Elements #53, Issue 4

BIOCATALYSIS: MORE BIO REACTION TECHNOLOGY: IN PRODUCTION NETWORKS GOING MOBILE WITH MICRO

ELEMENTSDECEMBER 2015 # 53

DATA STREAMS: BIG DATA MEANS BIG BUSINESS * ELEMENTS #53 DECEMBER 2015

THE INNOVATION MAGAZINE Farbprofil: 14359-02-452-1-3 in the future at at future the in us Visit partnership. lasting asuccessful, for way the paving customers, our for markets new up opens that force driving a is unit, innovation strategic our Creavis, devices. medical solutions for to tomorrow – construction from lightweight develop to know-how their on draw experts impassioned Our Germany. from group industrial creative the is Evonik ISO Coated v2-300 (ECI) (CMYK) v2-300 (ECI) (CMYK) Coated ISO

| Kunde: www.creavis.com. Evonik Evonik | Motiv: Creavis, Ideen Yoga, englisch, weltweit weltweit Yoga, englisch, Ideen Creavis, | Evonik Magazin, U2, englische Ausgabe, 3 mm Bundzugabe rechts rechts Bundzugabe 3mm Ausgabe, U2, englische Magazin, Titel: Evonik

| Format: 230 x 300 mm mm x300 230 in in of themasters yoga of ideas: on the future are Our experts 58 | Beschnitt: exercises to the solution. best | Bearbeitet: 3mm marcoreuke marcoreuke | Stand: 02.02.2015

www.evonik.com EDITORIAL www.evonik.com

Fundamental

Undertake more partnerships, communicate Process optimization through openly—according to an innovation study com- Big Data Page 04 missioned by VCI, these are the key elements that Dr. Ulrich Küsthardt pave the way to innovation. This is based on the Chief Innovation knowledge that innovation is a complex process Officer, CONTENTS Evonik Industries AG that runs in parallel, interrelated steps. Above all, ulrich.kuesthardt optimizing the process also means dealing with @evonik.com 04 Digital Intelligence Big Data analysis is the interface between business and science. This a new tool for process is why we seek to work closely with universities, optimization research institutes, and industry partners: to 12 Biocatalysis reach the goal faster together. Some examples in- New enzyme system enables clude our collaboration with Fraunhofer ICT-IMM access to 1-alkenes in Mainz (starting on p. 22) and our latest venture 15 Guest Commentary capital investment in Airborne Oil & Gas (p. 30). Prof. Harald Gröger on the potential of biocatalysis for Such partnerships also include open dialogue. basic and bulk chemicals Thirteen years ago, we launched the elements 16 Acetone from Waste Gas magazine to keep the scientific community, in

How bacteria convert CO2 particular, up to date on our innovation activ- into valuable raw materials ities and support our dialogue with scientists. 22 Small Production Plants The offer was well received, as our reader survey Small-scale chemistry from fall 2014 revealed. The positive results of the 03 opens up the potential of microreaction technology survey encouraged us to continue to refine the content and, especially, the look of elements. 26 Catalyzing Change Changing energy markets The central mission of the magazine, the pre- offer new opportunities for sentation of our innovation projects, has not catalyst development changed. But we have added a few new features, 34 Evonik Innovation Award including the guest commentary, where we in- 2015 vite university researchers to present their views The finalists on research trends.

10 Data Mining The finished product raises the same sort of Smart processes question as a new development: Will it persuade 20 Corporate Foresight the market—or, in this case, the reader? Tell us Soft robotics what you think. Let us know what you especially Our experts on the future are 29 CompanyNews 32 Professionals Dr. Jens Busse like or do not like at all. This is the only way we masters of the yoga of ideas: 38 Wishlist can improve ourselves and the magazine, and in 58 exercises to the best solution. Prof. Renée Schroeder have a dialogue with you. For us, that is funda- 39 Book Tips / Masthead mental.

Evonik is the creative industrial group from Germany. Our impassioned experts draw on their know-how to develop solutions for tomorrow – from lightweight construction to medical devices. Creavis, our strategic innovation unit, is a driving force that opens up new markets for our customers, paving the way for a successful, lasting partnership. Visit us in the future at www.creavis.com. Feedback Tell us your Dr. Jens Busse keeps entering new opinion of the territory—it’s his job. Page 32 new elements:

Cover and back cover: Maximus Chatsky Photography: Dirk Bannert / Evonik, Stefan Wildhirt Bannert Dirk Stefan / Evonik / Evonik, Chatsky Maximus Photography: cover: and back Cover [email protected]

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE

04 Illustration: Maximus Chatsky Maximus Illustration:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIG DATA BIG DATA MEANS BIG BUSINESS Data are the crude oil of the 21st century—but only if they are saved across the board and used productively. An interdisciplinary Evonik team has begun tapping into big data as a new digital process optimization tool.

Dr. Kai Dadhe ardly anyone would contest mation. The importance of big data simply the notion that everything cannot be emphasized enough. that can be digitized will be Most companies are fully aware of the digitized. And sooner or lat- significance and potential of digitization. er, that will cause the degree The actual challenge here is to make selec- of digitization to increase in tive use of this wealth of data for the classic the manufacturing sector. This applies both purposes of a manufacturing organization: Hto the horizontal supply chain between sup- for increasing productivity, optimizing pliers, production, and customers, as well as processes, and becoming more efficient. to the vertical supply chain along the vari- Even though the flow of data is constantly ous divisions within a company, from Pro- growing in many companies, only a small curement and Logistics to Sales and Mar- portion of that data is actually used. keting. Digitization is likewise in its infancy in Digital intelligence is everywhere to- the chemical industry. The reason is that Plants create a continuously day—every component, device, and module developing and improving processes and growing data stream. If they are used in the right way, it is yields more data than its predecessor, and methods is necessarily slower in the pro- possible to manage processes company employees and processes generate cessing industry, where cycle times are even more efficiently. a steadily growing wealth of digital infor- far longer than they are in the IT, tele-

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIG DATA

Digital information is a new, rich resource for future process optimization. Nevertheless, experience and expertise will remain as important as ever.

By comparing digital information with expert knowledge, pure data is turned into a profitable tool.

communications, and service sectors. ply chains unless we see the puzzle in its individual piece of equipment. Managing Nevertheless, given changing markets, entirety. and analyzing operating conditions foster growing customer expectations, and rising The future of the chemical industry will reliability and transparency. Digital intel- energy and raw materials costs, the chem- not include big business unless we optimize ligence also benefits areas outside of pro- ical industry simply cannot avoid the job of our use of digital intelligence. The words duction: Big data can be used, for instance, utilizing big data. “big data,” however, are often met with res- for simulating profit margins as a function Even before the era of fast-paced digitiza- ervations or even fear. Does this mean peo- of the cost of raw materials. And analyzing tion, chemical companies had always sought ple will become irrelevant? Are computers databases intelligently allows companies to keep their production state-of-the-art. taking over? What does big data actually to accelerate patent and market research, Evonik has been continuously optimizing its mean for production? estimate the volatility of individual mar- methods and processes and adapting them kets more accurately, and react to market to new demands for a very long time. Cost Big data couples human changes more quickly. and energy efficiency are among the most and digital intelligence important goals of each individual plant, Big numbers like terabytes, petabytes, and Turning data and innovations form a solid foundation for exabytes are not the issue here. Big data into practical tools 06 competitive, sustainable operations. does not mean that digital intelligence will Integrating digital intelligence is compara- Yet the tools we have been using for opti- one day be making decisions about process- ble to a technological evolutionary process mizing processes and increasing efficiency es and work sequences, or that each indi- in which certain basic prerequisites must are reaching their limits. There are several vidual employee will be his or her own IT be met. The company needs a certain infra- reasons for this. For one thing, improve- and statistics expert. Digital information structure, for example, if it is going to make ments traditionally focus on an individual instead represents a rich new resource for use of all of the available data. What is help- process step or subprocess. The way these future process optimization. ful here is that the large amounts of memory relate to upstream and downstream links in It will not be the only resource, howev- and the enormous computing power that are the supply chain is often obscured or only er: Experience and expertise will remain as needed are economically feasible today. All partly taken into consideration. important as ever. In the future, human and of the necessary tools are already on hand as digital intelligence will complement each well, with distributed computing and hori- Classic process optimization other and be closely intertwined. Compar- zontally scaled databases now routine, and is reaching its limits ing digital information with existing pro- parallel algorithms making modern data This is compounded by the fact that although cess knowledge and expertise will turn raw organization and communication possible. the digital information needed for optimiz- data into practical, profitable tools. In other This is not just about the tools, howev- ing processes may, in fact, be available in words, big data means using modern meth- er. Visualization is crucially important as isolated data silos, linking and networking ods and technologies to carry out all-en- well—if you don’t understand your com- these silos together remains difficult and compassing, interdisciplinary optimization puter, you won’t work with it. In their day- fraught with obstacles. Much of the digital programs aimed at enhancing value. to-day jobs, each and every employee must information available today is lost because it What does that mean in actual practice? be able to make intuitive sense out of the simply cannot be saved. If nothing else, data Big data can produce benefits in all areas of information, charts, and diagrams gen- usually have to be processed and analyzed the supply chain—benefits that are espe- erated from the data and to make the right by hand—a slow, complex process subject cially important in day-to-day production. decisions. Although it is indispensable, this to error. The result? Our view of the overall Today’s modern sensors, flow meters, and process of translating raw data into every- production process is obscured, preventing motors, for instance, deliver more than just day language also represents a challenge us from recognizing optimization potential standard data—they also provide continu- that we cannot afford to underestimate. and capitalizing on improved efficiency. ous reports on performance problems, fluc- Meeting that challenge requires more This list of shortcomings also contains the tuating operating parameters, and commu- than just specific IT tools—above all, it re- key to the solution, however: Collecting, nication errors. quires an understanding of day-to-day filtering, processing, and linking all of the Collecting, storing, and strategically us- processes. What are the problems that arise available digital information will give rise ing all of this information make operations with a given process? Where are its weak to a uniform language for the entire system. more efficient, allow personnel to identify spots? Where can digital intelligence be ap- Just as only a few puzzle pieces reveal very operating conditions with greater precision, plied to improve the situation? The end re- little about the entire picture, we cannot and make error analyses simpler and more sults are practical, customized tools that do tap into new opportunities for interdisci- accurate. Another advantage is the ability more than just make operations more effi- plinary, strategic optimization of our sup- to adapt repairs and maintenance for each cient and reliable—contrary to many ex-

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIG DATA

07 Illustration: Maximus Chatsky Maximus Illustration:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIG DATA

Performance Materials has done away with data silos and combined digital information from different sources. This is the basis for optimizing production processes, maintenance proce- dures, and energy and raw materials usage as well as for identifying sources of errors quickly.

BIG DATA IN THE REAL WORLD: PROCESS OPTIMIZATION AT THE TOUCH OF A BUTTON How much energy is my process using right now? Is catalyst activity still at the optimal level? Are all of my machines working smoothly? These are questions that crop up every day in production. Big data should help to provide answers more quickly.

