of Science and Technology is Seychelles, Tonga and Afghanistan. cleantech cluster embodies Abu area and include additional focusing on renewable energy research and sustainable Dhabi’s commitment to a sustainable laboratories, dormitories and retail technologies. The number of Solar energy is only one side future by pioneering the best outlets. Masdar’s first commercial students is expected to grow to of the story. How about other practices in sustainable urban building is also due for completion 600 over the next five years. alternative energy concepts planning, design and construction, by the end of 2012 and is expected in Masdar City? as well as educating residents about to house more than 50 companies. Masdar does not only develop efficient energy usage. Siemens’ Middle East headquarters renewable energy projects; it is a is scheduled for completion in 2013. interpretation of one of the region’s commercially-driven enterprise that How much energy does Masdar Construction will begin soon on the most iconic traditional architectural operates across the full spectrum of City consume compared to Masdar headquarters building and features, the Al Barjeel. This was the renewable energy and sustainable other cities? the International Renewable Energy prominent in many Gulf Cooperation technology industry. As you know, Compared to the 2011 average Agency (IRENA) headquarters. When Council (GCC) homes. Cities that the most sustainable option depends figures in Abu Dhabi, Masdar City it is fully built by 2025, the city is inspired Masdar City’s master plan on each country’s resources and has managed to cut water expected to have 40,000 residents include Shibam in Yemen, Aleppo in consumption by 54%, electricity and welcome 50,000 commuters. Syria and Marrakesh in Morocco, as consumption by approximately 70% well as traditional districts within Abu and cooling requirements by 50%. What places around the world Dhabi and other cities in the UAE Waste is sorted and recycled, and do you consider to be the and Gulf region. organic waste will be used for most inspiring with regard to . Masdar City also has a sustainability and carbon-neutral Generally speaking, what can geothermal test site – a pilot project living? Can you tell us how they cities do to drive climate that involves exploratory drilling deep influence you at Masdar? protection? underground to test the availability First of all, every country has its own We can all agree that of sufficiently hot geothermal water environmental context, but we learn is a threat that the global community to be used in thermal cooling. from many experiences around the shares. Rising temperatures and world, especially in regions that offer sea levels will have a major impact Early on, there was a lot of similar climatic conditions. The on our region and it is in our interest attention focused on Masdar design elements used in Masdar to find solutions. Our country is City, but this has since died were inspired by traditional Arabic already gaining global visibility as down. Is construction still architecture. For example, the wind a sustainability champion with an on schedule? tower inside Masdar Institute’s active role in international climate First of all, I do not feel that it has campus – which captures wind with negotiations such as Rio+20. Inside become quieter around Masdar City: its flexible flaps, directs it downwards Masdar City, we continue to improve Whether locally or abroad, the and uses it for cooling – is a modern energy efficiency standards in our

18 | Creating Chemistry Masdar City – Cleantech cluster on the Persian Gulf buildings, invest in sustainable will promote and adopt research, The United Arab Emirates transportation concepts: public transport and support public development and technological (UAE) has ambitious Cars with combustion awareness campaigns to inform our innovation. The new headquarters of aims when it comes to engines have to be parked society about how we can reduce the International Renewable Energy developing technologies at the edge of town. In their emissions. And yes, there is no doubt Agency will be based in this thriving for renewable energy place, electric vehicles ply that people can have a higher impact environment, underscoring Masdar’s and climate protection: the city’s streets and there on saving energy when they have aim to become a global cooperative Located 17 kilometers are a well-developed public intrinsic motivation. platform in the search for solutions to from the capital Abu Dhabi, transport system and the pressing issues of , Masdar City will be a shady sidewalks. How important is it for you climate change and the development showcase for sustainable The city was designed to exchange information with of human expertise in sustainability. urban development. by the team of legendary experts from all over the world? The buildings completed British architect Sir Norman Working in Masdar City – a test bed for Saving energy is a very important so far are already using Foster and also incorporates research, development and creation goal. How can we successfully 100% renewable energy. traditional Arabic urban of scalable innovations in renewable rise to this challenge? construction techniques. energy and clean technologies for In theory, development that is Masdar is the Arabic word The buildings are laid out in – means that sustainable and not damaging to the for “source” or “origin”. The such a way that they provide information exchange and knowledge planet is achievable. In reality, there pioneering project Masdar shade for the public roads sharing is part of our daily routine. are challenges at every step, and so City is in fact a large-scale and other buildings. This On a personal level, I was appointed far, global efforts of moving towards experiment: It embodies the reduces the average Sherpa (chief negotiator) to the U.N. sustainability in a collective manner, vision of a city that is nearly temperature in Masdar City Secretary General in the ‘The with a common framework, appear carbon neutral and barely by up to 20C (68F) compared Sustainable Energy for All’ initiative to have been quite feeble. Around produces any waste. Masdar to outside the city. The to support the appointed principal, the world, a large part of the City also serves as a think coolness of the lower layers Dr. Sultan Ahmed Al Jaber, the population still lives without access tank, where new solutions of earth is used for air- Chief Executive Officer of Masdar. to basic necessities. In the most for climate protection and conditioning in the buildings. I also serve on the boards of fragile environmental conditions, renewable energy can be Masdar City not only several regional and international the population typically has limited developed. The project was integrates environmentally initiatives and organizations: I’m financial means and the least initiated in 2006 by Masdar, friendly technologies, it also a Co-Chairperson of Women for adequate resources to address a company from the United wants to promote their Sustainable Growth and I was part these challenges. Integrating these Arab Emirates which takes development. For example, of the Sustainable Development societies into the economic and a multifaceted approach to it is home to Masdar Institute Dialogue panel in Rio. I am now development programs can speed research, development and of Science and Technology, looking forward to our annual flagship up the pace of sustainable commercialization of a university with a focus on events, the World Future and contribute to technologies in the renewable renewable energy research. Summit (WFES) and the Zayed Future improving their quality of life because energy and cleantech sector. The International Renewable Energy Prize awards ceremony, it builds an entrepreneurial platform Masdar is a subsidiary of Energy Agency (IRENA) is which will be held during the Abu that has tremendous positive impact the state-owned joint stock also going to set up its Dhabi Sustainability Week in January and yields long-term benefits for company Mubadala and headquarters in Masdar City. 2013. These are all platforms for the communities engaged. explores new economic and In order to live up to its knowledge exchange that energy diversification plans pioneering role, Masdar directly add to my experience Does sustainability also play for Abu Dhabi. has partnered with leading and understanding of industry’s an important role in your The developers of Masdar names, including BASF. best practice. private life? City are employing best- The strategic partnership On a personal level, I’m currently practice benchmarks, between BASF and Masdar Do you also aim to establish building my own home in a sustainable building materials began in 2009 and has platforms for knowledge sustainable way which will reduce and energy-efficient resulted in BASF being exchange in Masdar City itself? its impact on the environment and technologies. As a result, named a “preferred supplier.” On a wider scale, Masdar City and ultimately lower carbon emissions. the city’s energy consumption As a leading supplier of raw Masdar Institute of Science and I’m hoping it will serve as a case was 55% lower and water materials, formulations and Technology are attracting leading study for all Abu Dhabi community consumption was reduced systems for the construction academics, researchers and members to identify ways in which by 54% compared to the 2011 industry, BASF has provided businesses eager to situate they can implement sustainability average figures in Abu Dhabi. a range of products for the themselves in an environment that measures in their own homes. The energy used in the first building phase in Masdar buildings completed thus City, including the Masdar far comes entirely from Institute of Science and renewable sources. It is Technology. Some of the generated by a 10 megawatt products used in its solar power plant and construction were grouts 1 megawatt of rooftop and mortars, joint sealants, photovoltaic panels. Masdar coatings, tile adhesives I’m hoping my house will serve as a case City is also implementing and concrete additives. study for all Abu Dhabi community members environmentally friendly to identify ways in which they can implement sustainability measures in their own homes. Dr. Nawal Al-Hosany, Director of Sustainability at Masdar City To find out more, visit: www.masdar.ae

Creating Chemistry | 19 Cover story: The reality The BASF Verbund

Dr. Bernhard Nick is responsible for BASF’s Creating Chemistry: According 280 million metric tons of CO2 European Verbund sites in Antwerp, , to the International Energy emissions are avoided. This is more and Ludwigshafen, Germany, which employ Agency (IEA), industry accounts than a quarter of Germany’s annual for slightly more than half of CO2 emissions. A big contribution around 37,000 people. In a conversation with global energy consumption. towards this achievement came from Creating Chemistry, Nick explains how the BASF The chemical industry in the use of BASF’s concrete additives Verbund saves resources while also achieving particular requires a lot of and insulating materials in renovating profitable growth. energy and steam for its old buildings and in the construction production processes. How of new ones. Of course, emissions do can BASF credibly advocate occur during production, but we are energy efficiency? constantly working on keeping them Dr. Bernhard Nick: Chemistry is as low as possible. This is why we vital to ensuring that the needs of have set ourselves ambitious energy a growing world population continue and climate protection goals: By to be met in the future. BASF’s 2020, we want to reduce greenhouse products help to save resources and gas emissions by 40% per metric ton protect the climate and environment. of sales product compared with 2002 Above The photo shows some of the facilities Let us look, for example, at the levels, and we want to increase our in the northern part of BASF’s largest Verbund site housing and construction sector; by energy efficiency in production in Ludwigshafen/Germany. From here, the Verbund has expanded worldwide. BASF currently operates using the products that BASF sold processes by 35%. Our Verbund six Verbund sites. worldwide in 2011, more than is crucial to achieving this.

20 | Creating Chemistry How does the Verbund work? Who benefits most from The Verbund is based on the idea this system? 280 million of maximum resource efficiency. The Verbund helps BASF The avoidance in the number of metric tons

We aim to produce as much as achieve profitable and sustainable of CO2 emissions achieved in the housing possible with as few resources as growth. It enables more than and construction sector through the use of possible, and in doing so keep our €200 million to be saved in energy products which BASF sold worldwide in 2011. emissions to a minimum. To this end, costs each year in Ludwigshafen. we link up plants, energy flows, At the same time, the environment logistics and infrastructure. We are benefits: In 2011, BASF’s energy 35% therefore not focusing solely on consumption was lower by 2.6 million The targeted increase in energy efficiency individual processes, but on the metric tons of crude oil equivalent in BASF’s production processes by 2020. interplay between all plants and the thanks to the Verbund system and infrastructure at any given site. BASF the use of combined heat and currently operates six Verbund sites: power technology. This corresponds €200 million in Germany, Belgium, China, to a reduced environmental load The reduction in energy costs achieved through

Malaysia, and two in the United of 6.2 million metric tons of CO2 the BASF Verbund in Ludwigshafen alone. States. The Verbund system is also emissions. This is where ecology influencing thinking at all of our other and economy go hand in hand. sites. It already extends well beyond production. For example, we are Could other companies linking up the knowledge of our or towns also copy BASF’s employees and our broad technology Energy Verbund? base worldwide in order to provide There is good reason why our our customers with innovations in Verbund sites are constantly being all relevant sectors. The methods compared with small towns. If you of the Verbund system permeate examine the sites in detail, there are throughout BASF’s entire business. many similarities (see diagram on pages 22 and 23). In my opinion, How, for instance, are you the recovery of energy from waste increasing energy efficiency heat and residues, and the supply in production? of energy using combined heat and To begin with, we are focusing on power plants – which meet over capturing and reusing energy and 70% of BASF’s electricity needs Dr. Bernhard Nick resources released at our Verbund worldwide – serve as good role sites. When surplus heat is generated models. We are also transferring many Dr. Bernhard Nick has been in one factory, it is used for of our transport needs from road head of BASF’s Verbund Site production in another plant rather to rail based on innovative logistics Management Europe since January than being wasted. Additional energy concepts. Other companies or towns 2008 and is responsible for the is being produced at Verbund sites could use these solutions to save large BASF production sites in by our own combined heat and resources and reduce emissions too. Europe. The career of this power plants using gas and steam chemistry doctorate holder and turbine technology. They produce Finally, we want to uncover businessman has included setting steam and electricity at the same a secret: Who actually founded up the BASF Verbund site at time and, with a fuel-efficiency rating the Verbund? Kuantan/Malaysia, and working as of up to 90%, are highly efficient. The Verbund has been part of head of the Financial Evaluation and Natural gas – the greenest fossil BASF from the outset. BASF Strategic Planning units. fuel – is used as a raw material. At founder, Friedrich Engelhorn, owned large sites such as Ludwigshafen, a coal-gas factory in Mannheim in water supply systems have also been the 1860s. It produced an annoying optimized in such a way that drinking waste product: tar. Nobody in the To find out more, visit: water is only used for washing and factory could use it until Engelhorn www.basf.com/verbund_e drinking. Toilets are flushed using came up with the idea of using it the river water supply. to manufacture tar dyes and selling them at a profit. Together with others, he founded a chemical company called Badische Anilin- und Sodafabrik, or BASF for short. Efficient handling of resources is therefore in our DNA.