It is not always that easy to know whether a process is already run- of the project is twofold: implementing predictive maintenance and 08 ning optimally. Determining the corresponding parameters can be addressing concrete process issues. very time-consuming. Traditional processes, after all, are generally based on predefined schedules and a great deal of empirical data. Underlying the issue of predictive maintenance is the question of This is why, for instance, equipment maintenance is usually per- whether digital intelligence can be used successfully to create more formed in defined cycles, why catalysts are refreshed according to efficient and flexible maintenance and repair routines for specific fixed schedules, and why the consumption of energy and raw materi- machines. Production operations to date have shown these machines als is only monitored at long intervals. to be particularly susceptible to material deposits, which have a negative impact on process efficiency and are associated with increased But we can do much more than this if we use all of the digital infor- repair work. By using and analyzing all of the digital measurement mation available: We can manage and monitor processes the ideal data available, the team hopes to explain how the deposits arise in way every time, using all of the digital information available to selec- the first place, what process parameters encourage their formation, tively optimize important parameters. This approach yields snapshots and how they can be reduced. The objective is to develop suitable that focus on individual machines and record the flow of energy and maintenance tools that will minimize this negative influencing factor electricity at every second along the way. Digital intelligence even and save money. delivers forecasts that show how a reaction is going to proceed or indicate the exact moment when equipment or components will need The second subproject focuses on undesirable fluctuations affecting to be repaired or replaced. a specific material property in a large-scale technical process—a phenomenon that frequently arises in chemical production. Here the Over the past few years, Evonik’s Performance Intermediates Busi- team hopes to use big data to clarify why this parameter varies and ness Line has begun studying the advantages of using big data to which preceding process step is responsible. Could it be the result of address specific issues. The business line used process engineering fluctuations in the composition of precursors or intermediates? These applications to demonstrate how energy consumption can be mark- studies clearly demonstrate that finding errors and sources of error edly reduced. Digital data can also provide clear information about quickly and with certainty means having to look at the entire supply the exact point at which a catalyst needs to be replaced and can even chain. provide a basis for calculating the financial losses associated with a momentary loss in selectivity. The pilot project is pursuing multiple objectives. Existing data can be used as a tool for validating or refuting expert hypotheses regarding These initial steps are now being followed by a tremendous leap: the sources of error. Employees are learning to identify cause-effect This summer the business line teamed up with the Process Tech- relationships within a complex digital space and to apply that knowl- nology & Engineering Business Line (part of Technology & Infra- edge to real-life production issues. In other words, they are learn- structure) and Evonik’s Global IT & Processes Department to pursue ing to use and to trust data. If the project is successful in its aim of a project aimed at taking a more detailed look at the potential that improving efficiency and system availability while ensuring product digital information holds for defined production processes. The characteristics, the benefits will extend beyond the directly affected project explores how to use big data for optimizing processes from area of the company. Success will instead confirm that the tremen- the technical, methodological, and business perspectives, incorpo- dous potential that big data holds for the entire supply chain is more rating expertise from throughout the entire company. The objective than just theory.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIG DATA

Companies that utilize big data for their own ends are readying themselves for the questions and challenges of the future.

Big data analysis pectations, they also frequently simplify new digital tools for process optimization, The Expert in plant operation processes as well. The Performance Mate- and that this opens up the door to ideas and rials Segment has already had some initial suggestions that were previously impossi- experience with a few of these evolutionary ble. After all, the value of this approach is steps through its Performance Intermediates obvious to everyone: It allows the company Business Line. Various optimization projects to dispense with activities that are of little related closely to production have opened use and that create little value, freeing up up data silos, merging the resulting digital employees to pursue new tasks and more Benefits Transparency and information and correlating this informa- complex issues. It also prompts people to Dr. Kai Dadhe heads greater insight, fast tion in context. Because the latter is such an consider their own work from a whole new the Manufacturing 09 solutions to special important step, the business line developed perspective and adapt it to the challenges Intelligence Group in the Performance problems, fast what is known as a context model. A context that lie ahead. decisions, greater Intermediates Business efficiency, and cost model is a modeling blueprint that defines a The ultimate aim is to create an inter- Line, with a focus on optimization. logical way of merging data from different disciplinary analytical culture that links process management, areas, making the information usable for process, IT, business, and method exper- process information management, and op- specific issues. This model (for which a pat- tise into a highly interconnected network. timization. The group ent application has since been filed) allows Ideally, if we generate the company’s own takes a holistic ap- us to untangle the Babel-like chaos of data, big data expertise, exploiting digital intel- proach to technical as creating the possibility of querying certain ligence for day-to-day business will simply well as work processes, data quickly and easily and developing im- be the obvious course. The world of data is using modern methods and systems. portant process KPIs. dominated by a fast, dynamic pace. In a cer- Prerequisite [email protected] Big data analysis is tain sense, that also applies to implementa- more than IT: The re- Digital intelligence is tion—if you want to have a hand in setting quirements come from becoming a trusted partner the pace of the digital revolution and help operating activities. Big data is a completely new challenge for guide its development, you have to start Methodological and technical conditions the processing industry, with many ques- early to make strategic use of big data for must also be in place tions remaining open: What is an acceptable your own purposes. and the employees degree of transparency? Who should have Channeling the flood of data into an or- must be trained. access to which (previously classified) in- dered flow of information, turning that formation? Different types of expertise have wealth of data into practical tools, and cre- to be bundled in just the right way—how do ating a solid foundation for the changes that we do that? need to take place in work and organiza- What is clear about big data is that it tional processes—these abilities are simply changes the way individual parts of the a matter of being ready for the future. Be- company deal with data, makes digital in- sides enhancing productivity, processes, Objective formation more important, incorporates and performance, the impact of these com- All employees have at this information in every decision-making petencies outside of the company should not hand, at any time of process, and blurs the boundaries between be underestimated: Companies that utilize day, all the information they need to act disciplines and divisions within the com- big data for their own ends prove to be inno- optimally. The data for pany—it’s a challenge for everyone, in other vative employers, they ensure their techno- this is automatically words, and one that requires professional logical leadership, and they cement the trust prepared in graphic moderation and support. of their suppliers, customers, and partners. form so that it can be quickly understood. Based on the initial experience in Perfor- Most of all, however, these companies are mance Intermediates, we already know that readying themselves for the questions and

Illustration: Maximus Chatsky Photography: Evonik Chatsky Maximus Illustration: Photography: employees are extremely interested in using challenges of the future.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIG DATA GLOBAL CHALLENGES: BIG DATA

Sources: Studies by Boston Consulting Group, PricewaterhouseCoopers, Roland Berger Strategy Consultants, and Deloitte

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE

EV_E053_EN_1011_DataMining [e].indd 10 01.12.15 14:24 GLOBAL CHALLENGES: BIG DATA GLOBAL CHALLENGES: BIG DATA

DATA MINING Smart Processes Industry 4.0, Big Data, digitization, and the Internet of Things—behind these buzzwords is the ongoing process of networking human beings and machines and the desire to improve our ability to understand and predict the behavior of complex systems by analyzing gigantic volumes of data. These trends oﬀer industry the opportunity to design business and production processes more intelligently. As a result, the worlds of IT and business are increasingly merging. But what exactly does this mean? Here’s an assessment of the current situation.

11 Photography: Jetta Productions/Blend Images/Corbis Illustration: C3 Visual Lab Illustration: Jetta Images/Corbis Productions/Blend Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE

EV_E053_EN_1011_DataMining [e].indd 11 01.12.15 14:25 GLOBAL CHALLENGES: BIOCATALYSIS

With the help of a new enzyme system, Evonik can convert short-chain fatty acids to 1-alkenes. Now experts are working on transferring the enzyme system into living cells—for example Escherichia coli.

MORE BIO IN CHEMICAL 12 PRODUCTION NETWORKS Industry thrives on networks: Carefully devised integrated production sites ensure that production processes benefit from one another. These syner- gies create efficient value-added chains. The goal of Evonik researchers is to integrate biotechnological processes into this established system as seam- lessly as possible. Now they have established the basis for a biocatalytic process that can be used to obtain an important chemical intermediate.

ELEMENTSELEMENTS #000 #53 DAS THE INNOVATIONSMAGAZIN EVONIK INNOVATION MAGAZINE VON EVONIK GLOBAL CHALLENGES: BIOCATALYSIS

r g a C Schematic of a biorefinery n S A i S R c B A O that intelligently links w s M N l a a s O i chemistry and biology. I r te D B e m IO t a a Source: Biokatalyse 2021, t X m e r e Clustermagazin, Issue No. 2 ia Energy and I t ls D s CO2 E a (ﬁne) chemicals w ic n from wood a als rg eri o at In m f useful pla ste types o nts/Bio a New mass w ic n a g ional useful plants/ r nvent Biom o Co ass n I

S Fuels/energy/heat R L ec and new types yc A P li I ng R R of products O E A w T g D a r A s ic ls U t u e l e C M m t fu u l T E a ra si te l s S T r o MARKET S ia F A ls W

Landﬁll

Markets and consumers

Dr. Thomas Haas ithout crude oil, the Evonik, however, it is not just about switch- Figure 1. Focus on sustainability modern world would ing to biotechnological processes to produce come to a halt. But it established products. The experts have also A main focus of research at Evonik is biotechnolog- is not only our mo- set themselves the goal of integrating these ically utilizing third-generation raw materials. bility and energy processes and their intermediate products supply that need based on sustainable raw materials into the Raw materials Biotechnology “black gold”: The chemical industry also re- integrated production networks. Only then Wlies on secure sources of oil. Plastics, med- will it be possible to harness fossil and bio- Vegetable oils First Wheat Direct icines, coatings, paints, textiles, and much genic raw material flows and thereby pre- generation Corn fermentation 13 more are all based on this fossil resource. In serve and expand the established, efficient Sugar order to produce this diverse range of prod- value-added chains of industry, as well as ucts through a variety of process routes, the chemical process expertise developed Residual biomass Lignocellulose Second from agriculture hydrolysis industrial plants need the molecular build- over many years, along with the existing in- generation and forestry Integrated ing blocks of petrochemicals—primarily frastructure. Whether raw materials, prod- fermentation hydrocarbons of various chain lengths. ucts or processes, only integrated concepts Municipal waste On the basis of these raw materials, the will make industrial sites successful on into Third Syngas chemical industry has built and established the future. Such networks enable us not only Plant residues generation Industrial waste fermentation highly efficient value-added chains and -in to profit from the advantages of biotechnol- gases tegrated production networks. What one ogy but to continue to operate existing inte- company generates as a by-product can often grated production sites. be used by another company as a raw mate- Many industrial products, such as poly- rial. And the unique thing about chemical ethylene and other plastics, are extremely production is that specialty chemicals are hard to produce on a completely biotechno- not produced in isolation from base mate- logical basis—intermediates along the way, rials; rather, the two are inseparably linked on the other hand, are not. The Evonik ex- acrylic acid, which is used in the production in production. This allows the realization perts track down these molecular interfaces of superabsorbers and methionine, which of valuable synergy effects that ultimate- and develop alternative processes based on plays a role in animal nutrition. Evonik sells ly make the integrated production network renewable raw materials. 1-butene as a raw material, but it is also used economical. Some key substances, for example, are by the Group to manufacture such products 1-alkenes, which are hydrocarbon chains as plasticizers. Intelligently linking with a terminal carbon-carbon double A team from Evonik’s innovation unit chemistry and biology bond. Evonik uses propene, for instance, as Creavis, working in cooperation with sci- Dwindling petroleum resources, climate the starting compound for the production of entists from the University of Graz, has

change, and CO2 debates, however, mean the chemical industry will be dependent on alternatives from renewable sources in the future. To prepare, Evonik is working on increasing the share of sustainable raw materials in its production processes. Bio- technological processes play a particularly No matter what we are dealing with—raw materials, important role in the preparation of bio- products or processes—only concepts that integrate mass. Here, microorganisms such as bacteria, fungi or special enzymes are respon- biotechnology into chemical production will make

Photography: Callista Images/Cultura/Corbis Illustration: C3 Visual Lab Illustration: Callista Images/Cultura/Corbis Photography: sible for the chemical conversion stages. At industrial sites profitable in the future.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIOCATALYSIS

production, which means taking another Figure 2. New enzyme system uses atmospheric oxygen long path in development and upscaling, this The oxidative decarboxylation of saturated fatty acids to 1-alkenes with the in vivo production offers a number of advan- OleT enzyme. By the method shown above, hydrogen peroxide is used to tages. Because the starting materials—the transform long-chained fatty acids (C12 to C20) into 1-alkenes. By the method short-chain fatty acids—are extremely small shown below, the newly developed enzyme system uses oxygen to decarbox- ylize fatty acids with a chain length of between 4 and 22 C atoms. molecules, they can easily pass through the membrane of bacteria. The new enzyme system helps the bacteria convert this start- O OleT ing material in their cells into the desired 1-alkenes. Owing to the high volatility of the OH + CO2 n n 1-alkenes, they can be easily extracted from n = 7–15 H O + 2 H+ 2 H O 2 2 2 the aqueous solution by creating a slight vac- uum. As a result, the 1-alkenes form a molecular O OleT interface and thus enable a biotechnological OH + CO synthesis route to be linked with the down- n n 2 n = 0–18 O + 2 H+ 2e– H O stream petrochemical process. With the help 2 2 O of Evonik’s new enzyme system, butyric CamB acid can now be converted into 1-propene, CamA OH n which is used to produce superabsorbers and OH O the animal feed additive methionine. Valer- NAD(P)H NAD(P)+ OH O ic acid offers access to 1-butene—and that, in Glucose n turn, opens up paths to C4 chemistry, which Formate OH involves compounds based on four carbon at- Phosphite n Dehydrogenase Side products oms. But biotechnological processes can also be coupled with an integrated production network through another raw material: syngas. Syngas consists of a mixture of carbon monoxide or carbon dioxide and hydrogen. It is produced from municipal or agricultur- al wastes, as well as industrial waste such as the flue gas from steel production. It has 14 now found biotechnological access to been used in chemical synthesis for decades, The Expert 1-alkenes. Their breakthrough is based on a as bacteria are able to make larger chemical known research method, which they refined. building blocks from the small gas molecules. Short-chained alkane acids, or saturated In laboratory experiments, Evonik re- fatty acids, which occur naturally during searchers have been able to get microorgan- anaerobic bacterial processes, served as isms to generate pure 2-hydroxyisobutyric A promising start: the starting material for the 1-alkenes. An Researchers at Creavis acid (2-HIBS for short), the basic component established enzyme system, the OleT P450 of PLEXIGLAS®. The short-chained fatty ac- were able to quan- Dr. Thomas Haas monooxygenase, was used to produce the titatively synthesize ids used here as raw materials are particular- heads the Science & desired 1-alkenes from the short-chained propene as well as ly easy to produce biotechnologically from Technology unit at 1-butene with OleT in Creavis, which com- fatty acids. This enzyme system catalyzes the laboratory. syngas. With the tests involving 2-HIBS, the corresponding chemical reaction—ox- Evonik has opened up another point of ac- bines the technological expertise of the stra- idative decarboxylation—extremely ef- cess to basic chemicals using syngas. tegic innovation unit in ficiently and substrate-specifically. This To intelligently connect biology and chem- industrial biotechnolo- selectively and quantitatively produces istry, Evonik is continuing its research into gy, chemistry, physics, propene or 1-butene. this “third generation” of biotechnology. The and engineering. In addition to the enzyme system, how goal of this third generation is not only to thomas.haas ever, the reaction also needs an oxidizing make syngas from sugar or vegetable waste @evonik.com agent. While hydrogen peroxide has been and use it as a raw material but also to make used up to now, it not only results in unwant- syngas from other types of waste materials, ed secondary reactions but it can also dam- such as municipal waste and industrial waste age the enzyme system. The team of Evonik gases. experts and scientists from the University of The approach will allow industry to be- Graz has found an ideal alternative: A cas- come less dependent on both fossil raw mate- cade of two other enzyme systems now en- rials and several renewables, because all ef- 1 “Oxidative Decar- sures that the electrons required for the re- forts to establish biotechnological routes and boxylation of Short- dox process are no longer absorbed by H O bring them to market maturity are linked Chain Fatty Acids to 2 2 1-Alkenes,” Angew. but by oxygen in the air. to the price of oil. “Black gold” remains Chem. Int. Ed 2015, the main raw material flowing through the 54, 8819-8822 Next step: Transfer to living cells veins of industrial operations. This is why it is To achieve this, the research team had to find even more important to retain the integrat- 2 M.A Rude, T.S. an enzyme combination that displayed opti- ed production networks and place them on Baron, S. Brubaker, mal interaction and compatibility. They met a broader foundation—in other words, en- M. Alibhai, S.B. Del Cardayre, A. Schirm- this objective in less than a year, and are now able the use of black and green raw material er, Appl. Environ. working on transferring the enzyme system sources, depending on economic conditions Microbiol. 2011, 77, to living cells. For later commercial-scale and the supply situation. 1718-1727

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIOCATALYSIS

Guest commentary Biocatalysis meets

Prof. Harald Gröger petrochemistry has held a Chair of Organic Chemistry at Bielefeld University since 2011. harald.groeger @uni-bielefeld.de

Prof. Harald Gröger iocatalytic processes, which in a more narrow sense include the conversion of chemicals in just a few defined steps using Bisolated enzymes or microorganisms containing “As biocatalysts, enzymes have such enzymes, are already widely used in indus- an enormous synthesis potential, trial chemical production. In particular, bioca- 15 talysis has already become firmly established in even for reactions with non-natural the fields of fine chemistry and pharmaceutical molecules.” active ingredients. along with high stability. Until recently, hardly Interestingly enough, many of the starting com- any production processes that meet these tech- pounds for these products are petrochemistry- nical requirements could be developed with the based chemicals that are then further “refined” enzymes available. in biocatalytic production processes. This under- scores the enormous synthetic potential of en- One of the exceptions, which also illustrates the zymes as “natural catalysts,” even for reactions potential of biocatalysis for the field of basic and with non-natural molecules. In the industrial bulk chemistry, is the enzymatic production of segments of pharmaceutical and fine chemical acrylamide on the scale of several tens of thou- products, with their complex target structures sands of metric tons. Because of the striking that require numerous individual steps to build, developments in molecular biology, with the one criteria for the success of biocatalysis is the construction of tailor-made enzymes and highly high selectivity of the enzymes. efficient microorganisms as whole-cell catalysts, biocatalytic production processes may play In contrast, the expansion of the range of appli- a more important role in this area of industrial cations in biocatalysis to basic, bulk, and broad chemistry in the future. Coupled with advanced areas of specialty chemicals has been viewed approaches in process engineering, it should up to now as a largely unmet challenge. These therefore also be possible to transfer more and starting compounds, which are also typically more of the advantages of biocatalysis to the field based on petrochemistry, may be structurally of petroleum-based bulk, basic, and specialty simpler and significantly less expensive, but they chemicals in the future. For example, a series are required in considerably higher production of processes recently developed in the field of tonnages and tend to have a significantly lower oxidation chemistry, some of which have already price per kilogram. A suitable catalyst for this been tested on the pilot scale, has provided im- product class should display high activities and pressive proof of this great synthetic potential of space-time yields, as well as long dwell times, biocatalysis. Photography: Dieter Debo, Frank Preuss/Evonik Illustration: C3 Visual Lab Illustration: Preuss/Evonik Frank Debo, Dieter Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIOTECHNOLOGY ACETONE FROM WASTE GAS

The CO2-based Acetone Fermentation (COOBAF) project has shown that industrial waste gases containing carbon dioxide can be valuable raw materials for the biotechnological production of acetone.

Dr. Marzena Gerdom, Dr. Jörg-Joachim Nitz ccording to a widespread ods, carbon dioxide can serve as the sole feasible proof that industrial waste gases belief, carbon dioxide is a carbon source for the climate-friendly and can be turned into products such as acetone problematic greenhouse cost-effective production of acetone. (Fig. 1). gas. However, as a waste Within the scope of the VALERY project product of numerous com- (see elements 49), Evonik researchers had Problematic interdependencies bustion processes, carbon successfully cooperated with academic Some six million metric tons of acetone dioxide actually has potential for benefi- partners to develop a synthetic pathway for are sold annually in the global market. It is Acial use. Researchers at Evonik were able to valeraldehyde that uses carbon dioxide as a produced almost exclusively with the Hock demonstrate that carbon dioxide is a use- source material. In the recently completed Process of phenol synthesis, in which ben- ful raw material for the production of basic COOBAF project, Evonik and its academic zene and propene react with oxygen in a 16 chemicals. Using biotechnological meth- research partners were able to come up with radical reaction to ultimately become the

Figure 1. The idea behind COOBAF Acetogenic microorganisms convert waste gas streams into acetone, which is then used as a raw material for isophorone or PMMA.

H2 Gas fermentation with acetogenic microorganisms CO2

CO2- and H2-rich off-gas as raw material Acetogenic microorganisms CO2-based acetone as raw material for various products

Isophorone & Polymethyl methacrylate derived products (PMMA)

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIOTECHNOLOGY

coproducts phenol and acetone. This pro- Figure 2. Comparison of industrial and biotechnological production of acetone cess has a number of disadvantages: On one hand, it is based on petrochemical raw ma- The biotechnological method of acetone production does not involve phenol. terials, which makes it dependent on their availability and the price of petroleum. Fur- OH thermore, since the production of acetone is O O tied to the production of phenol, decreased + + 3 CO2 + 8 H2 + 5 H2O demand for phenol can easily result in a reduced acetone supply as well. Propene Benzene Acetone Phenol Carbon dioxide Hydrogen Acetone Water Evonik does not produce acetone, but Large-scale industrial production Alternative biotechnological production some of its business lines need this colorless solvent, for example for the production of isophorone and its derivatives, but also for polymethyl methacrylate (PLEXIGLAS®). This led to the idea to search for an innovative, biological synthetic pathway. The objective was to generate acetone and water from carbon dioxide and hydrogen—typical components of industrial waste gases—with the help of microorganisms (Fig. 2). The production was to entirely rely on existing byproducts and not use any raw materials in order to remove several tons of carbon dioxide from the atmosphere. In the bacteria, which may even have played a role ponent of industrial waste gases that is toxic past, the bulk of industrial waste gases with in generating the first life on earth. to many microorganisms. this composition had at most been used These microorganisms had to meet sever- Using gene transfer, the team trained the for thermal applications. In other circum- al requirements to be considered for further most promising strains to metabolize the stances, they had simply been burned off at development. They had to be able to quickly naturally formed acetyl-CoA into acetone.

the exit point of smoke stacks, returning the convert CO2 to products in large quantities, The project ultimately reached a major mile- carbon dioxide to the atmosphere. using the Wood-Ljungdahl pathway (Fig. stone in mid-2012, when the researchers In cooperation with academic partners at 3). They also had to be long-lived and suffi- came up with proof that their bacteria had Ulm University (working group of Prof. Dr. ciently resistant for economic fermentation, turned carbon dioxide into acetone. With Peter Dürre) and Rostock University (work- and needed the ability to grow in the pres- molecular biologists at Ulm and Rostock ing group of Prof. Dr. Hubert Bahl), Evon- ence of carbon monoxide, a common com- universities now focusing on the further 17 ik therefore initiated the COOBAF project in late 2011 with funding from the Federal Ministry for Education and Research (pro- motional reference 01RC1105A). While the Evonik team concentrated on the development of the fermentation and downstream process, the academic partners focused on Figure 3. Pathway of acetogenic bacteria microbiology and gene technology aspects. The first challenge was to identify microor- Genes for the production of acetone were transferred to bacteria that had the ganisms that were able to use carbon diox- ability to convert CO2 to acetyl-CoA via the Wood-Ljungdahl pathway. ide in their metabolism—not a widespread ability outside of the plant kingdom. Wood-Ljungdahl pathway Acetone synthesis Demanding requirements (Native pathway) (Synthetic pathway) for microorganisms CO H O 2 Acetone Scientists actually made use of bacte- CO dehydrogenase

ria for acetone production as early as 1916. CO2 2 [H] CO2 This development was pioneered by Chaim CO2 Formate dehydrogenase Weizmann, who would later become the Formate first President of Israel. The bacterium Clos- ATP, THF Formyl-THF synthase Acetoacetate tridium acetobutylicum was used until the Formyl-THF+ mid-20th century for the industrial-scale H+ Methenyl-THF cyclohydrolase H-S CoA Acetyl-CoA production of acetone, ethanol and butanol Methenyl-THF 2 [H] 2 [H] in the so-called ABE fermentation process CO-Dehydrogenase/ Methylene-THF dehydrogenase that relied on a carbohydrate substrate. Acetyl-CoA synthase H2O Acetate Methylene-THF However, ultimately the acetone yield of 2 [H] this process was no longer sufficient to com- Methylene-THF reductase Acetoacetyl-CoA Methyl-THF pete with Hock synthesis. Co-FeS-P In contrast to ABE fermentation, the Methyltransferase Methyl-Co-FeS-P H-S CoA COOBAF project did not use carbohydrates. HSCoA [CO] CO Instead, it used carbon dioxide as the source CO dehydrogenase/ of carbon. For that purpose, the researchers Acetyl-CoA synthase Acetyl-CoA tested a number of lesser-known acetogenic Acetyl-CoA Acetyl-CoA Illustration: C3 Visual LabIllustration:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIOTECHNOLOGY

optimization of the organisms’ genetic Figure 4. Continuous process management makeup, Evonik began to develop the fer- Growth of the bacteria can be increased significantly by continuously mentation process. The first challenge was removing the byproducts from the fermenter. to find a laboratory that had the necessary safety equipment for working with hydro- Feed gas gen and carbon monoxide. The Reaction Off-gas Technology laboratory in Marl fit the bill, Retentate particularly since the Marl Chemical Park R1 R2 also offered convenient access to suitable feed industrial waste gases. The researchers re- structured the laboratory to meet the requirements for biological work at the S1 UF level. membrane The Evonik team came up with a fermentation process at the two-liter scale. To ac- External commodate higher pressure levels, the as- pump sociated laboratory fermenter was made of Permeate steel instead of the glass variety customarily used in laboratory facilities. Hydrogen and carbon monoxide are only moderately wa- Cell ter-soluble at atmospheric pressure, but had suspension to easily reach the bacteria in the bioreactor’s nutrient solution as a substrate. The researchers also examined gases with different compositions, which revealed that the gases typically emitted by steel mills offered favorable conditions for acetone production. The cell supply was further improved with alternative gassing concepts. Figure 5. Faster growth Typical waste gas from Continuous A comparison of growth rates for continuous and steelworks is especially fermentation process batch process management. suited for the production Then the team encountered a sudden prob- 18 Continuous lem. The bacteria kept stopping their growth process of acetone using at a certain point in the fermentation. Was an important nutrient missing? Did the acetogenic bacteria. process generate a product that inhibited growth? It was ultimately discovered that the problem was caused by the interaction of multiple factors, primarily led by the concentration of the byproduct acetic acid. The Biomass batch process therefore had to be converted Batch to a continuous process, which included the process consistent removal of this byproduct. At the same time, a part of the cell output had to be returned to the reactor because the micro- Fermentation time organism growth was relatively slow (Figs

Figure 6. Higher productivity Process development resulted in a continuous increase in the volumes of acetone and biomass.