The Verbund is based on the idea of maximum resource efficiency. We aim to produce as much as possible with as few resources as possible, and in doing so keep our emissions to a minimum. To this end, we link up plants, energy flows, logistics and infrastructure. Dr. Bernhard Nick, President Verbund Site Management Europe, BASF

Creating Chemistry | 21 Cover story: The reality The Energy Verbund Special power plants are used to supply the Verbund sites with energy. These offer combined heat and CO2 emissions power generation, meaning that they produce both electricity and steam at the same time. The raw

material used is natural gas; its low CO2 emissions make it the most environmentally friendly .

Natural gas Incineration Power plant system

Steam

Naphtha (a component Production line of crude oil) Steam cracker Ethylbenzene Styrene

Water conservation in the Verbund If any heat generated in production processes cannot be used any further – because the temperature is too low to be useful, for example – it is drawn out, usually with cooling water. If the site is situated Aromatics by a river, the required water is taken from plant there and diverted through the plant. Afterwards, the heated water is sometimes cooled in cooling towers so that it can be used again. When the water is no longer needed, it is carefully screened for any Wastewater harmful substances, and is either Office building returned to the river, or is cleaned in Heated water the water treatment plant. At large Verbund sites, the water supply systems are so sophisticated that potable water is used solely for washing, showering and drinking, while toilets are flushed with river water to conserve resources. The water treatment plant keeps the environment clean by processing the wastewater.

Water 50% treatment By 2020, BASF aims to use half the amount of drinking water in production processes than Cooling water it did in 2010.

For simplification, our graphic shows only a section of a Verbund site. In total, BASF Verbund sites can contain up to 200 production plants. River water

22 | Creating Chemistry As electricity and steam are produced together, the rate of gas utilization can be as high as 90%. Another way 2.6 million in which CO2 emissions are kept as low as possible is BASF’s use of the Verbund system Understanding that whenever a plant generates excess heat during and combined heat and power production, it is not lost. A steam network diverts the generation saved the equivalent heat to another plant, where it is used in production. of 2.6 million metric tons of crude oil in 2011. the Verbund

At BASF’s six large Verbund sites countless pipes connect the various plants and buildings. Each complex Residues network follows a clear principle of using energy and raw materials as efficiently as possible. A closer look reveals a series of intelligent systems that help save energy.

Styrodur® (insulating Polystyrene board) Application

The Production Verbund Insulating material is produced using naphtha, a component of crude oil. In the steam cracker, which is at the heart of BASF’s production, naphtha is split into basic chemical building blocks. Pipes direct the raw materials from here to the various production plants around the site. To produce the insulating material Styrodur®, for example, two naphtha elements are required: ethylene and pyrolysis gasoline. The latter is broken down into its components by the aromatics plant in a process which produces benzene, among other things. The benzene is then gradually processed with the ethylene, first to form ethylbenzene, then styrene, and finally polystyrene, which is used for insulation boards in construction. This process chain involves more than just the flow of materials, though; it also incorporates the flow of energy. The energy released when incinerating the residue of polystyrene production is converted into steam for use in other plants. As such, less energy needs to be brought in from outside. Purification plant 216 million The application of the insulating material sold by

BASF worldwide in 2011 could reduce CO2 emissions by 216 million metric tons.

Creating Chemistry | 23 Cover story: The science Winds of change Often seen as a modern technology, electricity has actually been generated from wind power for 125 years.

Among the various alternative energy sources, wind power 1887 is seen by many as the most Professor James Blyth promising route to a cleaner designed the first known future. Prices for electricity electricity generating wind turbine. generated by wind energy are dropping, while the number of wind farms is growing rapidly. Today, the global wind power 1900 market is worth billions, yet The first wind turbine few people realize that the incorporating aerodynamics was designed by Poul la Cour. technology was first introduced 125 years ago.

The drive to convert wind into energy At the same time, he developed 1991 was initially private in nature: Scottish a process for storing excess energy The world’s first commercial engineer Professor James Blyth in lead batteries. offshore wind park began operating in Lolland, a Danish wanted to have electricity at his Then, in 1900, Danish scientist island located in the Baltic Sea. remote holiday home. In the summer Poul la Cour made a decisive of 1887, he built a simple wind turbine breakthrough. He carried out the very with fabric sails, which produced first wind tunnel tests, and established 2020 enough power for ten light bulbs. the aerodynamic principles for the Wind energy is expected Before his invention, windmills were ideal rotor blade. He proved that to provide more than 9% used almost exclusively to grind grain rotors with a lower number of blades of global power supply. The or pump water. actually produced more electricity. current figure is around 2.3%. Shortly after Blyth’s innovation, With this knowledge, he was able U.S. inventor Charles F. Brush to develop fast-moving wind turbines Source: BTM Consult, followed with an automatic capable of supplying small villages International Wind Energy wind turbine. with direct-current power. Development.

Growing Giants Turbines are getting increasingly larger in order to improve their energy output

25,000

Approximate 20,000 length of a soccer field

15,000 Above In 1887, Scotsman Professor James Blyth built the first ever wind turbine for power generation. Eight years later came a second, improved 10,000 design, which provided Energy output (kW) emergency power for 30 years to the psychiatric clinic in Montrose/Scotland. 5,000 Above right American Charles F. Brush looked to windmill technology in 1888 when constructing his 65-foot high turbine. 0 Year of production 1980 1985 1990 1995 2000 2005 2012 2020 Energy output 50 kW 100 kW 500 kW 600 kW 2,000 kW 5,000 kW 10,000 kW 20,000 kW Average rotor diameter 15 m 20 m 40 m 50 m 112 m 126 m 150 m 252 m (in meters)

24 | Creating Chemistry BASF contributes to making wind power profitable The forces exerted on modern wind turbines are immense. Winds can howl at speeds of up to 300 kilometers (186 miles) per hour, which causes the blades to bend by more than a meter (about 3 feet). In addition, the systems must be able to withstand weathering caused by prolonged exposure to UV rays, rain and the salty climate of the sea. Chemical solutions help ensure these giants can endure such challenging conditions for at least 20 years. This makes the turbines far more profitable: The longer they can operate, and the fewer maintenance shutdowns they require, the more electricity they can produce. In addition, BASF enables the turbines to be manufactured and installed in a cost-efficient way. Chemical innovations play an important role in many turbine components, including the foundations, towers, gears and rotor blades. Special BASF grouts secure the towers to the foundations for long-term operation and are quick to use, cost-efficient and utterly dependable under harsh weather conditions. Concrete additives help to make sure that both towers and foundations are efficiently manufactured to be long-lasting, while lubricants from BASF keep turbine gears running smoothly. Rotor blades benefit in three ways from chemical solutions: Firstly, today many blades are manufactured with special But soon progress began to slow 30 and 80 kilowatts. Combined with Above Spanning an fiber-reinforced epoxy resin systems significantly as increasing numbers progressive legislation regarding area of 110,000 m2, the from BASF, which ensure that the American Wind Power of central coal power stations pushed power input, this created a highly resilient components can Center in Lubbock, Texas, wind turbines out of the picture. profitable market. is a museum of gigantic be produced up to 30% faster This situation was exacerbated in the From its humble beginnings, proportions. Visitors can and thus more cost-effectively. 1950s with the introduction of nuclear wind energy has become a global marvel at one of the largest Secondly, BASF’s PET collections of American power and the excitement that industry with major markets in China, (polyethylene terephthalate) foam wind turbines. Some of surrounded the discovery. However, the United States and Germany. the machines date back will increasingly be used inside the oil crisis and increased skepticism Two trends are shaping the sector: to the early 1920s. blades longer than 60 meters about nuclear technology prompted Turbines are increasing in size in (197 feet) to help stabilize them. a wind renaissance that has order to improve output and wind Finally, multi-layered BASF coating continued to this day. Once more, power is gradually moving out to systems protect the outside of the key driver was Denmark – the sea. The first systems with a blades against weathering and Danish government at the time maximum output of 5 or 6 megawatts wear and tear. encouraged investors to build are already on the market, while BASF aims to offer wind turbine efficient wind farms. This policy rotor diameters of over 110 meters manufacturers innovative, tailored powered the development of today’s (360 feet) are nothing short of solutions by leveraging its multi- well-known three-blade turbines. gigantic. There is constant disciplinary expertise. BASF works In the 1980s, Danish rotors with a progress in terms of size, yield, and with its customers to continually diameter of approximately 20 meters innovation – ideas are already under develop its product range. (65 feet), produced energy yields development to harness the power of between 35 and 95 megawatt wind above the clouds. In the future, To find out more, visit: hours per year for the first time, kites, light aircraft and balloons might www.windenergy.basf.com with a nominal output of between be used for energy generation.

Creating Chemistry | 25 Innovation New discoveries Inventiveness is in demand: Innovations make our everyday lives easier in a host of ways, and help improve sustainability. In this section, we present a selection of inspiring examples.

Liters of light The idea is simple, the impact immense: Illac Diaz, a former actor from the Philippines, is bringing light to the slums of his home country’s capital Manila just by using humble discarded plastic bottles. An old bottle is filled with water and a small quantity of bleach is added to sterilize the liquid and keep it clear. The bottle is then vertically wedged into a hole cut in the corrugated iron of a hut roof, secured to stop it from falling down and Sustainability sealed with a bit of rubber. The makeshift bulb is ready. When the sun outside shines on the bottle, the water measurement inside it refracts the light and illuminates the A successfully managed process must be interior of the hut without the use of electricity. measurable and comprehensible. With this in mind, BASF developed a method for www.isanglitrongliwanag.org holistically assessing sustainability in agriculture called AgBalance™. It evaluates 69 indicators from the three dimensions – environment, society and economy. AgBalance considers, for example, the nutrient balance of soil, the biodiversity of species inhabiting farmland, plus residues in food and feed as well as fixed and variable costs. The method has received independent assurance by the global expert agencies NSF International, DNV Business Assurance and TÜV SÜD. Recently, AgBalance was ranked first in the 2012 ideas competition of the German Council for Sustainable Development. www.agbalance.agro.basf.com

Decoration Intelligent from nature temperature Cornstarch, potato and tapioca are everyday ingredients for chefs in different countries, but Lili control Giacobino does something different: She transforms Thermostats were not noted for their design these ingredients into bioplastic. With this very or learning capacity until the former head pliable material she is able to create colorful of development for Apple’s iPod and iPhone necklaces, earrings and bracelets. The designer got involved. That involvement led to Nest, the Digital plant care developed her special formula following months intelligent thermostat with a sleek and stylish There are people who talk to their plants. Now, plants are able to talk to their of experimentation in her own kitchen; the results appearance that is similar to Apple designs. owners. This is thanks to Koubachi, a spin-off from the Swiss Federal Institute are beautiful creations produced from natural The thermostat is a mini computer for the of Technology Zurich (ETH) that gives plants their own ‘voice’. The company ingredients. Giacobino does not ignore other home which recognizes the occupants’ habits has developed a sensor that alerts plant lovers when it is time to water again. everyday items; she even integrates materials such after a short learning phase. It is then able It measures humidity, temperature and exposure to light. This data is then as yogurt containers and tin cans into her collections, to control room temperature independently transmitted via Wi-Fi directly to Koubachi’s own system for assessment. pursuing her own distinctive form of , to ensure that the heating and cooling of the The application analyzes all the collected data and, based on the type of plant, finding a new valuable use for used items. home is as energy efficient as possible. determines whether watering is necessary. If action is required, the user is immediately informed via smartphone or computer. www.creativelili.com www.nest.com www.koubachi.com

Above Earrings made 26 | Creating Chemistry of biodegradable plastics. Efficient solar tree New Yorker Aidan Dwyer is just 14 years old, but has already created a stir in the solar industry. While walking in the woods, Dwyer wondered how trees manage to capture sunlight so efficiently. The young researcher worked out the exact spacing of tree branches using the famous Fibonacci sequence first published in the 13th century, and then incorporated these calculations into his solar module design. His invention looks like a tree trunk with solar panels facing in all directions on the branches. This allows sunlight to be more efficiently collected and transformed into energy. Although scientists have since noticed that Dwyer made some mistakes when calculating the yield, his solar tree still achieves better results than traditional roof-mounted solar panels. His idea of following nature’s example has now made it all the way to Abu Dhabi, where the teen inventor opened the World Future Energy Summit 2012.

www.amnh.org/yna

Above Young researcher Aiden Dwyer discovered that when solar panels are arranged like the leaves of a tree, they collect more light.

Left Dwyer’s invention takes inspiration from nature to produce solar energy more effectively.

Biotech oral care Now there is an easy way to wash out the pathogens that cause dental cavities: pro-t-action®, developed by BASF in cooperation with Organobalance, makes daily toothbrushing more effective with the help of micro- organisms. The patented, all-natural and safe bacteria in pro-t-action sticks to the troublesome bacteria Streptococcus mutans that cause cavities, and forms clumps that are more easily rinsed away from the mouth. Illuminating The first brand of toothpaste containing pro-t-action power usage is now available on the Eastern European market. Power consumption can be made visible: The Power Aware www.pro-t-action.com Cord functions as a type of detector. This illuminated cord glows and pulses more intensely as more power flows through it. Even appliances that consume power without your knowledge are very quickly exposed with the help of this product. The Power Aware Cord’s two Scandinavian designers, from the Interactive Institute in Stockholm, want their invention to encourage consumers to save energy. www.tii.se

Creating Chemistry | 27 From two perspectives: For & Against

Non-identical twins: Even when foodstuffs look the same, there can still be fundamental differences between them. Food fortification is a method that reinforces staple foods, such as rice, with nutrients in order to fight malnutrition. From the outside, nothing appears to be different.

28 | Creating Chemistry Better nourishment for all? When we do not eat enough protein or carbohydrates, we feel hungry. It’s different with vitamins and minerals. Even though these micronutrients orchestrate vital body functions such as growth, immune response and vision, their absence is harder to detect. Food fortification is a potential solution to the problem of malnutrition, but is it the right one?

Malnutrition, or “hidden hunger”, affects the world’s major micronutrient deficiencies: the lack of iodine, poorest people, especially mothers and children vitamin A or iron. One emerging intervention under five years of age. The micronutrient most against malnutrition is food fortification, a method lacking in the world’s diets today is vitamin A, by which staple foods are enriched with vitamins which is important for healthy skin, wound healing and minerals they do not naturally contain or are and eyesight. Vitamin A deficiency (VAD) is only present in small amounts. Some fortified foods responsible for a million child deaths every year. such as iodized salt have been used for almost It can lead to blindness and makes children more a century. susceptible to other diseases such as tuberculosis Proponents of food fortification argue that it and pneumonia. In addition, each year 18 million is an economical and effective way to combat babies are born with mental impairments due malnutrition. But do fortified foods really reach to iodine deficiency. UNICEF estimates that the world’s poorest? Or are detractors right to more than 2 billion people – almost a third of argue that only promoting better dietary habits the world’s population – suffer from some kind and improved local farming can lead to long-term of micronutrient deficiency. solutions? We asked M. G. Venkatesh Mannar, In the past two decades, fundamental efforts President of the Micronutrient Initiative, and have been made to fight malnutrition. Starting at Frank Braßel, Deputy Leader for Campaigns the 1990 U.N. World Summit for Children, leaders and Lobbying at Oxfam Germany, to share from around the world agreed to combat three their views. >>

Creating Chemistry | 29 From two perspectives: For

If you want to have solid food fortification programs, they have to be self- sustaining from day one. M. G. Venkatesh Mannar, President of the Micronutrient Initiative

30 | Creating Chemistry M. G. Venkatesh Mannar Creating Chemistry: Malnutrition In what way should food What has been the international is a serious problem in more than fortification programs take nutrition community’s biggest Since 1994, M. G. Venkatesh a hundred countries. It especially different approaches in achievement so far in the fight Mannar has served as President affects the poorest people of this different countries? against malnutrition? of the Micronutrient Initiative (MI). world. Proponents of food forti- The programs have to be country- Our biggest success has been in The Canadian NGO develops, sets fication see it as a cost-effective specific. First, you have to identify the area of salt iodization. In 1990, up and controls cost-effective, and sustainable way of fighting staple foods that are widely 25% of the world population used sustainable solutions for vitamin malnutrition. What do you say? consumed on a regular basis and iodized salt. Now, it’s more than 70%. and mineral deficiencies. MI is the M. G. Venkatesh Mannar: There are then work out how to fortify them. In We’d like to see this same success longest-standing organization of its three proven ways to close deficiency the Middle East, we have advocated with a range of staple foods and kind. It was formed in 1992 as a gaps. You can change people’s diets, fortifying wheat flour, but in Southeast condiments. We’ve made similar secretariat at the International which is a long-term approach. In the Asia or China, condiments like oil, progress in vitamin A supplementation, Development Research Centre, long and medium term, you can fish or soy sauce are better vehicles. especially for young children. In 1999, a member of Canada’s foreign aid enrich food with essential nutrients. In Central America, sugar is widely only 16% of children worldwide were program, and became independent And when you want to help grown and consumed. While I don’t fully protected with two annual doses in 2000. Every year, 500 million vulnerable quickly, we advocate eating lots of sugar, it has of vitamin A; by 2010, 66% of children people benefit from MI’s work. recommend supplementation. helped to provide vitamin A in many were receiving two doses, not Mannar was born in Chennai/ countries in the region. including China. But I would say that India. He studied chemical What are the advantages of food there is still huge potential to reduce engineering at universities in India fortification programs compared What role should governments malnutrition around the world. We and the United States and managed to the other approaches? play in the fight against continue to work in the areas of an Indian salt company for 17 years. Approaches to reducing vitamin malnutrition? supplementation and fortification. He has worked for different U.N. and mineral deficiencies must be Governments play a key role. They More recently, we have been working and aid agencies since 1973. complementary. They serve different set the policies and guidelines for to scale up the use of zinc, along with In 2010, Mannar received the needs and work in different fortified foods, but also monitor these oral rehydration salts, for the Tech Award for innovators who situations. Supplementation helps policies and enforce regulations. If all treatment of diarrhea in children are finding technological solutions highly deficient people, especially this is in place, the private sector will under the age of five. This will help to benefit humanity. pregnant women and children during make sure that fortified foods are us reduce child mortality. the first two years of life. With food economically viable. fortification, you can address the What’s the biggest mistake you whole population across the board. What are the Micronutrient see when analyzing past food Food fortification is not a miracle Initiative’s goals for addressing fortification programs? cure. Changing dietary habits malnutrition within the next There have been a number of failures remains the goal of every long-term three years? in the past 20 years. What often health policy, but it is difficult to We want to continue to help the most happens is that, initially, a donor achieve. Even in industrialized vulnerable: women and children in shows interest and a program is countries, where food is abundant, the most impoverished parts of the set up only to buy fortificants or fortified foods ensure that people world. This is the case for large parts equipment. But if the donor receive important micronutrients like of Southeast Asia, Sub-Saharan Africa withdraws, the program often stalls. iodine and vitamin A. I can’t imagine and some parts of Latin America and It’s a classic mistake, and I’ve seen how you could achieve this in less the Caribbean. Micronutrient it happen in countries where a good developed countries solely by deficiencies can be addressed at low fortification program has virtually changing dietary habits. costs and very quickly. come to a halt because there was no transition plan in place for when How can you make sure that food What is the rationale behind external funding ends. We have to fortification is effective and an NGO like the Micronutrient adequately plan the programs and reaches the world’s poorest, Initiative working with the make sure they deliver long-term, who generally suffer most from private sector in the area sustainable results. micronutrient deficits? of food fortification? That’s the key question. Critics say Most multinational corporations have At the U.N. Rio+20 conference, fortified foods don’t reach the poor, huge teams of experts and don’t BASF committed to reducing the and it’s true that it’s hard to reach the need much guidance. But we can vitamin and mineral deficiencies bottom 20% – poor people in remote make a difference with small national of 60 million people with fortified areas. These people often do not eat and local producers that are often not staple foods each year. What are foods that are centrally processed in aware of all the norms and guidelines your specific demands on the mills or factories – and it’s these on fortification. In addition, we can private sector in terms of foods that can be easily fortified. A interface between companies and addressing malnutrition? year ago, I visited a rural market in governments because we are seen The private sector should work Ethiopia, and the only processed as a neutral body that doesn’t favor actively with local governments to food I found was salt. Everything else particular companies or products. understand the issues and regulations was locally produced. So you need to related to food fortification and find other vehicles for such regions. comply with them in an economically To find out more, visit: Food fortification works best when viable manner that is not dependent www.micronutrient.org addressing populations that can on external subsidies. If you want to access processed foods. have solid food fortification programs, they have to be self-sustaining from day one.

Creating Chemistry | 31 From two perspectives: Against

Creating Chemistry: Malnutrition World Bank has published a study developing countries. They must Frank Braßel is a serious problem in more than which comes to the conclusion that again shape their agricultural policies a hundred countries. It especially agriculture based on smallholdings more actively; women should play an Frank Braßel has worked for Oxfam affects the poorest people of is more effective than large-scale important role in this. Germany since 2011 and is head this world. Proponents of food plantation farming. of its “Mahlzeit!” campaign. The fortification see it as a cost- Should those facing hunger international aid organization Oxfam effective and sustainable way What do you consider to be the and malnutrition first help was founded in the United Kingdom of fighting malnutrition. What do main challenges to putting your themselves? How can you in 1942 and today has branches you say? ideas for combating malnutrition make that happen? in 17 countries. The “Mahlzeit!” Frank Braßel: We are not in principle into practice? Those affected do try to help campaign advocates a shift opposed to food fortification, but do Firstly, we should stop viewing themselves, but do not always have toward ecological and socially fair not see it as a long-term solution to agricultural land and food as purely the opportunity to do so. Oxfam is agriculture. Braßel was born in 1958 global hunger. We see the problem commercial commodities because funding hundreds of projects aimed in Herne, Germany, and studied as being one of unfair distribution. they form part of the basis of human at helping people to help themselves. German and History at the Ruhr- It is a scandal that, in an ever richer coexistence. Various instruments For example, we are making it Universität in Bochum. In 1986, world, one in seven people go to bed can be used to encourage small possible for people to exchange he co-founded the human rights hungry. Food fortification does not farmers. For example, we can provide information on farming methods – organization FIAN (FoodFirst therefore tackle the cause of the microcredit or open up local markets, because we believe that small Information and Action Network), problem but rather the consequences. as Oxfam has helped to do in Bogotá. farmers can best learn from other which advocates a right to food for We at Oxfam believe that all people These do not cost much and open small farmers. everyone. From 2005 to 2011, are able to feed themselves as long up important new sales channels for Braßel worked for the Church as they have access to land, water, small farmers. Can these approaches really Development Service (EED) at the markets and fair working conditions. ensure that people everywhere independent SIPAE agricultural What role should the private have adequate food supply? research center in Ecuador. What, in your opinion, is driving sector play in combating There is already enough food today, the private sector to get involved malnutrition? but almost a third of it ends up in food fortification programs? Large corporate groups should, rotting. Instead of creating ever more You can probably assume that a first and foremost, ensure that they food and thereby destroying nature, company does not develop products comply with national legislation we propose that the food available unless it is also able to do good and global human rights and should be better distributed business with them. With food environmental standards. This would and used. fortification programs, firms can already represent considerable hope for government support. progress. In poor countries where And you do not see food state control is weak, companies fortification playing an important What strategy do you propose should also think in a more role in combating hunger? instead to combat malnutrition? preventative way and make an effort In emergencies it may make sense, We think in terms of long-term and not to cause harm. For example, but there is also the risk of making short-term measures. In the short in recent years, 5% of the arable people dependent on charity and not term, it is necessary, for example, farmland in Africa has been taken taking their right to food seriously. to put a stop to food speculation over by foreign investors, meaning and abolish the blending rates for it cannot be used for vital local food agro-fuels. It is crazy that food is production. This is absurd. increasingly being used to fill gas tanks and not to feed hungry mouths. What should politicians do This increases prices, and causes to help? many people to be driven from their Politics has a decisive role to play. land. In the long term, we advocate Governments are best placed to act a food system focusing on small in the public interest. In this case, this farmers who are able to feed means preventing malnutrition and themselves and their communities. enforcing the right to food. For This is more secure than obtaining industrialized countries, this entails supplies via the world market, on rethinking their own failed agricultural which prices fluctuate widely. And it policy, reducing subsidies, and To find out more, visit: is also better for the environment opening up their agricultural markets. www.oxfam.org because it saves resources. Even the There is also much to do in

32 | Creating Chemistry

In emergencies, food fortification may make sense, but there is also the risk of making people dependent on charity and not taking their right to food seriously. Frank Braßel, Head of the “Mahlzeit!” campaign at Oxfam/Germany

Creating Chemistry | 33 Viewpoint BASF

The best investment in human development

“Providing micronutrients to the undernourished is the best investment in human development,” believes the Copenhagen Consensus, a group of leading economists that includes five Nobel Laureates.