Acetone Biomass

Acetone and Acetone

biomass concentration biomass Pressure 2L fermenter 2L fermenter cylinder (batch process) (continuous process)

S1 laboratory with anaerobic workstation (left) and two-liter fermenter. C3 Visual Lab Illustration: Evonik Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE GLOBAL CHALLENGES: BIOTECHNOLOGY

suitable not only as a feed gas but also as a The experts Figure 7. The downstream process strip gas. The acetone could be removed at The absorption-based process delivers high yields and purity. the speed required by process management. Was it better to remove the acetone from the strip gas by condensation or absorption? It turned out that absorption was the method of choice due to the higher yields (Fig. 7). CO2/H2 containing Absorbents feed gas The researchers identified a functional Dr. Marzena Gerdom Acetone absorbent in various simulations. It is able has been working to take up large quantities of acetone and in the Bioprocess Technology & LCM Absorbents is consumed only in small volumes. What department of the loaded with is more, the resulting acetone has a puri- Process Technology & acetone ty level of around 95 percent, which could Engineering Business Off-gas easily be increased to over 99 percent. Since Line of Technology loaded with & Infrastructure as a acetone the only major contaminant is water, which process engineer since does not interfere with isophorone process- 2011. es, the next milestone had been reached, marzena.gerdom and the project was almost done. @evonik.com The last step involved life cycle assessment (Figs. 8a, b). Compared to the mere combustion of industrial waste gases, the CO balance of the biotechnological ace- Bioreactor Absorber Distillation columns 2 tone production was much more favorable (Scenario 1). Even if the researchers took into account that the hydrogen component of the waste gas could be used thermally (Scenario 2), which meant that the lost heat Dr. Jörg-Joachim Nitz source would have to be compensated with is a team leader at In- natural gas, the biological process was more novation Management Crosslinkers, where 4,5). Furthermore, the researchers recog- favorable than the currently used chemical Figure 8a. LCA he focuses on research nized that the addition of certain cofactors benchmark process at the large industrial projects in the field of Production phases to the nutrient medium resulted in signif- scale. isophorone chemistry. for which an LCA was icant yield increases. Thus, magnesium se- By the time the project was completed joerg-joachim.nitz conducted. @evonik.com lectively increased the acetone yield, while in late 2014, the initial process productiv- 19 other trace elements boosted the entire pro- ity had been increased by more than three CO2,

H2, CO ductivity non-specifically. Over the course orders of magnitude. Another factor of 20 of the project, the process development led would now be required for the new proce- to the continuous increase of fermentation dure to economically compete with petro- Fermentation acetone yields (Fig. 6). Ultimately, the ini- chemicals at the industrial scale. The project process tial process productivity was increased by team sees potential for such increases both several orders of magnitude. on the genetic and the process technolo- The next step was to address the down- gy sides. All in all, it has been possible to Downstream stream process. The low vapor pressure of show that it is feasible in principle to pro- process acetone helped the Evonik team find an op- duce sought-after valuable materials from

tion for stripping the acetone from the fer- the “waste product” CO2 via biotechnolog- mentation broth. In this context, the mix of ical methods, and to do so in a way that is Acetone hydrogen and carbon dioxide proved to be cost-effective and competitive.

Figure 8b. Results of the Life Cycle Assessment (LCA) Depending on the scenario, the LCA of the biotechnological acetone production showed a different reduction of the contribution to the greenhouse effect compared to the conventional chemical process. Left: Scenario 1, no substitution of the thermal energy of the feed gas. Right: Scenario 2, substitution of the thermal energy with natural gas.

3.0 3.0 Benchmark: Hock synthesis from fossil resources Benchmark: Hock synthesis from fossil resources 2.0 2.0 -0.2 0.7 <0.1 <0.1 0.7 <0.1 <0.1 1.0 1.0 1.8 1.1 1.1 0.0 -3.6 0.0 -3.6 3.4 e/kg acetone] e/kg e/kg acetone] e/kg 0.0 0.0 2 2 -3.7

-1.0 -1.7 -1.0 [kg CO [kg CO

-2.0 -2.0 Global warming potential (100 years) years) (100 potential Global warming Global warming potential (100 years) years) (100 potential Global warming Steam Water SUM Steam Water SUM Electricity Electricity Waste gas as Waste water benchmark Waste gas as Waste water benchmark raw material uptake during Comparison to raw material uptake during Comparison to 2 fermentation 2 fermentation from natural CO CO Additional emissionsgas combustion ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE 20 CORPORATE FORESIGHT: SOFT ROBOTICS

ROBOTS IN DAILY LIFE Gentle Machines Sometimes the future is closer than you think: Ro- bots, for example, already have their own population statistics. In 2013, the International Federation of Robotics counted one and a half million in industry alone. Today, most of the tasks these machines per- form are easy to standardize. But more and more, robots are also taking on more complex and even social activities. In Japan, for example, friendly robots sit at the reception desks of hotels or entertain seniors by singing and dancing.

Robotics experts are convinced that the use of robots in places other than the factory floor will continue to grow. But more widespread use also increases the risk of accidents occurring in the interactions between humans and robots, as robots are not (yet) intelligent enough to be able to properly assess all 21 dangerous situations.

Soft robotics offers the opportunity to minimize this risk. Soft robots are made of flexible, deformable materials that give way in a potential accident and can therefore prevent injuries. A few questions need to be answered before they can be used more widely, however: What are the requirements for the different types of materials? What are the best tools and methods for serial production of soft robots? As part of its Digital Futures focus theme, the Corporate Foresight Team is working on the answers to these questions and determining the growth opportunities for Evonik in the field of soft robotics. However, there is one problem that cannot be solved with new materials: Social Interaction with robots is still poorly accepted in everyday situations.

More information Harvard Biodesign Lab on Soft Robotics: bit.ly/1X2CzTg University of Chicago, Jaeger Lab, on Soft Robotics: bit.ly/1X2Epn5 Photography: Vincent Fournier/Gallery Stock Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE SOLUTIONS: MICROREACTION TECHNOLOGY GOING

Dr. Jürgen Lang, Dr. Patrick Löb, Prof. Michael Maskos MOBILE lant designers and engineers in the chemical industry are used to thinking on a huge scale. Some world-scale plants and integrated production sites are WITH larger than a small city, and chemical plants can completely overshad- Pow a church steeple. In the future as well, multi-million-dollar investments will continue to make sense for the production of MICRO bulk chemicals for stable or growing markets or multi-use intermediates. In the future, small-scale chemistry could make big In many cases, however, “big” alone is no headlines. Production plants with a compact design longer the key to lucrative processes. Times have changed: Customer expectations grow work flexibly, economically, and with precision. or change quickly, resources are increas- EU projects have proven that the EcoTrainer from ingly scarce, and many markets are more volatile than before. All of that increases the Evonik with its high-tech infrastructure is ideal for investment risk for new plants. The pace of tapping the potential of micror eaction technology innovation and the pressure to innovate are also increasing. New or improved substanc- for sophisticated chemical syntheses. es must be available within a few years, consequently requiring a shortened time to 22 market. Last but not least, the mobility of a production facility has become increasingly important. Chemical syntheses can be lucrative in regions or at sites where there is no room or infrastructure to locate conventional plants or where equipment is needed The POLYCAT plant only for some time. in the EcoTrainer is suitable for producing Building small means advanced pharmaceutical ingredients under keeping risks small GMP conditions. Microreaction technology, combined with a standardized plant infrastructure in a container format, provides an answer to these ical process itself: Reactions are easier to trends. The idea behind it is simple: If you control, processes become more precise, build small, you also keep your risks small. and systems that are hard to manage be- With small-scale chemistry, it is possible to come manageable. react quickly to changes in consumer de- For Evonik, microreaction technology is mands and the desires of customers, more an extremely attractive field of activity. A effectively predict and influence costs, and great deal of the added value of the Group minimize land usage and resource con- is in fine and specialty chemicals—in other sumption. Above all, upscaling from the words, substances that the market needs in laboratory to commercial production is relatively small quantities but that are deci- faster and more direct. Small-scale chem- sive for the proper functioning or quality of istry eliminates intermediate steps and products. At the same time, requirements interfaces, and process parameters can be for the quality, performance and reproduc- transferred directly from the laboratory to ibility of the substances are exceptionally production. high. Small also means mobile. Because of the Currently there are only a few chemical REACH legislation, the transportation of companies and research institutes in Ger- reactive substances is subject to strict re- many that have vigorously addressed the quirements. If necessary, production can issue of small-scale production. Evonik take place on site. A facility measuring just and Fraunhofer ICT-IMM, the former Insti- a few square meters can be easily transport- tut für Mikrotechnik Mainz, joined forces ed to the customer’s site and installed there. A chemical plant on a hook: the EcoTrainer for many years ago to become pioneers in this Furthermore, milli- and microtechnology POLYCAT at the time of delivery to Fraunhofer field. In several publicly funded projects,

have significant advantages for the chem- ICT-IMM in Mainz in November 2013. Evonik’s Process Technology & Engi- ICT-IMM Fraunhofer Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE 23 SOLUTIONS: MICROREACTION TECHNOLOGY