We at BASF’s Nutrition & Health business ecosystem’: We partner division took up this call for action. with highly complementary It quickly became evident to us stakeholders, including the United We are driven by that the benefits of micronutrient Nations, civil society, academia, fortification are huge: Consumption development agencies and local a desire to make of fortified foods improves health, food producers in more than 30 real, sustainable which directly leads to better developing countries. The diverse educational opportunities and strengths of these partners are improvements improved productivity. At the same key for effective food fortification to people’s lives. time, it prevents costs accrued by programs. For instance, our partners Walter Dissinger, treating illnesses that are caused advise governments on national President Nutrition & Health at BASF or aggravated by micronutrient policies, regulation, and quality deficiencies. The benefits are even control for micronutrient fortification, more evident when one considers how whereas we enable local food small the costs can be to help those in producers to fortify staple food need, in particular low income groups by providing them with technical in developing countries: A bottle of nutrition expertise. cooking oil enriched with vitamin A, One example of a very successful for example, costs only 0.2 euro cents multi-stakeholder partnership is more than a conventional one. SAFO (Strategic Alliance for the This is why we started our food Fortification of Oil and Other Staple fortification program, which combines Foods), an initiative supported by the social responsibility with financial self- German government which promotes sufficiency. With such a dual bottom the local production of affordable line, food fortification is an approach fortified staple foods in six developing to Corporate Social Responsibility countries. BASF contributed that is sustainable and scalable. technical assistance and developed Taking center stage in all our food portable mini laboratories for fortification efforts is the ‘inclusive analyzing the vitamin A content in

34 | Creating Chemistry fortified foods. The result: SAFO has are helping around 225,000 farmers Above Food fortification improved the diet of more than secure good harvests – but our enriches staple foods with vitamins and minerals to 150 million people. business with crop protection address the nutrient deficiencies The success story of food products for soybeans in India prevalent in a particular country. fortification was decisive for BASF’s also grew. public commitment at the United ‘We create chemistry for a Nations Conference on Sustainable sustainable future’ – that is BASF’s Development, Rio+20: BASF will purpose. Social responsibility is a strive to reduce vitamin and mineral core element of our strategy. Within deficiencies in people suffering from BASF’s Nutrition & Health division, we or at risk of malnutrition – each year want to contribute to the improvement 60 million additional people shall of the nutrition, health and wellbeing benefit from fortified staple foods. of consumers all over the world. We We believe that micronutrient are driven by a desire to make real, fortification is one possible answer to sustainable improvements to people’s the question of how to fight ‘hidden lives. Micronutrient fortification is Walter Dissinger hunger’ in the world. Yet food one of the ways we hope to achieve fortification alone is not capable of this. This is why we will continue Since 2010, Walter Dissinger has solving the problem of hunger. to move forward with the best been President of the Nutrition & Through engaging in the long-term investment in human development. Health division at BASF, which approaches of improving agricultural works to support and improve the production and dietary diversification, diet, health and wellbeing of people BASF makes a vital contribution to around the world. Prior to this, the the easing of these problems. In our industrial engineer worked at Samruddhi business model, for To find out more, visit: BASF’s Styrenics and Performance instance, BASF agronomists advise www.food-fortification.com Chemicals divisions, and was head Indian farmers throughout the www.wbcsd.org/rio-20/ of the crop protection business in growing season. Not only does this membercommitments.aspx Latin America. ensure our customers’ success – we

Creating Chemistry | 35 Feature: Quality of life The reinvention of light

36 | Creating Chemistry Organic light-emitting diodes (OLEDs) create a world in which illuminated wallpaper and windowpanes that turn into a source of light at night are possible. Experts are convinced that in the next few years, these promising energy savers could revolutionize the lighting sector.

he centuries-old door is three meters making these values better still. Before major high, dark and heavy, allowing no lighting manufacturers incorporate OLEDs into light to pass through. But behind this large-scale production, they must reach a lifespan door, the future of lighting is being of several tens of thousands of hours and achieve developed. This is where Professor an efficiency that is approximately twice that of Dr. Karl Leo has his office at the existing fluorescent tubes. DresdenT University of Technology, Germany. Together with his team, he is developing a very Light for wellbeing special lighting panel. The 52-year-old works at the It is not only because of their efficiency that OLEDs university’s Institute of Applied Photophysics. At are the light source of the future. “Their light is the same time, he manages the Fraunhofer more flattering, softer and more forgiving than any Research Institution for Organics, Materials and other light source, which is why I call it the ‘light for Electronic Devices (COMEDD) in Dresden and is wellbeing’,” says Rogier van der Heide, head internationally recognized as a pioneer in the field designer at Philips Lighting (see interview on page of organic light-emitting diodes (OLEDs). He and 41). The secret to their ‘feel-good’ factor lies in the his team are aiming to realize the potential of way they emanate light. In contrast to all other past OLEDs to imitate natural light as accurately as and present artificial light sources, OLEDs do not possible. “OLEDs are a technological sensation emit light from a point; they are a flat light source. that enables us to completely rethink artificial “With OLEDs, it is also possible to regulate the lighting,” enthuses Leo. color temperature and adapt the light to the time of day,” explains Leo. So, it is possible to have a The competition for efficiencies warm white light for the morning and evening hours The expectations placed on OLEDs are high; they and a cool white for daytime. “This is something are expected to become more efficient than all which has hardly been seen before with lighting,” existing light sources and, someday, to be able he says. to convert nearly 100% of their energy supply into Another property of OLEDs is inspiring lighting light. These weighty ambitions place demands on designers as well. They are made of wafer-thin materials developers and lighting manufacturers organic materials, and in the foreseeable future it alike. With electric light bulbs, halogen lamps, and may be possible to place them like a second skin energy-saving lamps, a large proportion of the over wallpaper, ceilings, or windows. This would energy is converted into heat instead of light – the enable a ceiling to create the perfect illusion of a surface of a 100-watt electric bulb, for example, summer sky, or a wall to become a virtual spring reaches a temperature of more than 200C (392F) meadow. When switched off, OLEDs are white, when lit. By contrast, the OLEDs being developed relective, or transparent – so they could be used to in Dresden remain at around 30C (86F), so they’re help create windowpanes that let in sunlight during always safely cooler than body temperature. the day, then transform into flat lamps in the dark. The luminous efficiency of commercial OLEDs The rooms of the future might be able to do away is currently between 45 and 60 lumen per watt. In entirely with lamps as we know them today. the laboratory, values of more than 90 lumen per watt have already been achieved. For the purposes Carbon molecules create light of comparison: A standard fluorescent tube OLEDs function according to the same principles achieves 45 to 75 lumen per watt. At 10,000 hours, as LEDs. With both types, light is produced using the lifespan of OLEDs is also promising, even at semiconductors. These are solids that conduct this stage. Leo and his team are working on electricity under certain conditions. When >>

Increasing efficacy Luminous efficacy shows the amount of light produced per watt of electricity. It is measured in lumens per watt (lm/W).

Light bulb Halogen Energy saving lamp OLED Organic light-emitting diodes (OLEDs) may 13 lm/W 20 lm/W 55 lm/W expected to reach soon revolutionize the lighting market. Their Lifetime: Lifetime: Lifetime: more than 100 lm/W light output promises to break all records. 1,000 hours 5,000 hours 20,000 hours

0 102030405060708090100

Source: U.S. Department of Energy: Energy Savings Potential of Solid-State Lighting in General Illumination Applications 2010 to 2030, Elektrizitätswerke des Kantons Zurich (EKZ). Creating Chemistry | 37 Feature: Quality of life

electricity flows through semi- to 1979 when the Chinese-American of research in the field of organic 2010 as the world’s largest OLED conductors, they start to glow. The chemist Professor Dr. Ching W. Tang electronics at BASF. BASF’s light installation: The wall is made difference between LEDs and OLEDs discovered a blue glowing researchers achieved their first up of more than 1,000 small panels. is the “o,” which stands for “organic.” phenomenon in organic matter when breakthrough with highly efficient A camera records every movement While LEDs use tiny inorganic crystals working on solar cells at Kodak’s molecules a few years ago. Now made in front of it and translates based, for example, on gallium nitride, research department in the United they are working on extending their them into electrical impulses that light OLEDs are made from pigment-like States. Eight years later, he and his lifespan and on developing the robust up individual panels. The natural organic compounds that are normally colleague Steven Van Slyke lighting systems we call diodes. ‘feel-good’ light could also be used used to coat a base material by presented the first light-emitting in hospitals and doctors’ surgeries in means of vapor deposition. diodes made from organic layers. Practical applications the future. Enquiries are also coming The structure of an OLED is a bit In the animal kingdom, the principle Well-known lighting manufacturers from museums interested in a gentle like a sandwich (see graphic on page is age-old: Glowworms are like have already made use of the new light source without UV rays and 39). The organic layers are positioned nature’s OLEDs. Their bodies contain technologies. Two of the leading strong heat emission. Japan is between two flat electrodes, which a natural substance called luciferin companies are Osram and Philips. already a step ahead; the first are around a hundred times thinner that reacts with oxygen thanks to an Almost four years ago, Osram, a exhibition halls here have already than a human hair and are invisible enzyme. The energy produced is subsidiary of Siemens, introduced been equipped with OLEDs. to the naked eye. When an electrical almost entirely emitted as light; the first OLED light sculpture – known current is passed through them, the but while the luminous molecules as Early Future – onto the market. The start of mass production molecules in the organic layers start in glowworms disintegrate, in OLEDs Since then, Osram has expanded The new technology is inspiring Asian to glow. If red, green and blue they revert to their original state. this business and created entire manufacturers in particular. In Japan, substances are combined, white Companies such as BASF are conference rooms for its customers following the Fukushima nuclear light is created. “We have so far working on making the molecules with a combination of OLED and disaster and the temporary closure used only glass as a base, but produce light for longer and more LED lighting. In 2011, the company of most nuclear power stations, flexible materials are likely to be efficiently than has been the case opened its first OLED pilot production almost everybody is trying to save used in the medium term,” says Leo. so far. BASF is a leader in the line in Regensburg to enable such electricity wherever possible, The organic semiconductors must development of blue luminous applications to be available on a according to Dr. Takuya Komoda, be well protected against steam and substances – the biggest challenge larger scale in the near future. Here, Research Director in the organic air and be properly encapsulated. that these organic materials present. Osram is researching how these lighting division at Panasonic. It is still difficult to achieve this on As Dr. Karl Hahn explains, “blue light sensitive light panels can be Lighting accounts for 16% of Japan’s pliable materials. has much more energy than green processed on an industrial scale. total energy consumption. “In order and red. This means that the The Dutch company Philips has to reduce the power consumption of Glowworms – nature’s OLEDs molecules can disintegrate and christened its first OLED lighting lighting, it is urgently necessary to The beginnings of OLEDs go back lose their effect.” Hahn is in charge module Lumiblade, presenting it in introduce next-generation lighting

38 | Creating Chemistry devices. OLEDs will be a very including OLEDs as an energy-saving Good business prospects important lighting source in the future and environmentally friendly “Annual sales of small OLED displays 5 – 10 because they are able to provide both technology of the future. Several already amount to around $4 billion,” How many times longer an OLED high energy savings and an excellent million euros are flowing into says Professor Dr. Leo in Dresden. In lasts compared to a light bulb. lighting atmosphere,” says Komoda. European research projects in which a few years, this figure will have risen Although energy-saving lamps are the scientific community and industry to double digits. If costs fall and more efficient right now, this will are working together to develop efficiency increases, experts believe change. “We are planning to raise OLEDs that are more efficient. In that nothing will stand in the way of the power efficiency of OLEDs up Germany, the Federal Government an OLED revolution. 40,000 to 100 lumen per watt by 2018.” is supporting research and “LEDs have been under research The number of hours that an LED lasts for. In 2011, the Japanese company development through its OLED 2015 for 40 years longer and thus have Lumiotech, which specializes in program. Together with business an edge today. But provided OLEDs, gave the market new partners, it has invested more than OLEDs reach an energy efficiency momentum by launching affordable $1 billion (€800 million) since 2006. comparable to that of LEDs, both hanging light panels and OLED desk This initiative includes follow-up solutions will each take their own 10,000 lamps at a unit price of $410 (€315) ventures like the Kobalt Project, share of the lighting market – The number of hours that an OLED currently lasts for. and $650 (€500) respectively. launched in the spring of 2012 and precisely because they represent Additionally, Konica Minolta is taking involving partners such as Philips complementary alternatives,” says Source: Dresden University of Technology part in the lighting revolution of the and BASF, where the focus is on Dr. Felix Christian Görth of BASF future with its Symfos light panels. developing cost-efficient OLED Future Business. The organic light The company has also made components for applications in the panels will therefore not entirely headlines with a type of print head for lighting market. monopolize the market, even in the OLEDs. Instead of ink, this device, future. For certain applications, such the first of its kind, applies electronic OLEDs in displays as car headlights, point light sources functional materials and is thus able OLEDs are already widespread in the are still in demand. LEDs might to ‘print’ organic lights. display industry. For example, Korean therefore be the future of point light company Samsung is already using sources and OLEDs the future of Governments embrace OLEDs mass-produced flat light panels in its flat lamps. For Görth it is no longer Policymakers have also recognized latest cell phones and tablets. This is a question of whether OLED the potential of these energy-efficient a chance for OLEDs to truly show technology will be commercially To find out more, visit: miracle lights and has been what they are capable of. They emit successful. “OLEDs have, after all, www.oled-research.com promoting their development for light themselves and do not require played an important role in cell phone www.basf-futurebusiness.com/en/ years. In the United States, the any background lighting – this saves displays since 2011,” the BASF expert projects/organic-electronics/oled Department of Energy has been electricity. The sharp, high-contrast points out. “The only thing still open supporting research, development images load quickly. The design is to debate is how big the market will and the manufacture of efficient light equally captivating: the first 55-inch ultimately be,” he adds. sources such as LEDs and OLEDs OLED TV sets presented by The fact that the big breakthrough Top left The organic light-emitting since 2003 with its “Solid State Samsung and Korean electronics is still to come for OLEDs is apparent diodes (OLED) lamps made by the Lighting Program”. The government’s group LG are only a few millimeters from Professor Leo’s office in Franco-Italian company Blackbody aim is to reduce electricity thick. Browsing the web for Dresden. He still has a conventional are simultaneously stylish and energy-saving. consumption for lighting purposes. information on OLEDs, it’s possible reading lamp on his desk, and the In the European Union (E.U.), the to glimpse the future: Images show room is still lit by traditional Below This display made from aim is to achieve a 20% reduction in prototypes with flexible displays; fluorescent lamps on the ceiling, yet organic light-emitting diodes by 2020. examples include e-books, that can he is convinced: “It may not be long (OLEDs) is only a few millimeters thick. It impresses thanks to its flat To achieve this, the E.U. is promoting be folded like handkerchiefs and cell before OLEDs become commonplace design as well as its sharp picture. research in the energy sector, phones that can be rolled up. in many offices like mine.”

How OLEDs work:

Emitter layer Conducting OLEDs are built like a sandwich, layer with a filling made up of wafer-thin Cathode Anode layers of organic material. These layers are placed between a Encapsulation Substrate positively charged anode and a negatively charged cathode. When an electrical current is passed through them, electrons and positive charges flow into the middle of the Light sandwich and coalesce. In so doing, they cause the embedded molecules to glow. Because the organic layers are very sensitive to water and oxygen, they must be encapsulated for their protection.

Creating Chemistry | 39 Feature: Quality of life

nly the right mixture want several tens of thousands of red, green, and of hours,” says Hahn. BASF’s BASF blue light produces researchers are working to achieve the white light of this goal in the company’s chemistry an organic laboratories. Day after day, lab researchers are light-emitting diode assistants are using vapor deposition O(OLED). But until now, manufacturers techniques to coat small glass plates have had to make do with a blue with dye molecules and materials that taming blue light dye that is relatively inefficient. The make them shine. Countless diodes fluorescent emitters currently on the have been produced in this way. “We market convert no more than a constantly test new combinations,” Having the blues is not always a bad thing, quarter of the energy into light, with says chemist Dr.-Ing. Soichi at least not for BASF’s researchers. In 1897, the rest being converted into heat. Watanabe, originally from Japan. they produced the first ever artificial “What we want, however, are lamps Watanabe is completely covered and not hotplates,” says Dr. Karl Hahn in protective clothing. “The wafer-thin indigo-colored pigment. This dye, which who is in charge of BASF’s research layers on the diode must not, under had previously been an expensive luxury in the field of organic electronics. any circumstances, be contaminated imported from India, was suddenly affordable, BASF chemists therefore started with dust particles,” he explains. Even and can today be found in virtually every pair of looking for a solution to the ‘blue a single speck of dust would act like problem’ a few years ago. They a mountain on the much smaller jeans. The company now wants to create another discovered molecules that shine blue molecular layers and destroy the innovation involving the color blue, but this and are able to convert the energy lamps. Steam and oxygen are also time on the lighting market. almost entirely into light. These poison to the organic molecules. molecules belong to the highly They would quickly spoil. “It’s like efficient phosphorescent emitters with sushi. I would prefer to eat it used in OLEDs. There was just one fresh rather than a couple of days snag, however: they only lasted a later,” says Watanabe. The lab few minutes. assistants must immediately seal While long-lasting red and green each individual glass plate with variants of the highly efficient OLEDs another glass plate once all the are already available, there is still no molecules are in place. corresponding blue in the palette. The finished diodes are tested The reason for this is that blue light is in two chambers. In the first, trials particularly aggressive. “It is very are run on light intensity and other short-waved and thus highly charged parameters. In the second, which with energy. Blue light is therefore looks like a small recording studio, able to destroy molecular bonds like the durability test is carried out. no other light can,” Hahn explains. A large number of switchboards are The challenge for BASF researchers attached to electrical cabinets and is to find molecules able to withstand computers. On the black cabinets, this strong energy over a long period. 360 diodes shine for days on end. An OLED must be long-lasting in The series of figures on the screens order to be suited to applications show which lamps are worth such as lamps, cell phone displays, continuing to work on. Watanabe and TV sets. However, finding the and his colleagues continually right dye is not the end of the story. assess these data. The other materials in the blue OLED In 2014, BASF hopes that the sandwich (see diagram on page 39) blue dye and the associated system must be robust in order to enable components will be ready for the OLEDs to shine brightly and over mass lighting market. By 2016, the a long period. BASF is therefore BASF blue should have the working on the entire materials necessary depth of color for the system for blue diodes and aims display industry. The researchers to be the leading supplier worldwide are aware that they will have to for these active components. fight hard for every inch of progress BASF has already managed to until then. “We are working on a extend the few minutes of life of its pioneering development, and every early molecules to several thousands day this rekindles the team’s spirit of hours. “But lamp manufacturers of discovery,” says Hahn.

Left With their efficient blue OLEDs, BASF researchers want to revolutionize the lighting market.

40 | Creating Chemistry What is your favorite piece of design using organic diodes and what makes it so fascinating? I really love the OLED chandelier designed by Tommy Voeten of 1212-Studio, which was further detailed and engineered by Philips. It was inspired by DNA, and expresses the idea that groundbreaking OLED technology adds new, fundamentally different possibilities to the way we light our environments.

That sounds sensational, but also fairly upmarket. When will luminous wallpaper be stocked at my local store? It would be fantastic to have luminous wallpaper, and of course we are Creating Chemistry: Luminous looking into ways of making light wallpaper, windows and doors flexible and uniform. Any new form Taking lighting to as flat sources of light – organic of light that expands the freedom of light-emitting diodes (OLEDs) designers is interesting and relevant. are revolutionizing the lighting For a long time, light was limited to a new dimension market. What new opportunities the light bulb and the tube light, but do OLEDs offer with regard to now new concepts are constantly lighting design? being developed. Will luminous Rogier van der Heide, Philips Vice President and Chief Rogier van der Heide: OLEDs offer wallpaper become widely available Design Officer, talks about fascinating new organic much greater integration of light into in future? We’ll see. Check back with objects, furniture, cars, buildings, us in two years! lighting concepts and his personal visions for the future. architecture… even fashion. Suddenly, illumination can go where How will the new OLED lighting it has never been before. With concept change our living and Above left The design of this chandelier, made of OLEDs, designers have unparalleled working environment? OLED lighting tiles, is the work of Tommy Voeten from possibilities to use light in new and OLED is more flattering, softer and 1212-Studio, and was inspired by the structure unexpected ways. more forgiving than any other light of DNA. source. It renders human skin Above right Rogier van der Heide. Can you tell us what organic beautifully. We all look better in OLED lighting concepts you are light, which is why I call it the “light currently working on? for wellbeing.” With OLEDs, we can We are working on many concepts create environments that are more based on OLEDs. We’re looking into pleasant, better for our wellbeing and integration in car interiors, and we more inspiring than we could before. recently launched a mirror that radiates light just around your face. Which lighting vision would you like The OLED lighting it uses is incredibly to implement in your own home? natural, flattering and soft – the For my home I love the concept perfect light by which to see your of “the human scale.” That means features! I love such concepts; they avoiding light sources above eye level truly draw from the unique properties and having a number of small lamps of OLEDs as a new art of light. scattered around the space, instead of one strong lamp in the middle on the ceiling. It dramatically improves the atmosphere of any room.

Creating Chemistry | 41 Insight

A glimpse Refined and inviting The design for these Japanese sushi rolls was produced by a laser cutting around the globe: into paper-thin sheets of seaweed. packaging

Minimalist, playful, sustainable or uniquely regional – a look at diverse examples of packaging from around the world shows just how inventive this industry can be.

Practical and Economical functional and useful The lid of this Korean With this unique butter packaging also Chilean lamp made of serves as a spreader thermoformed plastic, the for when customers packaging and product are on the move. are one and the same.

Ecological Fruity and and clever functional A simple piece of folded This Japanese banana card is used to make juice packaging looks this Philippine snack and feels like a banana. packaging, with no glue involved at all.

42 | Creating Chemistry Round and sound Packaging for a good cause: Children in developing African countries can assemble their own soccer ball using the cardboard from aid packages.

Innovative and environmentally friendly This Dutch packaging actually forms part of the contents – it is used to create a child’s chair made of corrugated cardboard.

Compact and minimalist This shoe box from the United States is made of recycled papier- mâché and takes up very little space when stacked.

Playful and Evocative traditional and exquisite These Ukrainian This family pack of tea containers are used for from Singapore recalls sour cream and play traditional regional on local culture and architecture. traditional milk jugs.