neering unit and the experts from Mainz noscale, polymer-supported catalyst sys- have collaborated with other partners to tems, continuous processing approaches, research the ways small-scale plants can be and a modular, small-scale plant. designed, built, and used for specific pro- For POLYCAT, the EcoTrainer concept duction processes. was developed for the first time to meet the Several factors work in favor of this re- requirements of the Good Manufacturing search. A good range of small-scale ver- Practice (GMP) regulations for syntheses of sions of many components such as mixers, active pharmaceutical ingredients (APIs). heat exchangers, and two-phase reactors is The project partners selected the production now available. Additionally, the knowledge process for an API as their model synthesis. of flow patterns, heat exchange, and mass For the participating pharmaceutical Hans-Joachim Kost transfer processes in small pipings and tiny company, it was important that the synthe- from Fraunhofer ICT- components has grown. The rapid progress sis of this active ingredient be transferable IMM during the final in automation and digitalization also pro- as fast as possible from the laboratory to the assembly of a modular microreactor in a rack motes the construction and operation of pilot scale. At the beginning of the project, for the process cham- highly integrated small-scale plants. there was neither a suitable catalyst nor a ber of the EcoTrainer. Microreaction technology does not, how- process for the critical step in this synthesis, ever, simply mean a miniaturization of con- the selective hydrogenation of a nitro group ventional components. On the contrary, to in a heterogeneously catalyzed gas-liquid realize a complete process in the space of reaction. just a few square meters, you have to take Big Various alternatives were analyzed in enough: an entirely new approach. Whereas a volu- The reactor the search for the best process. The cata- minous tank serves its purpose in a large- from the lyst, solvent, reaction temperature, and scale plant, small-scale chemistry requires POLYCAT 68 cm sequence of processing steps, among other a reaction chamber with a completely new project. parameters, were varied. A mini fixed-bed design and function. Heat exchangers, mix- reactor with an upstream dispersion unit ers, and other necessary components are yielded the most efficient results. built and arranged in such a way that they The reactor consists of an approximately take up little space, and yet are reliable and one-centimeter-thick capillary tube load- easy to maintain. Catch basins, locks, and ed with catalyst through which hydrogen electrical equipment must be integrated, and the dissolved reaction partner flow. as well as process control technology, air One particularly selective catalyst system conditioning and exhaust systems, fire-ex- was a substrate of hyperbranched polysty- 24 tinguishing devices, emergency doors, and rene, which had pores and tubules in which sufficient storage space for raw materials. the nanoscale active palladium catalyst is But how small is small? As Evonik has deposited. In this case, the polymer simul- shown, a full-fledged chemical production taneously provided protection and served facility needs no more space than a compa- as substrate and dispersing agent. rable 40-foot overseas container. The pro- The processing cham- Process costs decline ber in the EcoTrainer: duction infrastructure Evonik has devel- Above, still empty; oped over the last few years measures just significantly below, filled with a three by three by twelve meters. The pro- All told, the project coordinated by Fraun- modular facility for cessing chamber for the integration of the hofer ICT-IMM addressed, solved, and inte- manufacturing an API. actual production plant takes up about half grated a broad array of scientific problems. of the entire area. This is enough room to ad- The desired product was ultimately pro- dress the needs of typical production capac- duced by successfully using the catalysts ities of as much as 500 metric tons per year. and reactors developed in the project in the In the past few years, EcoTrainers such EcoTrainer. For the first time, the EcoTrain- as this one have been used in several EU er was equipped and used as a multipurpose projects to determine their suitability in plant. Both the EcoTrainer concept and the practice. As part of the CoPIRIDE project, process design proved to be viable and eco- the cubicle was equipped with a univer- nomical. Optimization potential was found sal supply system for water, process gases, primarily in downstream processing. electricity, heat, and electronic data. This The cost accounting for the model reac- ensured a basic configuration that can be tion showed that, thanks to the continuous used for integrating a variety of production processing approach alone, overall produc- facilities. tion costs were 23 percent lower than with a comparable discontinuous batch-mode APIs are also suitable process. Converting the work-up of the re- for containers action solution to a continuous operation The EcoTrainer was also a central component would further reduce both the production of the EU POLYCAT project, on which a total costs and the process time. of 19 companies, universities, and research The POLYCAT project provided valuable institutes collaborated from 2011 to 2014. The results for the entire industry, as highly objective of POLYCAT was to develop inno- selective hydrogenation reactions play an vative and sustainable synthetic pathways important role in a large proportion of the and production concepts for fine chemicals manufacturing processes for pharmaceuti- and the pharmaceuticals industry. It aimed cal active ingredients and specialty chem- to reach this by means of innovative na- icals.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE SOLUTIONS: MICROREACTION TECHNOLOGY

Microtechnology is not the solution for all This is why in the future both Evonik and The Experts processes, however. An estimated 10 to 20 Fraunhofer ICT-IMM will be working more percent of chemical syntheses are suitable intensively on the issues of digitization and for small-scale production. These include automation. From our current vantage point, primarily highly exothermic reactions such a lot is possible: compact small-scale plants as the synthesis of ionic liquids, which nor- with individual synthesis modules that au- mally generate a significant amount of un- tomatically log in and log out and flexibly desired by-products. They also include mix- adapt their capacity to the demand, or even Dr. Jürgen Lang works ing-sensitive processes where, for example, self-optimizing processes that automatically as senior scientist at the final product quality is determined recognize and take countermeasures against Innovation Manage- by how fast and thoroughly the reaction deviations in certain process parameters. ment in the Process partners come in contact with each other. Experts at micro- Additionally, “smart” EcoTrainers are Technology & Engi- process technology neering Business Line. Anionic polymerization of styrene, for ex- also suitable as an approach to mobile units In this position he deals ample, can be run continuously in a small The former Institut für for energy use. For electrochemical pro- with new technologies, reactor at room temperature, and is there- Mikrotechnik Mainz cesses, for instance, they can be equipped new processes, inter- fore far less complicated. Ozonolysis, epox- GmbH (IMM) was to tap the excess renewable power from national collaboration integrated into the idation, fluorination, and sulfonation reac- the network. A new pilot plant building at projects, standardiza- Fraunhofer Society in tion, and modern plant tions can also benefit from miniaturization. 2014, with the goal of Fraunhofer ICT-IMM in Mainz, which will design. becoming an auton- largely be used for container plants, will juergen.lang omous Fraunhofer High added value provide room for new developments of this @evonik.com Institute by 2018. Until in a tiny space then, the Fraunhofer kind. POLYCAT has shown that through the use Institute for Chemical of a compact high-performance infrastruc- Technology (ICT) will Economical and ture a sustainable chemical production pro- provide support for it ecological benefits cess with high added value can be located on a partnership basis. As far as all future developments are con- in an extremely small space. Consequently, cerned, small-scale chemistry is a new tool In addition to continu- Evonik and IMM plan to continue their re- ous chemical process for integration on a wide variety of levels. search and work in this field. In August the technology (primarily From a technical standpoint, it promotes the Dr. Patrick Löb two partners concluded a license agreement the use of microre- development of equipment and infrastruc- heads the Continuous on the use of the container technology. actors), Fraunhofer ture that is not only efficient and reliable but Chemical Engineering ICT-IMM specializes division at Fraunhofer The partners’ goals and expectations in decentralized and also intelligent and highly flexible. In eco- ICT-IMM. The core complement each other perfectly. As a glob- mobile energy tech- nomic terms, it makes syntheses lucrative, competencies are the al player, Evonik spots market trends and nology, medical probes increases their added value, and minimizes development, realization, and application potential for new products and can identi- and sensor technology, cost risks. 25 of microreactors for fy future applications for the EcoTrainer at microfluidic analysis The investment costs for conventional systems, and nanoparti- organic chemical pro- an early stage. Fraunhofer ICT-IMM brings cle technologies. batch processes for chemical production are duction processes. In in its many years of experience in microre- as much as 50 percent higher than for mod- addition, he coordinat- action engineering and development ser- ular systems. Savings in maintenance and ed the EU POLYCAT Fraunhofer ICT-IMM project. vices, so it can custom-design small-scale in Mainz-Hechtsheim human resources and, above all, through processes quickly and precisely for specific fast upscaling and shorter time to market patrick.loeb (Germany) is headed by @imm.fraunhofer.de customer requirements. An interesting side Prof. Michael Maskos are added benefits. Another beneficiary of effect in this context is that cost-effective and has around 180 intelligent and small-scale production is the employees. small-scale chemistry can reduce the bar- environment, as the savings in energy and rier to entry into container production for raw materials can be particularly favorable. small and medium-sized producers, and Even though many people still associate a thereby expand their customer base. chemical plant with high smokestacks and Despite the successes so far, microreac- imposing reactors, the future of numer- tion technology still faces challenges when ous high-grade substances lies in the mi- it comes to producing chemicals. Syntheses croworld. Intelligent processes in extreme- Prof. Michael Maskos are a result of complex interrelationships ly small spaces combine the environmental has been the director of and are a component of long value-added and economic goals of the manufacturers Fraunhofer ICT-IMM in Mainz (Germany) chains, so it is not enough to make the reac- with the rapid advances in industrial auto- since 2014. In addition, tor and the adjacent equipment smaller—it mation and digitization and thereby meet he has been the head of is also important to modify the entire range the requirements of advanced and sustain- the chair of Chemical of peripheral equipment. This concerns, for able production. Process Technology/ Microfluidics at example, the product reprocessing through Johannes-Gutenberg filtration, precipitation or gas separation, Universität in Mainz which is often extremely expensive and since 2011. time-consuming. michael.maskos The automation and digitization of pro- @imm.fraunhofer.de cesses is even more important. Digital intelligence is essential for making container syntheses economical and precise. For example, initial synthesis steps and substance analyses can already be automated in the laboratory phase. For production, current automation systems can be used for devel- Nineteen companies, universities, and research oping process control systems for chemical institutes participated in the POLYCAT project,

Photography: Fraunhofer ICT-IMM (5), Stefan Wildhirt/Evonik (1) Wildhirt/Evonik Stefan (5), ICT-IMM Fraunhofer Photography: microprocesses. which was funded by the European Commission.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE SOLUTIONS: CATALYSIS

132 132132 Transformation of the energy system Source: International Energy Agency The International Energy Agency predicts that oil, coal, and gas will still be important sources of power, heat, and chemical raw materials in 2040.

123 123123 2012 2040 20122012 20402040 Fuel Fuel[exajoules,Fuel EJ] [exajoules,[exajoules, EJ] EJ] 123 179 123123 179179

Oil OilOil 54 78 5454 7878

Biomass and waste BiomassBiomass and and waste waste67 116 6767 116116

Natural gas Natural gas Natural24 gas 24 24 155 155155 27 2727 22 17 2222 17 17 26 Coal CoalCoal Nuclear 13 NuclearNuclear 1313

Hydro 18 1.8 HydroHydro 2.5 1818 8,8 1.81.8 2.52.5 8,88,8 Wind onshore Geothermal WindWind onshore onshore GeothermalGeothermal

0 8.1 0.07 0.07 0 0 8.18.1 0.07 3.2 Other 3.23.2 renewablesOtherOther Solar thermal renewablesrenewables SolarSolar energythermal thermal energyenergy 0.4 0.05 0.4 0.050.05 0.4 0.5 Wind offshore Photovoltaics 0.50.5 WindWind offshore offshore PhotovoltaicsPhotovoltaics 0.002 0.0020.002Ocean OceanOcean

Transformation [EJ] 2012 2040 End use [EJ] 2012 2040 TransformationTransformation [EJ] [EJ] 20122012 20402040 EndEnd use use [EJ] [EJ] 20122012 20402040 Power and co-generation plants Refineries and other transformation 172 166 154 149 172PowerPower and andco-generation co-generation plants plantsRefineriesRefineries153 and andother other transformation transformation 150 172 141 150 135 166166 149 133 153153127 154154 150 149 141141 150 118 135 150 109 133133 127 150 135 102 127 118118 98 95 100 109109 100 87 10210298 98 95 100100 68 100100 87 8795 61 68 42 50 68 32 50 30 37 3461 61 50 12 13 19 3242 42 50 37 13 14 11 17 50 2.5 32 50 30 3037 34 34 19 0 1.4 17 0 12 1213 13 19 0 13 1314 14 11 1117 2.52.5 0 1.40 1.4 0 0 0 0 Direct heat Biofuels losses Industry losses Transport Services Direct Electricity Hydrogen Residential Direct Commercialheatheat Oil products losseslosses BiofuelsBiofuels losseslosses IndustryIndustry ServicesServicesOther end use Electricity Transformation HydrogenHydrogenTransformation TransportTransport and own use consumptionElectricity Commercial Oil products ResidentialResidential Non-energy use Commercial Oil products Other end use Distribution lossesConversion losses Transformation Transformation Other end use and own use consumptionconsumption Transformation Transformation Non-energyNon-energy use useand own use Conversion losses C3 Visual LabIllustration: DistributionDistribution losses Conversionlosses losses

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE SOLUTIONS: CATALYSIS CATALYZING CHANGE The global energy and raw materials markets are in a state of flux: Raw materials are changing and new systems and processes are replacing the old. Evonik’s Catalysts Business Line has responded to the changes by expanding its product range and investing in selected new developments.