Creating Chemistry | 43 Feature: Food and nutrition

44 | Creating Chemistry Boxing clever

These days, nearly as much research and development goes into how we package our food as goes into the food itself. Innovations and high-tech solutions mean that the cartons, films and bottles ensure that food is kept fresh and safe, helping food production to become more efficient and safe.

n Austin, Texas, there is a supermarket where Freshness is imperative 1 Modified Atmosphere customers are advised not to come empty The demands made of packaging are high. Packaging handed to do their weekly shopping: fabric Guaranteeing freshness and hygiene is a particular bags are the order of the day. Shoppers challenge, as foods must often cover great “Depending on the food, who fail to bring these must buy compostable distances when travelling from their place of origin packaging has to be firm, containers to take home their purchases of fruit to supermarket shelves. Further time passes flexible, transparent, printable, Iand vegetables, which are largely locally grown. before they find their way into a shopping basket, or impermeable to aromas, Known as the first precycling supermarket in the and then again before they ultimately end up on the oxygen or carbon dioxide,” United States, it does not offer any packaging dining room table. Highly developed technology explains Dr. Rolf-Egbert at all. ensures packaging can keep products impeccably Grützner from polyamide market What may work on a small scale, however, fresh and hygienic. A quick glance in the development at BASF. There is is simply inconceivable at a larger level, with food refrigerated section shows the complexity of no such thing as a universal packaging now an essential part of our everyday what is involved – the packaging for cheese and material that can do it all. The lives. “Packaging is key when it comes to sausages, for example, is made of a wide range bottom section of the packaging protecting our products, guaranteeing our high of plastics. The differing characteristics of these is made of plastic, such as quality standards, preventing food waste and composite materials are combined to ensure the polypropylene. Polypropylene informing consumers,” says Dr. Anne Roulin, packaging is ideally suited to the food. The base provides flexibility, protects Global Head of Packaging and Design at Swiss of the packaging, for example, can be produced against moisture, and can food conglomerate Nestlé. There are many reasons to have different characteristics than the lid or act as a seal. The flexible, for the growing need for food packaging. More wrapping film. removable, and often resealable than half of the world’s population lives in cities, Hard-wearing composites made of various lid is made of a five- or where there are few options for growing materials are also well suited for use in what is seven-layer film. The uppermost 1 food independently. The planet’s 3.5 billion known as Modified Atmosphere Packaging layer contains polyamide like city-dwellers thus buy their products outside or MAP. With this technology, the air surrounding BASF’s Ultramid® which is of the home – and they usually come packaged. an edible product is replaced with a protective particularly stable and pliable, In addition, the rising number of single-person atmosphere specially tailored to the food. keeps out oxygen and carbon households, which prefer smaller portion sizes, One example is a mixture of nitrogen and dioxide, and retains its shape and the growing trend of eating on the move carbon dioxide. These slow-reacting gases at higher temperatures. The lid between appointments are giving rise to an replace oxygen, and slow the growth of ensures an extremely high increasing amount of packaged food. germs, all without using any preservatives. puncture resistance; it prevents To ensure the solution works >> oxygen from entering the packaging and any fat contained within the food from going rancid, or harmful microorganisms developing.

Left Today, there is more to packaging materials than meets the eye. Consumers rarely realize how much sophisticated technology is hidden in these high-tech containers. Creating Chemistry | 45 Feature: Food and nutrition

properly, the packaging material absorbers or special acids. As an Reducing the weight 5 1.3 billion must form an effective gas barrier. example, American firm Sonoco is of packaging is another way of The number of metric tons of food Otherwise, the valuable protective currently developing packaging with protecting the environment while production – around one-third of atmosphere would quickly be lost. integrated microchips that collect protecting companies’ bottom lines. the total – lost or wasted every information about the condition of As well as cutting the CO2 emissions year worldwide. Regional preferences a product, such as moisture and generated during transportation, In Japan, the development of temperature. It raises the alarm when making packaging lighter can reduce sophisticated packaging systems preprogrammed thresholds are costs too. Corrugated cardboard, 95 – 115 kg is also driven by regional eating exceeded or fall below target. “In frequently used in transport The amount of edible food per person preferences. Japanese consumers the future, I expect to see a shift in packaging for food, can be reduced that is lost or wasted each year in react very negatively to packaging business models towards direct in weight with the help of fluid industrialized countries. that no longer appears perfectly contact with consumers,” predicts synthetic dry strength agents. These intact from the outside; even Dr. Anne Roulin from Nestlé. mean that fewer paper fibers are Source: Food and Agriculture Organization, harmless creases or folds in packets needed to construct the cardboard, Statistical Yearbook 2012. can cause perfectly fine food to be Environmental awareness without compromising its strength. left on the supermarket shelf. Fish Alongside freshness, increasing and seafood are often on the menu, numbers of consumers want Focusing on health and it is particularly important that packaging that can be recycled. In many countries around the world, they are kept fresh and protected According to a survey of 6,000 the trend towards greater against spoiling. It is popular to consumers in ten different countries, sustainability goes hand-in-hand with package foods accompanied by carried out by Swedish carton an enhanced awareness of personal small sachets filled with substances manufacturer Tetra Pak, recyclable health. As well as information 6 that bind moisture, such as silica gel packaging is one of the public’s key about the contents, food packaging and starch polymers. “For Japanese priorities, as it is seen as kinder to should also provide details relating to consumers, the presence of sachets the environment. nutrition, calories, and possible indicates that the product is very well Consumers and legislative allergy triggers. protected,” explains Sven Sängerlaub regulators are becoming increasingly Potentially dangerous substances from the Fraunhofer Institute for concerned with packaging. The aim are not limited to the food, however – Process Engineering and Packaging here is primarily to encourage the they can also be found at times in the (IVV). In contrast, many Europeans efficient use of resources. This trend packaging material itself. In 2010, view such tiny sachets of moisture- is particularly noticeable in Europe. In researchers at the Zurich Food Safety binders with suspicion, and their the , for example, a tax is Authority in Switzerland found that presence inside a package can prompt applied to packaging manufacturers mineral oil residue contained in

skepticism about the food it contains. according to the average CO2 cardboard packaging was being emissions of the materials used – transferred to foods. The main source Minimizing waste 36 to 57 euro cents per kilogram of the problem was deemed to be ink How can consumers accurately for aluminum packaging, 6 euro cents used in newspaper printing, which assess the condition of products? for cardboard. found its way into the packaging via Uncertainty in this area often leads can recycled paper. The residue traces to waste: “Too many consumers see be worthwhile for packaging detected also occasionally came the best before date as an absolute manufacturers and food companies. from inks used to print the food cut-off point, although many foods In Europe in particular, demand is packaging. These oil residues can still be eaten after this time,” on the rise for paper and cardboard evaporate at room temperature, and 2 Increasing recycling explains psychologist Stephan packaging with environmentally can then be transferred to dry foods, rates, reducing material Grünewald, from rheingold, a German friendly recyclable fibers, which are such as pasta, semolina, rice, or requirements market and media analysis institute. also cost-effective. In addition, cornflakes. This is even possible Every year, in industrialized countries, companies are working to come merely when the transportation BASF products that contribute to 95 to 115 kilograms of perfectly good up with solutions that simplify packaging of the food contains reaching the goals of reducing food is lost or wasted by each packaging designs so that recycled paper. Certain components material requirements and person, according to a study by the recycling 2 rates rise. of mineral oil are suspected of being increasing recycling rates include Food and Agriculture Organization of carcinogens, according to the World additives, which make plastics the United Nations (FAO). Biodegradable materials Health Organization’s Joint Expert more elastic and resistant to In years to come, ‘intelligent’ or Recycling is one thing; there is Committee on Food Additives, ageing and tearing. They are used ‘active’ packaging could help reduce growing demand for renewable and the FAO. >> in processes such as recycling food waste. This is a response to materials that are biodegradable too. 3 PET beverage bottles. Additives experts’ efforts around the world to Drinks cartons or food containers, ® belonging to BASF’s Joncryl come up with new ways to inform for instance, can be made of family ensure that the recycled consumers about the perishability of biodegradable plastics 4 formed material obtains the quality of new food and to protect against spoiling. partly of renewable raw materials. PET. Moreover, paper chemicals The new systems could display the After use they can be disposed of from BASF enable the production state of a product, and at the same and composted with the rest of the of new paper and board from time increase its lifespan with oxygen food waste. recycled fibers.

46 | Creating Chemistry 4 Biodegradable plastics

3 Water-based adhesives There can be plenty of garbage left suited for use in what are known as over after sports events, music closed-loop systems – closed Water-based adhesives offer an concerts, and busy days at the waste systems that can be set up alternative to traditional adhesives. zoo. To turn disposable cutlery in stadiums, hotels and businesses. They do not contain potentially and food packaging into valuable Here, the operator will exclusively harmful ingredients like solvents compost, BASF has developed provide visitors with compostable or aromatic amines which could biodegradable plastics based on food serving items. After use, this migrate into the food. In addition, renewable materials. The product packaging is mixed with leftover ® they help optimize production ecovio has been available since food and collected in organic waste ® processes, as laminates made 2006, and is made of ecoflex , disposal units. A special waste with these adhesives can be a , and disposal firm then empties these processed quickly, cutting costs polylactic acid derived from the units, and transports the garbage and increasing flexibility. BASF renewable raw material corn to a composting facility. This recently launched the first (maize). Due to its molecular ensures far fewer extraneous water-based compostable structure, ecovio breaks down in materials make it into the facility, adhesive, Epotal® ECO, a similar way to organic waste, as which would otherwise have to be which can be used for fully microorganisms decompose the carefully removed. The Seattle biodegradable packaging. plastic with the help of enzymes. Mariners baseball club is one of the The material ecovio can be first organizations to apply this used, for example, in biodegradable system. Around 80% of waste garbage can liners, shopping bags, generated during one of the team’s cup coatings, and food containers home games is sent for composting. made of foam. It is particularly well

Above Additives ensure that recycled PET boasts the same quality as new plastic.

6 Adhesive information

Labels with the required information are applied to food packaging with the help of specifically formulated adhesives. Pressure-sensitive adhesives, which are used to produce 5 Reducing weight self-adhesive labels, pose special challenges. On frozen products Below Composite materials BASF has managed to develop for example, the label must help to keep food fresh. a system, based upon the stay in place at sub-zero innovative product class temperatures. polyvinyl amine, which enables When used in the food sector, paper producers to respond to adhesives also have to comply the fluctuating quality of their raw with a range of strict regulations. materials. The trick is to combine “That’s why we have our raw an anionic and a cationic materials for pressure-sensitive polyvinyl amine. This improves adhesives regularly tested and the mechanical strength of the certified by an independent packaging paper, allowing its institute,” states Michael weight to be reduced while Gutsmann, who is responsible maintaining the same stability. for pressure-sensitive adhesives BASF markets this dry marketing at BASF. strengthening system under the name Carrier System.

Creating Chemistry | 47 Feature: Food and nutrition

Mineral oil barrier in packaging Over the last few years, research Going forward, one way of reducing into the best, most secure types of or even entirely eradicating mineral food packaging has made major oil residue in paper and cardboard advances. Guaranteeing safety, packaging is to use water-based providing freshness, and delivering binders for mineral oil-free information, our food’s containers printing 7 of newspapers. are increasingly sophisticated and In addition, food can be protected play an important role in our against the migration of unwanted everyday lives. substances through functional barriers. Functional barrier 7 Mineral oil-free solutions 8 are currently available printing for practically all types of packaging and standard manufacturing Under the Joncryl® processes. In this way, our food is Right Packaging made of recycled brand name, BASF has reliably protected from mineral oil and paper fibers may contain mineral oil developed aqueous other potentially critical substances. residues that can migrate into food. binders that national newspapers in the United Kingdom and already use for mineral oil-free flexo printing. Joncryl is also ideal for printing food packaging.

The mineral oil barrier protects food 8 Functional barrier solutions

Food packaging is often made of recycled paper fibers. This recycled The water-based dispersion Similarly, food packed into paper paper packaging can contain newspaper ink, which researchers have Epotal® A 816 can be used to coat and cardboard can be protected identified as the main source of potentially harmful mineral oil residues films. It creates the desired barrier with newly developed water-based in cartons. These oil residues evaporate at room temperature and can effect in liner bags, which are often dispersions applied onto the thus be transferred to dry foods that contain fats, such as noodles. used to package foods like cereal. board. “This innovative water-based Three further BASF solutions are functional barrier solution will give available for the protection of food packaging producers more flexibility packed into cardboard. in creating their end products, BASF’s polyamide Ultramid®, whether they want to print the barrier can be applied to the inside of or coat the paper or cardboard,” cartons to provide functional explains Lauren Ritacco from barrier properties. Moreover, it BASF’s Paper Chemicals division in NoodlesNNoooododleddless Other packages 3 (possibly oil residues is suitable for usage in protective Europe. A series of tests, carried out from newspaper ink) inner pouches. In addition, the by the Zurich Food Safety Authority, Oil barrier biodegradable plastic ecovio® FS Fraunhofer IVV and Innoform, 1 Paper can be used to create the among others, have proven the transport packaging functional barrier for cartons. effectiveness of the four functional 2 The barrier made of ecovio FS barrier solutions. Paper can either be applied directly to the cardboard or be added to Mineral oil residues can migrate from: a hybrid material along with paper 1. the inner side of contaminated primary packaging or plastic, which is then used for 2. contaminated outer packaging, for example, corrugated liner bags and lamination. The board packaging used to hold products during transportation product also shows improvement 3. contaminated packages in close proximity, for example, in cardboard stiffness and provides on the supermarket shelf or in delivery trucks sealing properties.

48 | Creating Chemistry Well packaged Today, packaging must do more than protect food. Nicolas Eilken, 3D Design Director at design and branding agency Lothar Böhm and lecturer in packaging at the Brand Academy of Hamburg/Germany, explains the many roles it fulfills.

Above Nicolas Eilken, 3D Design Many consumers decide which products to Rising levels of packaging waste continue Director at Lothar Böhm buy when browsing the supermarket shelves. to be a problem. What are you doing to How can packaging encourage them to make counteract this? Above right Different kinds of cheese require different kinds of a purchase? We are looking at ways of reducing volumes, to cut packaging. Freshness, for example, is primarily expressed the burden on transport and logistics. In addition, through graphic design, while the material itself we are working to save materials by minimizing the can convey a sense of sustainability or premium thickness of packaging. quality. If consumers pick up the product, they might see that the packaging is easy to open and Are there any food packaging functions that Creating Chemistry: Industry is constantly resealable, which makes it convenient to use. All you would like to see developed? developing new materials for packaging and these factors can persuade them to purchase, and Most functions can already be carried out, such protecting foods as well as reducing furthermore, to return to the brand the next time as cooling or self-heating packaging. Scientists are environmental impact. With such diversity, they shop. currently working on how to add moving images how do you choose the right packaging for or changing messages to packaging. This would your designs – to pack cheese, for example? Your design agency Lothar Böhm has allow us to communicate far more engagingly with Nicolas Eilken: That would depend on the type offices in Hamburg, London and Warsaw. smaller packaging units. It remains prohibitively of cheese. Some types of cheese ripen in their Do Polish people prefer different things expensive, but I think it’s on its way. packaging and need air to circulate, while others to the British or the Germans when it comes require a barrier against oxygen. Consumers’ to food packaging? needs also play a role, as does presentation – Comparatively speaking, the Germans are less things like a viewing window, the cheese’s willing to experiment and are very rational. appearance on the shelf, and differentiation from Packaging should convey a sense of quality; the competition. And of course, the material needs customers look for high quality at a good price. to be sustainable. They also want to see what they are buying. British people are a step ahead in terms of design – they are even happy with pink packaging for cheese! In Poland, meanwhile, packaging must be authentic and playful, with even brighter colors. As each nation has different habits and customs, it is difficult in the food industry to produce packaging that can be employed globally.

Creating Chemistry | 49 Feature: Resources, environment and climate From trash to treasure

In developed countries, primary supplies of raw materials for high-tech industries are beginning to dwindle, but there are still large untapped reserves to be found in both household and industrial waste. The recycling of rare metals is in its infancy, but it already has some influential supporters – including a Japanese virtual singer.

50 | Creating Chemistry hree years ago are often dependent on imports to is a key topic in the media these Japanese authorities meet their demand, because it allows days. These metals are rarely found recruited Hatsune them to develop their own local in concentrated form in the Earth’s Miku for a recycling sources of supply. crust, which makes it hard for campaign. The virtual companies to mine them. There are character, who is Shortage of resources 17 rare earth elements, and they are popularT among young people in The main reason for the growing used in catalysts, LEDs, magnets and Japan, invited her fans to return their demand in special metals is the other products. The most important old cell phones for recycling. In success of microelectronics. These rare earths mines are located in addition, a competition encouraged days, almost every Western China, which today meets more than the public to take part in the phone household uses smartphones, video 90% of the world’s demand. The recycling scheme. It was a game consoles and laptops. At the largest rare earths mine in the resounding success: In a hundred same time, the consumption of these western world, the Mountain Pass days, more than 570,000 phones goods in emerging markets like China Mine in California, was closed in 2002 were collected at almost 2,000 and India is likely to rise dramatically. because it was not profitable. shops. With the campaign, the In addition, the semiconductor There are several reasons for the government wanted to tap an often industry uses an increasing variety of scarcity of certain metals. Some overlooked source of raw materials: raw materials. Today, semiconductors naturally only occur in small amounts, electronic waste. contain about 60 different chemical while reserves of others have not According to experts’ estimates, elements – compared to just 12 in been developed yet; worldwide 20 kilograms of cell phones contain the 1980s. supply of the metalloid germanium, as much as one metric ton of gold The fact that many different for example, could be exhausted in ore. And gold is not the only resource technologies use the same materials 17 years. But sometimes raw in cell phones: A typical mobile phone complicates the matter further. materials are scarce because they contains about 40 raw materials, Alongside microelectronics, other come from politically unstable including rare special metals such advanced technologies like fiber-optic regions. For example, a major mining as indium, palladium, cobalt, and cables for telecommunications area for minerals like coltan, which tantalum. While the names of some networks, fuel cells, wind turbines contains tantalum, is located in the of these elements may not be familiar and catalysts are driving up the Democratic Republic of the Congo to us, they are extremely important demand for rare metals. A 2011 where civil wars have been raging for for the production of future E.U. study concluded that the years. In other cases, government technologies. This is why companies development of alternative policies can artificially limit supply. and governments are increasingly might suffer if member states ran For instance, in recent years China trying to recycle old cell phones and short of special metals. The heavy has reduced the export of rare other high-tech scrap. metal indium, for example, is not only earths. “Among other reasons, the The matter is even being a basic component of modern flat Chinese government did this in an discussed at the highest political screens and lasers, but also of solar attempt to force companies to shift levels. Last year the European panels. As the market for new production into their country,” Commission presented a “roadmap technology will grow in the long term, explains Dr. Hubertus Bardt, an to a resource-efficient Europe”, which so too will the demand for rare expert on natural resources at the outlined ways for industry and special metals, which the production Cologne Institute for Economic business to increase resource of so many cutting edge products Research, a non-governmental think efficiency by 2020, with one of the relies upon. tank in Germany. proposed strategies being metal Limited supply of rare metals has recycling. And two years ago, Rainer Small quantities, huge impact pushed companies and researchers Brüderle, then German Minister of Depending on the metal, the amounts to look for solutions. Australia will Economics and Technology, stated being used can be surprisingly soon begin producing rare earths at a raw materials congress of the small. Whereas in 2011 the world from local mines. In California, the Federation of German Industries production of copper amounted Mountain Pass Mine is reopening. (BDI): “Recycling is the most important to a total of 17 million metric tons, Many industrial companies are domestic source of raw materials.” in contrast, the yearly output revising their processes to make Recycling is now recognized as of indium could be pressed into better use of their stock of scarce an important contribution to meeting a cube with an edge length of just materials. Japanese universities are future demand for rare metals. This is 56 centimeters (1.8 feet). looking for materials that could particularly the case for industrial Although the quantities consumed replace rare metals. >> nations with few natural resources, seem small, the scarcity of special such as Germany and Japan, which metals – especially the rare earths –

Recycling is the most important

Hatsune Miku is a virtual character that performs songs created by domestic source of raw materials. users of a music software package. Rainer Brüderle, former German Minister of Economics and Technology

Creating Chemistry | 51 Feature: Resources, environment and climate

The secret value of landfill of valuable metals to be extracted Another valuable strategy is, of from it – but this seldom happens. course, recycling. The extraction According to UNEP, every year of materials from high-tech waste 40 billion metric tons of electronic is referred to as “urban mining.” scrap are thrown away. Only a tiny Whereas mass metals like lead or amount is recycled – in the case of aluminium are already recycled in cell phones, it is only 2% or 3%. The large quantities, rare metal recycling rest ends up in the waste stream; is is a nascent industry. “At the combined with other metals – a moment, almost no rare metals are process called – or recycled, but this is the goal we have shipped to developing countries, to set ourselves,” says Dr. Stefan where the regulations for disposing Gäth, Professor of of electronic waste are less strict. and environmental research at the According to experts, between 50% University of Giessen, Germany. and 80% of E.U. electrical scrap is A report published last year by exported to developing countries the United Nations Environment although the Basel Convention of Programme (UNEP) confirms Gäth’s 1989 forbids this practice. assessment. Among 37 special metals analyzed in the report, 32 The perils of backyard recycling had recycling rates close to zero. The illegal international electronic There are various reasons why scrap trade is responsible for these kinds of metals are not yet environmental pollution and can being widely recycled. Sometimes, cause health hazards for people in recycling companies face developing countries who dispose of technological problems. Whereas the waste. In addition, when recycling precious metal recycling is relatively is unregulated, it is often inefficient, easy, rare earths are hard to extract and metals are not recovered at from electronic scrap. Cost is another optimum rates. Experts estimate factor – and not just for rare earths: that, on average, developing world The energy required to recycle recyclers retrieve only 25% of the indium from screens, for example, is gold in old mobile phones. Modern enormous. And in the case of metals recycling processes increase the rate like wolfram, beryllium or gallium, to 95%. This is why, at the moment, the amount of metal being used in experts are discussing the high-tech products is so small that introduction of a cell phone Electrical waste is sorted recycling it would only make sense if deposit system. “This way, society before recycling. combined with the recycling of other would put a value on e-scrap and metals like copper or gold. In this create an incentive to bring mobile situation, rare metals are mere phones back to official collection company Siemens recycles indium (€65 million) to $155 million by-products of an extremely complex points,” says Gäth. from old X-ray machines. (€120 million), according to Gäth’s recycling chain. Worldwide, there are At the same time, some Maybe, one day, it could even estimates. At the moment, mining only a few recycling plants that are companies are developing their own be profitable to mine old landfill sites. landfill sites would still be too able to recycle rare metals this way systems to recover the treasures German waste management expert costly to make it worthwhile, but (see feature on pages 54 and 55). hidden in high-tech waste. Japanese Gäth has already carried out test Gäth believes that will change “The industry is only just beginning to car maker Honda has started drills in three closed trash dumps in as raw material prices continue realize the full potential of rare metal cooperating with partners to retrieve Germany. He found a wealth of scrap to increase: “I think this could be recycling – it’s a step by step rare metals from car batteries, while metal, including old vacuum cleaners the case sometime between 2025 process,” says Bardt. electronics manufacturer Hitachi has and disused cars. A garbage dump and 2040.” There are logistical challenges, too. announced plans to recycle rare in Hechingen, a small town in the Scrap needs to be taken to a modern earths from hard drive magnets. south-west of the country, contains recycling plant for the maximum levels Furthermore, German technology raw materials worth $84 million

Rare metals in modern technologies

Rechargeable batteries: Both electric cars Flat panel displays: Indium-based alloys are an production currently comes from China. and laptops need powerful batteries. In order ideal transparent conducting material for flat panel Its recyclability is limited. to produce these batteries, lithium and the heavy displays. Indium is one of the rarest raw materials metal cobalt are often used. 40% of cobalt on Earth. Reserves could run out in 2020 – Fiber-optic cables: Manufacturers of originates from the Democratic Republic of especially because this metal is difficult to replace fiber-optic cables are dependent on the supply the Congo, where civil wars have been raging and its recycling quota is low. Zinc, copper and of germanium, which is also used in infrared for years. lead mines produce small amounts of indium. devices. The metal is a by-product in copper, lead and zinc mining. Demand in Europe could Turbines: High-tech turbines are not only used Thin-film photovoltaic cells: Many rare metals rise by 250% by 2030. However, germanium for airplanes, but also for power stations. The rare are needed for producing these photovoltaic cells, reserves are expected to last just 17 years at element rhenium helps to make them resistant including cadmium, germanium, indium and current rates of production. to heat and corrosion. Rhenium is a mining gallium. Gallium is also used in other by-product, and the major exporter is Chile. semiconductor products. It is a by-product of The metal is easy to recycle. refining bauxite and about 75% of worldwide

52 | Creating Chemistry Municipal recycling concepts

In 2009, each citizen of the European Union waste disposal program in 1991. Because (E.U.) produced an average of 510 kilograms garbage trucks were not able to access the small of household waste. However, in the United lanes of local favelas, the city started a barter States this figure was even higher, with program: garbage for food. Every two weeks at 61 every citizen producing 720 kilograms on designated places in the city, locals can exchange average. Given the growing mountains of four kilograms of recyclable materials for one trash, many municipalities have to come kilogram of food. Depending on the season, up with solutions for how to deal with citizens are also able to swap their garbage for household waste. school materials or plants. In the United States, San Francisco leads the Several E.U. member states have introduced way in terms of recycling. In 2009, the mayor waste separation systems since the 1990s, started a waste separation system similar to those becoming role models for municipalities around found in Europe. Now, only 22% of household the world. A number of E.U. directives have waste ends up in the landfill – one of the lowest also led to increasing recycling rates across rates in the country. The city plans to recover all Europe, although statistics still vary widely its household waste by 2020. between countries. A European model of how to deal with household trash is found in Amsterdam, the Netherlands. The city burns 99% of its household and industrial waste and uses the energy produced to generate electricity for the local In 2009, each public transport system, street lights and for 75% of all households. In addition, the residual heat citizen of the from incineration is used to provide heat for 12,000 households. Metals like iron, copper and United States aluminium are collected and sold, while the rest of the waste is used as construction materials produced an for roads. Communities in emerging markets often average of cannot afford this kind of investment in recycling technology, but some have come up with 720 kilograms of innovations of their own. The Brazilian city of Curitiba, for example, introduced a revolutionary household waste. Precious metals from ceramic auto catalysts