Tim Busse, Dr. Hans Lansink Rotgerink he world’s hunger for energy ical processing industry, and the petro- base products in the petrochemical indus- will continue to be satisfied chemical industry in particular, are strong- try. About two thirds of global production is mainly by coal, oil, and gas— ly affected by the energy markets because used to manufacture the bulk plastic poly- even in the year 2040. This many of their basic chemicals such as eth- propylene, and propylene is also used for the was the conclusion drawn ylene, propylene, butadiene, and butene are production of important chemical interme- by the International Ener- obtained from oil and gas. These processes, diates such as propylene oxide, butyralde- gy Agency in its most recent World Energy as well as the downstream processing of hyde (and oxo alcohols), cumene, acryloni- TOutlook. According to the report, crude oil, these raw materials to more complex mole- trile, acrolein, and acrylic acid. coal, and fossil fuel gases will remain the cules and products of the chemical industry, Propylene is obtained mainly as a by- 27 most important energy sources in the fore- require catalysts. product of ethylene production in steam seeable future, not only for power and heat crackers, or in catalytic cracking process- but also for chemical raw materials. So will Increasing need es in refineries. In steam crackers a mix of it be business as usual, then? for new catalysts hydrocarbons from petroleum is split into Not by a long shot. For many years now, For industrial chemical and petrochemical shorter molecules. Each cracker delivers the energy markets have been undergo- processes Evonik currently supplies about a particular ratio of propylene to ethylene ing profound change. Within a short space one hundred types of catalysts, many of (P/E ratio), depending on feed and opera- of time, unconventional sources of oil and which are for oxidation and hydrogenation tional mode or design. For a long time the natural gas, buried deep in rock, (tight oil reactions. Some of these are used as stan- demand for propylene and ethylene cor- and tight gas) have perceptibly increased dard catalysts in the same application by responded roughly to the overall P/E ratio the supply of inexpensive fossil fuels by the different customers and in different regions. delivered by the crackers. But this ratio has use of fracking. Major importers of energy, However, the great majority have been now fallen from 0.38 to 0.30, while de- such as China and the US, are increasing developed by the Catalysts Business Line mand for basic chemicals and plastics in the their energy production capacity by cre- jointly with the user for a particular pro- growth regions, particularly Asia, has reg- ating processing capacities based on their cess or a defined process step. In this proj- istered a strong increase. The result is that own raw materials. In addition, India, Chi- ect-based business, Evonik draws on the conventional processes for propylene pro- na, and Australia plan to utilize their coal advantages of its knowledge and many duction no longer meet demand and have deposits as sources for chemical raw mate- years of expertise in a variety of application been supplemented by on-purpose technol- rials more intensively than before. areas. This flexible and practical approach ogies for obtaining propylene, for example Evonik is closely monitoring the current is increasingly in demand worldwide, be- from propane or methanol. changes in the energy markets. The chem- cause customized catalysts ensure an optimal, cost-efficient, and sustainable solution Selective hydrogenation in for the customer. greater demand than ever Chemical companies usually work with a Due to the exploitation of shale oil (also particular portfolio of raw materials so as to known as tight oil) and shale gas (tight gas), be able to react flexibly to changes in supply the starting material propane is now avail- structures, process requirements, and pric- able in significantly larger quantities and at es and availability of raw material. Changes much lower prices than only a few years ago. in the energy markets also cause movement As a result, the thermocatalytic production in the catalyst market. Customers develop of propylene from propane is becoming in- Changes in the new processes to be able to continue work- creasingly important. About 15 new plants energy markets also ing cost-efficiently, and this gives rise to a have been established worldwide in the last need for new catalysts. six years for this propane dehydrogenation cause movement in A good example is afforded by propylene. (PDH); this corresponds to about seven per- the catalyst market. This liquid gas is one of the most important cent of global propylene capacity. More

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE SOLUTIONS: CATALYSIS

Processes based on sustainable raw materials The Experts will become increasingly important over the long term. In this area, entirely new fields for catalyst development are opening up.

Tim Busse has been heading the Industrial & Petrochemicals Market Segment in the Catalysts Business Line since July 2012. [email protected]

than ten additional plants are in the proj- Petrochemicals market segment are inves- ect development or planning stages. tigating the conditions under which, for This has given rise to demand for new example, high-grade chemicals such as sol- Dr. Hans Lansink specialty catalysts, such as for selective vents and monomers can be produced from Rotgerink has been hydrogenation, for the following reason: bioethanol and other starting materials. with the Catalysts Busi- In the core process of dehydrogenation of Reactions of this kind were carried out as ness Line for 26 years, propane, undesired byproducts with mul- long ago as the 1950s; the challenge now is to currently as Senior Business Development tiple bonds are formed, which reduce the develop cost-effective processes for them. Manager for the EMEA yield of the process, lead to coking of the This too calls for experience when, for in- region. reactor system, and prevent attainment of stance, identifying which modified or new hans.lansink-rotgerink the degree of propylene purity required for catalyst is best suited for a particular pur- @evonik.com PP polymerization. This is where Evonik’s pose, predicting its performance in a com- catalysts help: They selectively hydroge- mercial-scale plant, and finding the right nate these byproducts, thus permitting the basic process-engineering operations for 28 production of propylene of the highest level scale-up to the optimal catalyst. of purity and, moreover, in an economical Evonik is currently constructing a new, process. Evonik’s catalysts for selective hy- ultra-modern facility at the Marl site to drogenation were developed many years create adequate capacities for the scale- ago, and demand for them has increased up of new fixed-bed catalysts. This will be steadily ever since. used from early 2016 to produce catalysts in quantities ranging from a few kilograms Sustainable raw materials to 100 kilograms and to ensure subsequent actly production structures, suppliers, and as a field of development transferability, particularly of molding for- markets will look like in ten or 20 years’ The transformation in the energy markets mulations, to commercial production. In the time. This is why most public discussion also opens up entirely new fields for catalyst future this investment will allow Evonik to on the topic revolves around short-term development, most particularly in the area react more rapidly and flexibly to the dy- shifts in supply and demand. Fracking, for of sustainable raw materials. Already today namics of changes in raw materials and the example, is indeed in the headlines and about ten percent of all chemical products associated changes in catalyst requirements. the subject of much debate, but its overall are obtained from bio-based raw materials. contribution to the global supply of ener- In terms of quantities produced, the most All a question of (oil) price gy and raw materials is in fact relatively important product in this market by a long Perspectives for biological alternatives for small. Moreover, the profitability of uncon- margin is bioethanol, obtained by fermen- raw materials are naturally always deter- ventional deposits waxes and wanes as the tation of plant sugars. Enormous bioethanol mined by the current price of oil. When this price of crude oil rises and falls. The same production capacities have been established price is high, investments in new bio-pro- applies to the boom in biomaterials. The rate within the last ten years, particularly in the cesses are worthwhile; when low, interest in at which bio-based raw materials will grow US and Brazil. The global output of bioetha- biological processes quickly wanes. Evonik in importance on the global scale depends nol plants today is of the same order as glob- is convinced, however, that processes based on a multitude of factors, not the least of al propylene production. Most of the alco- on sustainable raw materials will become which are the political environment and the hol is burned as an additive in gasoline. But increasingly important over the long term. willingness of industry to make the corre- bioethanol is also increasingly being used as They often have better energy and emission sponding investments. a chemical raw material because consumers profiles, foster innovation, and, not least, The only certainty here is that the range are increasingly demanding “green” prod- reduce dependency on fossil fuels. For this of raw materials and their global availabili- ucts, be they sneakers or Lego bricks. reason, sustainable raw materials some- ty will continue to change and require flexi- Evonik is following this development, times receive political support, even if only ble, reliable, and practical action. The aim of taking a number of different approaches. temporarily. In view of the long payback Evonik is to develop jointly with customers Various projects, for example, are current- times for a new plant, however, such sup- and partners catalysts that are competitive ly investigating the potentials of bioetha- port appears to many potential investors to in economic, technological, and ecological nol for new catalytic processes. Working be too uncertain. terms, and that will help ensure that highly jointly with customers, experts from the The world continues to need energy, and efficient processes remain available in the

Catalysts Business Line in the Industrial & more of it. Nobody can say today what ex- future. Evonik Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE

RUBRIK: THEMA CompanyNews

REACHING HIGH: C4 VIA NEW PATHS With new production plants in Antwerp (Belgium) and at Marl Chemical Park, Evonik has expanded its C4 capacities in Europe and thereby consolidated its leading position in C4-based products. The plants in Marl have now commenced operation following the successful start of production in Antwerp at the end of June. Evonik’s total investment in both sites is in the triple-digit million euro range.

he new production facilities process, refineries transform ceeded in making this material from the refinery in Gelsen- Thave resulted in capacity heavy crude oil components stream utilizable by separating kirchen, about 15 km from the expansion for butadiene (An- into fuel components. Fluid any unwanted substances from Marl site. Because the residual twerp), the plasticizer alcohol catalytic cracking produces a the FCC-C4 stream. The new butanes are a valuable raw isononanol (Marl), and the fuel C4 material stream that con- technology incorporates dis- material for the Scholven re- additive MTBE (both Marl and tains other substances besides tillations, chemical reactions, finery, Evonik returns these by Antwerp). According to market the components that can be and adsorption techniques, pipeline to Gelsenkirchen. analyses, global demand for used for chemical processing including a 90-meter column these products is growing by (olefins). For this reason, the that removes butanes that are two to five percent annually. industry has thus far not used of less interest to Evonik from The Marl plant marks a this FCC-C4 material stream. the FCC-C4 material stream. technological milestone for By developing its own new Afterwards, the butenes con- The centerpiece of the 29 Evonik. Thanks to an entire- technologies and combining tained in the material stream new plants in Marl is a ly new process worldwide, these with others procured ex- can be processed further to 90-meter-tall column, Evonik’s highest. It sym- FCC-C4 material streams can ternally, Evonik has now suc- produce specialty chemicals. bolizes the new tech- be used for the production of Evonik draws the FCC-C4 nology, which is making a wider range of chemicals. material stream by pipeline special material streams Steam or naphtha crackers from refineries useful to C4 chemistry for the first have so far been the major time anywhere. source for the extraction of basic petrochemicals. How- ever, there are significantly more FCC crackers than steam crackers worldwide. FCC stands for “fluid catalytic cracking.” With this Photography: Evonik Photography:

Investment in Airborne Oil & Gas ➜ Fatty acids from algae ➜

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE

CompanyNews

raw materials, Evonik’s Per- technology laboratories for need of replacement. This is an New innovation sonal Care Business Line serves medical devices are planned in attractive entry point for AOG. all the large cosmetics enter- other regions. The next planned For Evonik, the oil and gas in- centers for the prises. The products include, opening is in Darmstadt, Ger- dustry is an attractive growth cosmetics industry among others, emulsifiers, many, to serve the European market and an important surfactants, active substances, market. innovation field. Furthermore, vonik has opened inno- conditioners, thickeners, and the company is a market leader Evation centers in Midrand emollients. in polyamide 12, market- (South Africa) and Singapore, ed as VESTAMID®, which is which develop product solu- Investment in well-proven in pipes for oil and tions in the area of personal gas production and transport. care. The new facilities supple- A laboratory for pipeline specialist ment the worldwide network AOG of laboratories of Evonik’s medical devices in cosmetics business, which also Shanghai hrough its venture capital Award for includes sites in Essen (Ger- Tarm, Evonik has invested in ® many), Guarulhos (Brazil), vonik has opened its first Airborne Oil & Gas (IJmuiden, CoverForm Hopewell (Georgia, USA), and Eapplication technology Netherlands) and now holds a series application Shanghai (China). Addition- laboratory for medical devices. minority interest in the Dutch ally, Evonik has added a hair Located in Shanghai, China, company. The investment was he Society of Plastic Engi- laboratory to the applications the laboratory will provide made jointly with HPE Growth Tneers (SPE) has awarded laboratory that has existed support to medical device Capital (HPE) and Shell Tech- the Grand Prize in the Elec- manufacturers who use Evonik nology Ventures. Airborne Oil tronical/Optical Parts cate- polymers in their projects. & Gas (AOG) possesses a unique gory to the visually appealing Evonik’s RESOMER® and technology for the production Mercedes touchpad, which is RESOMER® Select brands of thermoplastic composite equipped with an extremely offer a range of biodegradable scratch-resistant surface made polymers that are widely used with CoverForm®. The auto- in a variety of medical devic- motive suppliers Continental es, such as orthopedic screws, and Daimler are the first users plates, etc. Implanted devices to integrate CoverForm® into designed with RESOMER® mass car production together resorb without a trace in the with Evonik and the machine 30 body over six months to two manufacturer KraussMaffei. years, eliminating the need for The decision to use this tech- secondary surgery to remove nology developed by Evonik Testing cosmetic active ingredients’ the devices. AOG flowlines ready for shipment to and KraussMaffei came about effect on skin cells. a customer. Evonik plans not only from the requirements for in Guarulhos (Brazil) since to provide customers with a pipes for a variety of offshore on the touchpad. It must be 2012. More than one hundred reliable supply of the material oil and gas applications. possible to manufacture the employees worldwide work in but also to help them find the The current offshore oil & gas three-dimensional component research and development for best way to use the material infrastructure consists of either using injection molding, and the cosmetics industry. for their specific design and rigid steel pipes or so-called the surface of the part must not When it comes to products production requirements. This flexibles. The latter consist of show any scratches or chem- for hair and body care, con- includes selecting the most multiple layers of steel and ically induced changes, even sumer demand varies dramat- suitable RESOMER® product for polymers. AOG’s thermoplastic after intensive use. ically worldwide. In Brazil, the application, characterizing composite pipes dispense with Continental manufactures for instance, women often the production process (injec- steel entirely and are therefore the touchpad in Babenhau- wash their hair twice a day tion molding and extrusion) for not susceptible to corrosion. sen for the C-Class, S-Class, and therefore need more care. successful design and scale- They have extremely high me- V-Class, GLE-Class, GLC-Class Conditioners with regenerative up, as well as manufacturing chanical stability but are also and GT-Class in the Mercedes effects, which are not washed technical samples for feasibil- flexible. As an added advantage model range and for the May- out after application, are par- ity studies. The aim is to help they are lightweight and can be bach. The company uses the ticularly popular. In Europe, customers develop and bring fabricated in lengths of up to 10 CoverForm® process, in which consumers prefer products their medical devices into kilometers, which means that the part is coated with a highly with a light consistency that production faster. New applied AOG’s pipes can be installed crosslinked, scratch-resistant are rinsed out. relatively simply and cost-ef- acrylate layer during the injec- At roughly five percent per fectively. Rigid steel lines are tion molding process. Surfac- year, the worldwide market for welded together from segments es produced in this way are cosmetic products is grow- that are 10 to 20 meters long, extremely scratch and chem- ing faster worldwide than the using highly specialized and ical-resistant. A production global gross domestic product. costly pipelaying vessels. volume of more than a million In Brazil alone, the demand has A number of operators faceplates is expected to be risen steadily in recent years have qualified AOG’s pipes for reached as early as 2016. by about 10 percent. The main offshore oil and gas transport driver in emerging economies lines. A considerable amount is the growth of a middle class of the 150,000 to 200,000 km with strong purchasing power. Interested customers at the opening of globally installed transport As a supplier of high-quality of the new lab in Shanghai. lines is over 20 years old and in

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE

CompanyNews

Dr. Peter Nagler Innovation Awards receives award for ROHACELL®

r. Peter Nagler, Head of he AVK Federation of Re- DInternational Innovation Tinforced Plastics presented at Evonik, received the IAIR awards to two Evonik devel- Award for Chief Innovation Of- opments containing the PMI ficer of the Year in the chemis- structural foam ROHACELL® try section in the Europe region for sandwich components at at a ceremony in London. The the Composites Germany Con- citation for the award highlights ference. his influential role in Evonik’s The new development strategy for innovative products “ROHACELL® Triple F—Pro- and solutions: “Peter Nagler’s duction-Ready Foam Cores conviction of the importance of for Sandwich Components” networks, internationalization, received second prize in the and sustainability paved the Innovative Products and Appli- way for innovative research and cations category. The “Pul- investments that have expand- Press Process for Large-Scale ed Evonik’s business and tech- Production of Complex Fiber nologies throughout Europe.” Composite Parts,” for which The internationally re- ROHACELL® is used as a foam nowned IAIR (International Al- core, was awarded third prize ternative Investment Review) by the jury in the Innovative Marine algae will be used to produce Awards are presented annually, Processes and Systems cate- omega-3 fatty acids. by a research institute under gory. the patronage of the European An innovative manufactur- Commission, to companies and ing process, in-mold foaming individuals for business per- (IMF), is now enabling the pro- FATTY ACIDS formance, sustainability, and duction of complex three-di- innovation. Peter Nagler, who mensional structural cores for FROM ALGAE holds a doctorate in chemistry, industrial-scale CFK sandwich 31 has been head of Internation- components. ROHACELL® DSM Nutritional Products (Switzerland) and al Innovation since January Triple F can significantly lower 1, 2015. He took on the then the cost per part by reducing Evonik Nutrition & Care are cooperating on the newly created post of Chief waste, manual work, and cycle development of algae-based omega-3 fatty acid Innovation Officer in 2011. In times, and produce 1,000 to products for animal nutrition. The products will early 2015 Dr. Ulrich Küsthardt 50,000 complex 3D sandwich be used especially for aquaculture and pet food succeeded him in this position. structures per year rapidly and applications. The aim is to meet the increasing efficiently. This is particularly attractive for applications in demand for omega-3 fatty acids by harnessing the automotive segment and naturally occurring marine algae using sustain- aircraft construction, but also able biotechnological processes based on natural for sports articles. non-marine resources. The PulPress process is designed for the highly automated, continuous, and DSM has expertise in the cultivation of marine Dr. Peter Nagler, Head of cost-effective series produc- organisms and long-established biotechnolo- International Innovation at Evonik. tion of fiber-composite profiles gy capabilities in development and production. with complex part geometries. It innovatively combines the Evonik’s focus for decades has been on indus- pultrusion and compres- trial-scale biotechnological production of amino sion methods, as well as the acids in large-volume fermentation processes. fiber composite materials and Until now, the omega-3 fatty acids used in the ROHACELL® rigid foam aquaculture have been obtained exclusively from structural core used in the marine sources such as fish oil. The envisioned process. The process enables the molding of highly complex algae-based omega-3 fatty acid products will be parts with narrow component an alternative to fish oil. This will help keep up tolerances and outstanding with the increasing demand for omega-3 fatty component properties, and is acids in animal nutrition without endangering particularly well-suited to the global fish stocks and will contribute to sustain- serial production of cars. able aquaculture. Photography: Evonik (3), AOG, Shutterstock AOG, (3), Evonik Photography:

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE PROFESSIONALS

At the beginning of his career Dr. Jens Busse spent a lot of time in control rooms, optimizing processes and training plant personnel.

DR. JENS BUSSE Open to New Ideas Dr. Jens Busse studied process engineering and at the beginning of his career worked primarily with simulations and energy optimization for sites. Today, he is constantly on the lookout for attractive start-ups for venture capital that fit well with Evonik’s innovation activities. Ever since Busse, who is now 43, joined the Group as a specialist in process technology, he has forged ahead into uncharted territory again and again.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE PROFESSIONALS

hen Jens Busse as- into marketing,” he says. In 2009, Busse sesses start-ups, moved from process engineering to Crea- “I got to know many he considers a great vis, Evonik’s strategic innovation unit. He colleagues during my deal more than just worked there as head of the Development their technological Line Energy Generation in the newly start- work at Process innovation. Other ed Science-to-Business Center Eco², which Technology. I’m still key questions include: What are the market focused on energy efficiency and climate Wopportunities of this technology? What ex- protection. His team conducted research on benefiting from this pertise does the start-up team bring? Could heat recovery, hydrogen technology, and network today.” Evonik benefit from collaboration with, or membranes. “I was responsible for a variety Dr. Jens Busse participation in, this company? Busse is a of projects, had to apply for public funding, member of the Venture Capital Team, which and managed large consortia with as many has been Evonik’s corporate venture arm as ten internal and external partners,” says since 2012. The team has €100 million at its Busse. The disciplinary responsibility was disposal for medium-term investments. new. He credits intensive training and “ex- “I work on behalf of a variety of business cellent senior managers, who taught me a lines to find technologically suitable start- great deal” for helping him in this step in ups that make our products better or expand his development. their function,” explains Busse. “This kind Busse has been part of the Venture Capi- of assessment requires technological ex- tal Team since early 2015. While his work at pertise, although obviously the colleagues I Creavis focused on developing technologies work with closely in the business lines are to the point where they could be transferred the ultimate experts.” to the business units, his efforts are now di- Busse spends three days each week at rected at helping start-ups that have a new the Essen site and two days at the Hanau product enter the marketplace. Busse says, site—when he is not traveling. His travel “It’s exciting for me, because it’s the next step destinations frequently include relevant on the way from R&D to commercial success.” conferences where start-ups are presenting While it all seems like such a straight and the sites of the start-ups themselves, for path in hindsight, it was anything but that. the purpose of getting to know them better. “There’s no question that I wanted to de- “Our team also takes a look at the people velop my skills further and do something behind the start-up, because the person- different,” says Busse. “But I couldn’t have alities of the founders largely determine predicted that my path would lead to Crea- the success or failure of a technology.” This vis and now the Venture Capital Team.” 33 requires some insight into human nature— After spending a number of years in a cer- something that Busse acquired in earlier tain position, he simply kept his eyes and positions. ears open to the options the Group offered. And because of its size, Evonik offers a lot Busse’s specialty: of options—even when it comes to switch- Charting new territory ing to completely new subject areas, as in Busse studied mechanical engineering with Busse’s case. “The fact that my ‘visibility’ a concentration on process engineering at in the Group increased over time because of Ruhr University Bochum, where he earned my work certainly facilitated such a funda- his doctorate in process synthesis. In 2001, mental change,” he says. he began his career in the process engineering unit of the former Degussa AG. There he was part of a team that developed training simulations for various plants. These kinds Evonik Venture Capital: of simulations are now used to train today’s On the trail of new technologies plant operators just like flight simulators are Evonik intends to invest rience in the venture used to train pilots. But back then, it was a total of €100 million capital sector, as well new territory. “It was classic project man- in young technology as employees who have agement,” says Busse. “We also had to do a companies and spe- worked a number of lot of work to sell people on this new tool.” cialized venture capital years in technical and funds over the medium operational positions In another team he focused on demon- term. Investment in at Evonik and know the strating the potential for energy savings innovative ideas and company extremely at chemical sites and plants. “Ultimately, solutions is oriented well. They are located our goal was to identify best practices that to the megatrends that in Hanau (Germany), we could then transfer to other sites,” says are most important to Essen (Germany), Par- the company—health, sippany (New Jersey, Busse. “We functioned as ambassadors.” In nutrition, resource ef- USA), and Woodlands this position, Busse worked closely with the ficiency, and globaliza- (Texas, USA). company’s processes and sites and got to tion. The key regions know many colleagues who are now valu- are Europe, the United To date, the team has States, and Asia. able contacts. In addition to the training evaluated the business simulation and energy optimization, he was plans of more than The team from Evonik 1,500 start-ups. Evonik part of a team that managed internal train- Further information Venture Capital con- currently holds an ing sessions for improving the marketing of on Evonik Venture Capital: sists of eight invest- interest in seven start- products and services for process engineer- ment professionals ups and three funds. venturing.evonik.com with relevant expe- Photography: Dirk Bannert/Evonik Dirk Photography: ing. “You could say that was my first foray

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE INNOVATION & CULTURE: THE EVONIK INNOVATION AWARD

Nominated for the Evonik Innovation Award 2015 REWARDING CREATIVITY Recognition is an important driver of creativity. This is why work on new ideas is particularly well rewarded at Evonik. Once a year, the specialty chemicals company confers its own Innovation Award for outstanding research success and the creative minds behind it. There are three teams in the finals for the Innovation Award 2015 in each of the two categories New Products/System Solutions and New Processes. Their projects are presented on the following pages. The nomination is intended to underscore that second and third place are just as reflective of great achievements as first place.