Catalyst ground Extraction into powder Consignment Catalysts De-canning of catalyst weighed

Blending Processing and sampling and refining Optimum batch Smelting Refining size for smelting There are currently more than half a accumulated billion cars on the roads worldwide, plus around 200 million trucks. Their catalysts contain valuable precious metals like platinum, palladium and rhodium. They help to eliminate engine emissions such as carbon monoxide. The recycling of spent automotive 45 46 78 Kg Consignment weighed catalysts is a complex process Analysis Sample sent that enables the re-use of their for analysis Rh Pd Pt precious metals. BASF operates a Kg Rhodium Palladium Platinum plant that can recycle these catalysts Report of analysis in Cinderford, in the United Kingdom and value of batch Catalyst grade material for sale (see story on pages 54-55). relayed to client to customers

Creating Chemistry | 53 Feature: Resources, environment and climate

Garbage is good

Supplies of precious metals are dwindling, while both prices and demand for them are expected to continue to rise over time. BASF relies on an environmentally friendly process to recycle precious metals from ‘end-of-life’ materials – mostly spent automotive catalytic converters and electronic scrap materials. These ‘throw-away’ items contain significant amounts of recoverable, valuable metals. Recently BASF invested approximately $4.9 million in building a state-of-the- art recycling operation for the recovery of precious metals from industrial scrap materials in the United Kingdom.

well established The future of the plant can be tradition of recycling found in a factory hall behind the precious metals can main building. Since last year, the be found in the small space has been occupied by a highly English town of efficient industrial shredding machine Cinderford, located that looks like a giant slide connected in GloucestershireA on the border to a huge metallic silo. Sitting next to of Wales and England. The recycling the machine is a truckload of raw of valuable metals from a variety of material: ceramic substrates sources has been going on here recovered from spent catalytic since the 1960s. The BASF Metals converters. The substrates are fed Recycling plant, part of the into the machine, which grinds them company’s global network of into a fine white powder that is loaded precious metals recycling and into large white sacks that are refining operations, now serves subsequently stacked on nearby as its European hub for recycling shelves. “The powder is later fed into catalytic converters. a high-temperature , which breaks down the metals it contains,” explains Dr. John Setchfield, site manager. The heaviest materials of the mixture are the platinum- group metals, which concentrate at the bottom. These melted precious metals can then be removed by tapping into the base of the furnace. Above Dr. John Setchfield has worked at the Cinderford site for half of his life.

We want to considerably expand our catalyst recycling operations in Europe, which is why we have made such a significant investment here. The melts operator is making flux additions during the melting of sampled material. Dr. John Setchfield, site manager of the BASF Metals Recycling plant in Cinderford, U.K. The melting serves to ascertain the precious metal content of a scrap metal delivery.

54 | Creating Chemistry Left Too valuable for the garbage: There are many hidden precious metals in electrical waste.

Below These copper collection discs are prepared for the precious metal analysis. The laboratory in Cinderford evaluates thousands of samples every year.

To find out more, visit: www.catalysts.basf.com

Beneficial metals Shanghai/China, Lincoln Park/ the air,” says Setchfield. “In fact, it Catalysts, especially automotive Michigan and Seneca/South would take 100 modern vehicles, catalysts like those being processed Carolina. The refining of materials equipped with BASF emissions in Cinderford, contain valuable primarily takes place in Seneca, control solutions, to equal the precious metals which help to where BASF operates a large furnace pollution put out by just one vehicle eliminate engine emissions such as designed for precious metals recycling. produced prior to 1974. Platinum, carbon monoxide. Most of the metals “We want to considerably expand palladium and rhodium are the key recycled in the plant will ultimately our catalyst recycling operations in components that make catalytic be used to support BASF’s mobile Europe, which is why we have made emissions control systems work – so emissions catalysts business. The such a significant investment here,” those are the metals we are focused business develops and markets a says Setchfield. on recovering here in Cinderford.” wide range of emissions reduction This year, the plant in Cinderford As global automotive production technology for motor vehicles. will celebrate its 50th anniversary. continues to grow, and emissions BASF Metals Recycling is a Setchfield has seen how the recycling regulations become increasingly service provider for other businesses business has changed over the years: stringent, the need for these valuable whose scrap is bought by the from the manual melting down of old precious metals will increase. By company at world market prices and jewelry to the state-of-the-art recycling these limited resources, then processed. It buys scrap from recycling of catalysts and electronic BASF is helping to ensure a reliable, other businesses at world market scrap materials. Before Cinderford secondary source of precious metal prices and then processes it. became part of BASF, the site supply, leveraging the already mined A majority of its customers are was owned by the U.S. chemical and recoverable reserves that exist in industrial scrap dealers that company Engelhard. scrap materials. disassemble old cars or collect In 2011, BASF more than doubled At present, Cinderford’s facility for household electronic waste such the local operating footprint and the ceramic catalyst process does as personal computers and TVs. manufacturing capacity to enhance not even cover half of the 5,000 the existing Cinderford site. square meter (about 54,000 square The facility’s brain foot) factory hall. But there is a reason “One of the specialties of our plant is Successful pioneers Setchfield has left all this space that we not only process industrial “Engelhard, which was acquired unoccupied: “Next year we want to scrap, we analyze it at the same by BASF in 2006, invented the install a new process here for the time,” says Setchfield as he enters the automotive catalytic converter nearly recycling of electrical waste,” he says. laboratory, which is located on the 40 years ago. Since that time, the He still has a lot in store for the plant second floor of the main building. emissions control solutions of to ensure that it continues to make It is here that employees test batches Engelhard and BASF have prevented history. of precious metals ranging from more than one billion metric tons of platinum, palladium and rhodium pollutants from being released into to gold and silver. Given its role, the laboratory is considered the ‘brain’ of the Cinderford facility. When scrap is delivered to the facility, Cinderford site employees weigh it and take a small sample to ascertain the precious metal content and to estimate the value of the load. Each sample is melted and melded with liquid copper, cooled and then cut into small solid discs, ready for analysis in the laboratory. “Every sample is tested a number of times to avoid deviations,” explains Laboratory Supervisor Ben Hillary. Each year the laboratory evaluates thousands of samples. The Cinderford site is part of a global network of multiple BASF sites that engage in the recycling and refining of industrial scrap materials, including sister plants in Rome/Italia,

Creating Chemistry | 55 Invention

Pioneering thinker – Then Justus von Liebig

oday he is known as the founder of organic chemistry (see box on page 57), but initially it did not seem like Justus von Liebig – born in Darmstadt, Germany, in 1803 – would have such a remarkable career.T Due to poor grades, he was thrown out of school without graduating. He then began an apprenticeship as a pharmacist, but this also ended quickly when an experiment with silver fulminate nearly blew the roof off the laboratory and Liebig was let go. Nevertheless, chemistry remained his passion, and became his life. He studied the subject in Bonn, Erlangen and Paris, and his work on fulminic acid brought him such acclaim that renowned natural scientist Alexander Justus von Liebig examined and noted von Humboldt expressly recommended him for a the molecular compounds of hundreds professorship to the Grand Duke of Hesse. At of plants and animals. Using this information, he created the 21 years of age, he was appointed as a professor classification system of organic of chemistry in Giessen. He went on to become chemistry and discovered principles the greatest chemist of his era and his laboratory that still influence our lives today. became the birthplace of modern chemistry. In this laboratory, Liebig laid the foundations of knowledge crucial to chemistry today with the development of elementary analysis and the identification of carbon and in organic compounds. His inventive nature was a huge help in this work; he used a glass “five-bulb apparatus” to enable the rapid and reliable capture and weighing of carbon dioxide. Liebig and his students employed the device to examine the molecular composition of hundreds of plants and animals. Through this work, Liebig established the systematics of organic chemistry. He also identified chloroform and the aldehyde group as organic compounds – one of the most important classes of compounds in organic chemistry. Liebig did much more than revolutionize our understanding of chemical relationships; we can also thank the self-taught German for a number of practical discoveries, including many world firsts: baking powder, baby formula that could replace breast milk, chemical fertilizer and “Extract of Meat” – the first ever bouillon cube. Above Another invention from Justus von Above The “five-bulb apparatus” is made out of the finest glass and is filled with concentrated Liebig: His “Extract of Meat” was the potassium hydroxide. In a short period of time it collects carbon dioxide created during world’s first bouillon cube. combustion so that it can be weighed on an analytical balance. With this invention, Justus von Liebig revolutionized elementary analysis.

56 | Creating Chemistry o this day, Japanese chemist Professor at Japan’s Yamagata University, he Professor Dr. Junji Kido is driven by immediately began working on OLEDs. A little luck Pioneering the same curiosity that characterized played a key role, as he explains: “While we were his visits as a boy to his father’s working on existing polymer-based organic plastics factory. In his organic light-emitting diodes, we inadvertently created thinker – chemistry research, he is fascinated white OLEDs.” Rather than the expected red light, byT one idea in particular – creating things that have Kido and his colleagues saw a white light where never existed. He has done exactly this by inventing they had applied orange coloring to a blue Now the white OLED (organic light-emitting diode, polymer. He realized that the color of the light see feature on pages 36-41). Before his discovery, came down to the concentration of the coloring. Junji Kido only colored OLEDs existed, which were used To move his discovery out of the lab and on to the in car radios and cell phones, though not in market, he co-founded the lighting firm Lumiotec, lighting technology. which launched the first mass-produced OLED While studying for his doctorate at the worldwide in 2011. Polytechnic Institute of Brooklyn (now known as The multitalented innovator feels a close the Polytechnic Institute of New York University), connection with the founding fathers of organic he found a way to make illuminating plastics in his chemistry, particularly Justus von Liebig. After all, laboratory. Kido comments, “I was sure that this it was the method that Liebig developed to identify could be a groundbreaking discovery if I could just carbon and hydrogen in organic compounds that use it to make organic light-emitting diodes. These enabled Kido and his team to create high- could then replace traditional light sources.” performance semiconductors and over 1,000 In 1989, when he was named Assistant different materials for carbon-based OLEDs.

I was sure that this could be a groundbreaking discovery. Professor Dr. Junji Kido, Professor at Yamagata University in Japan

Organic chemistry

Organic chemistry studies the structure, composition and reactions of carbon-based compounds. These compounds may contain any number of other elements, including hydrogen, nitrogen, oxygen and sulfur. Today, scientists are aware of more than 15 million organic compounds. Carbon-based compounds form the basis of almost every life form. They are also used in a wide range of applications; the compounds form a key component of drugs, plastics, synthetic fibers, paints and foods. You can see their effects with the naked eye at breakfast time: If With his invention of the white organic light-emitting diode (OLED), bread is left to toast too long, it turns black – Professor Dr. Junji Kido is following this burning is a clear indicator of the presence in the footsteps of Justus von Liebig, of carbon compounds. the founder of organic chemistry.

Creating Chemistry | 57 Ingenuity Chemistry around us

Tip:

Non-iron shirts are best left to drip-dry on a coat hanger. They should then be ready to wear – if any small creases remain, they will smooth out with the effect of the wearer’s body heat. What makes a non-iron shirt stay crease-free?

Very few people actually enjoy ironing. But how stabilize the cotton and prevent the fibers from exactly do non-iron textiles maintain their shape, swelling up and creasing. and prevent creasing? Ordinarily, cotton fibers These materials do not need to be ironed – To find out more, visit: swell during washing and fail to regain their prior this saves energy and helps protect the www.basf.com/performance-chemicals form once dry. This is what causes fabric to look environment. An added bonus of this technology www.intermediates.basf.com/chemicals/glyoxal wrinkled. Non-iron materials, however, are treated is that treated cotton dries faster because it with special products known as binders that absorbs less water.

58 | Creating Chemistry subscription to www.basf.com/creatingchemistryIf you would like a free you can register online at

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