The award: The standards: The jury: The teams: The finals: The CIO Award: motivating sustainable demanding interdisciplinary conclusive surprising Winning the Inno The six finalists are The members of the Innovation occurs at During the final round, The Chief Innovation vation Award means selected on the basis of audience select the the interfaces between each of the nominated Officer (CIO) Award having done outstand the criteria of econom winners of the Inno traditional disciplines teams has ten minutes acknowledges an ing work. The winning ic importance, environ vation Award during such as chemistry, to present its project. individual achievement. team in each of the mental advantages, and Evonik’s traditional biology, and engin The members of the Last year, it went to two categories can also societal benefit. The Christmas Colloquium. eering. Accordingly, audience then evaluate the molecular biologist look forward to a cash team that accumulates The audience is made up most of the teams that not only the scientific Dr. Mechthild Rieping, prize of €30,000. enough points with its of about 200 members make it to the finals are depth but the quality of who received the project in all criteria of the Group’s senior interdisciplinary. the presentation, be award and the €5,000 has an opportunity to management, as well cause a new develop prize money for her reach the final round. as researchers from all ment is only innovative inventiveness. Rieping segments. if it is successful on the has been responsible market. And that in for more Evonik patents cludes good marketing than anyone else, based and a professional sales on a Group-wide com approach. parison.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE INNOVATION & CULTURE: EVONIK INNOVATION AWARD

New Products/System Solutions New Products/System Solutions

Linerless labels: Gas separation with fibers: TEGO® RC silicones for Hollow-fiber membranes for innovative labeling systems harvesting nitrogen

® SEPURAN N2 for energy and Typical application for linerless labels: cost-efficient food packaging. nitrogen extraction.

® urrently, up to 40 percent linerless labels are printed first, he new SEPURAN N2 ing nitrogen to accumulate on Cof the weight of a standard, and afterwards coated with Thollow-fiber membranes the feed side. self-adhesive label consists silicones. represent an unprecedented The purity of the nitrogen of a liner that winds up in the Applied to the top of the cost and energy-efficient tool can be controlled by adjusting garbage as soon as the label is printing, newly developed for harvesting nitrogen. This the amount of air fed into the peeled off. Thanks to the pat- TEGO® RC silicones ensure has been well-received on the fibers. The smaller the initial ented TEGO® RC technology, optimal adhesion and release market: Evonik is currently amount of air, the higher the this liner is no longer neces- effect with respect to the expanding its capacities in re- purity of the nitrogen. Nitro- sary. A team from the Interface adhesive layer. This way, the sponse to increasing demand. gen with a purity of 95 to 98 & Performance Business Line labels can be rolled up like an In order to acknowledge this percent is adequate for many has been nominated for the adhesive tape without sticking new development, the team of applications, and this is exactly Evonik Innovation Award 2015 to each other and are reliably experts from the High Perfor- the process regime that reveals for this development. dispensed, whether manually mance Polymers Business Line the economical superiority of 35 Labels are sophisticated or automatically. has been nominated for the the technology. The investment systems. A conventional label In cooperation with ma- 2015 Evonik Innovation Award. costs and energy consumption ® laminate consists of a liner, chine manufacturers, Evonik With sales volumes of US$10 of SEPURAN N2 technology the adhesive, and the actual has shown that UV silicon- billion, the nitrogen market is are lower than those of the label. A fourth layer, a silicone izing can be easily integrated the second-largest gas market classic technique (fractionating release coating, is invisible yet into modern, fully automated in the world after oxygen. The air at low temperatures). crucial to the label’s function. plants for the production of gas protects chemical storage The new technology is This layer ensures that the label labels. Typical applications facilities and server farms from piggybacking onto the success can be removed from the liner are linerless thermal-printed fires and explosions. In the food of SEPURAN® Green, an Evonik rapidly and without leaving labels, wrap-around labels, industry nitrogen extends the product that has established residue. Systems without liners and microperforated decorative shelf life of cheese and fruit, itself on the biogas upgrading are far more sustainable. These labels. End applications range and in liquid form it is used as a market. SEPURAN® now stands save not only 40 percent of the from food packaging and labels coolant for freezing blood and for customized membrane weight and the associated ma- for transport and logistics to tissue samples. technology for the processing terial costs but also conserve consumer goods. Nitrogen is extracted from of industrial gases such as hy- resources. In Europe alone, up the air, which consists of 78 drogen and helium. With this to 300,000 metric tons of paper percent nitrogen and nearly system solution, Evonik covers and plastic liner waste are dis- 21 percent oxygen. Made of the entire value chain—from carded every year. polyimide that has been spun monomer and polymer synthe- When used as a separating into hollow fibers, SEPURAN® sis to production of the hollow ® layer, TEGO RC silicones make N2 hollow-fiber membranes fibers and ultimately of entire linerless self-adhesive products represent a particularly ef- modules. a reality. RC stands for “radi- ficient way of separating the ation cured.” Instead of heat, two gases. The manufacturing UV radiation is used to cross- process yields 0.5 mm-thick link and cure these silicones— hollow-fiber membranes, which takes only a fraction of a which are then bundled, em- second. Compared to labeling bedded in a special resin, and systems with thermally cured finally embedded in a stainless silicones, this method reduces steel module. As compressed energy consumption and is air is fed along the bore side gentler on the label. This is why of the hollow fibers, oxygen ® TEGO RC silicones can be used Dr. Stefan Stadtmüller, molecules—which are more Dr. Goetz Baumgarten, for heat-sensitive liners such as spokesperson of the nominated mobile—preferentially diffuse spokesperson of the nominated

Photography: Evonik Illustration: C3 Visual Lab Illustration: Evonik Photography: BoPP films. During production, TEGO® RC silicones team through the membrane, leav- SEPURAN® N2 team

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE INNOVATION & CULTURE: EVONIK INNOVATION AWARD

New Products/System Solutions New Processes

The best form of For a clear consumer conscience: lightweight construction: New surfactant based on Fiber-reinforced plastics certified palm kernel oil

Pre-impregnated carbon fibers based on VESTANAT® PP. Sustainable: Oil from palm kernels.

igh strength, high rigidity, wise they cure prematurely. vonik’s new surfactant ness director of Base Products Hlow weight: Fiber-rein- In VESTANAT® PP, Evonik ETEGO® Betain P 50 C stands at Personal Care. forced plastics offer enormous has developed a polyurethane out for its superior sustain- TEGO® Betain P 50 C can potential in lightweight con- (PU) matrix system that offers ability profile and improved be produced with existing struction. With VESTANAT® a new route for the automated application properties. RS- production facilities, so no ad- PP, a new matrix system for production of components from PO-certified palm kernel oil ditional investment is required. pre-impregnated carbon fibers composite materials. is used in it instead of coconut Moreover, a key problem of (“prepregs”), these plastics are By virtue of a chemical oil. For the development of the current betaine production now easier to produce. For this trick, the PU matrix cannot production process, the global was solved during process system, the developers from crosslink below 140°C and team from the Personal Care development, and that enabled the Crosslinkers Business Line therefore remains stable when Business Line, the Production a significant reduction of pro- have been nominated for the stored at room temperatures. & Engineering department of duction time for the product. 36 2015 Evonik Innovation Award. Because it softens beginning the Nutrition & Care segment, The next step is to transfer the Fiber-reinforced plastics at 80°C, it is easy to mold the and Procurement has been process to the production of ex- are key to lightweight con- prepregs into the shape of the nominated for the 2015 Evonik isting betaine products. struction. Extremely strong desired component before the Innovation Award. Following production tests glass or carbon fibers embed- curing process. Other advan- For more than 50 years, in China, the first commercial ded in a polymer matrix are tages are the fast curing and cocamidopropyl betaine batches of TEGO® Betain P 50 responsible for their unique good mechanical properties, (CAPB) has been one of the C have now been manufac- mechanical properties. But which allow the same compo- most successful surface-ac- tured in Germany. Additional their potential is still not fully nent properties with less mate- tive substances on the market production sites are earmarked realized, because manufac- rial than other matrix systems. for personal care products for Indonesia and the United turing components from these VESTANAT® PP com- such as liquid soaps, shower States, with another facility composites is complex and bines ease of handling with products, and shampoos. The planned for Brazil in 2016. A time-consuming. the potential for continuous products and processes have number of customers from the With resin transfer molding production. Evonik is currently been optimized many times cosmetics industry are cur- (RTM), for example, the dry holding discussions with sev- through improvements such as rently conducting their own fibers are placed in the form, eral leading car manufacturers increasing the content of the laboratory tests with samples impregnated with resin, and who want to use VESTANAT® active ingredient and elimi- of the product. Initial revenues the composite is produced PP in the production processes nating preservatives. But the from the new surfactant have with the help of a curing agent, of their future models. basic formula has remained already been generated. pressure, and temperature. the same: A hardened coconut However, even in commercial oil or a hardened coconut fatty production in the automotive acid is reacted and forms CAPB. industry, RTM can only pro- Because coconut oil is duce components in batches. becoming more widely used Prepregs make production in the food industry and its easier, because in this con- production is subject to strong tinuous method the fibers are weather-related fluctuations, already pre-impregnated with the Personal Care Business resin and curing agent, so all Line has now developed a new that is needed to cure them in process for producing a betaine the mold is a high tempera- based on RSPO-certified palm ture. However, the prepregs in kernel oil. “This respects the current use, which are pre- sustainability ethic of our cus- dominantly based on epoxy Dr. Guido Streukens, tomers and end users and offers Ralf Klein, resins, can be stored for only spokesperson of the nominated us greater supply security,” spokesperson of the nominated short periods at –20 °C; other- VESTANAT® PP team says Ralf Klein, the global busi- TEGO® Betain P 50 C team

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE INNOVATION & CULTURE: EVONIK INNOVATION AWARD

New Processes New Processes

A simpler pathway to methionine Lightweight construction made easier: Process optimization by Mass production of a new precursor complex sandwich components

Evonik’s latest methionine complex in Singapore. A mass-produced component made from ROHACELL® Triple F.

team from the Animal Nu- Additional cooling is required new foaming process now These foamed PMI cores can Atrition Business Line and for safe storage and handling. Aoffers a simple way of be used for manufacturing Technology & Infrastructure This is where the researchers producing ROHACELL® Triple F complex 3D components in has shown that major process stepped in. In Singapore hy- structural foam in complicated commercial quantities, and improvements are possible drocyanic acid is not liquefied shapes. Thanks to this process, their considerable rigidity and even for a well-established and stored; instead, it is di- Evonik has cleared an import- temperature resistance make product like methionine. The rectly absorbed from the vapor ant obstacle on the road to mass them suitable for subsequent process is now simpler and phase into a solution, where producing sandwich compo- processing using high-pressure intrinsically safer, because it it reacts directly with MMP to nents in complex shapes for or wet-pressing techniques. eliminates liquefied hydrocy- give the new, far less critical the automotive industry. The Doing so allows manufac- anic acid. For this achievement intermediate MMP-CN. first vehicles with ROHACELL® turers to create composite com- the team has been nominated The process was rapidly de- Triple F components were ponents with lightweight foam for the Evonik 2015 Innovation veloped, tested in a pilot plant presented at this year’s IAA, an cores quickly and efficiently. 37 Award. in Hanau, and finally integrat- accomplishment that earned The automotive industry then Evonik has been producing ed into the Singapore plant. the team of developers from the uses these in bodies, chassis, the amino acid methionine for Consequently, it will be an High Performance Polymers and add-ons. The ROHACELL® animal nutrition for nearly 50 essential component of future Business Line a nomination Triple F cores are foamed in situ years and is a technology and methionine complexes. This for the 2015 Evonik Innovation by LiteCon Advanced Composite market leader in the field. A success was possible because Award. Products GmbH, a joint venture major objective of the re- Evonik pooled its skills for the Right now, the primary established in 2013 by Evonik searchers in the Animal Nutri- purpose, combining expertise method of making sandwich Industries and SECAR Technol- tion Business Line is to main- from methionine production, cores for fiber composite ogy. LiteCon manufactures the tain this technological lead by process engineering, analytics, components is by producing finished components as well, continual process optimiza- and pilot-plant operation. blocks that are then cut into the and production of the first series tion. Their latest success was desired shape in an additional is already underway. incorporated into Evonik’s new step (CNC milling, for in- methionine complex in Singa- stance). However, the consid- pore in October 2014: Instead erable amount of manual labor of hydrocyanic acid, the plant involved, as well as the rela- uses MMP-CN (methylmercap- tively large volumes of waste, topropionaldehyde cyanohy- make large-scale production drin) as an intermediate. This cost-prohibitive. makes the process more stable This is where Evonik and safer. stepped in, developing a new Three intermediates, in-mold foaming (IMF) process methylmercaptan, acrolein, for its rigid ROHACELL® Triple and hydrocyanic acid, are F polymethacrylimide (PMI) essential to the production of foam. The process, which methionine, and Evonik itself makes creating complex geom- produces all three in its fully etries considerably easier, in- back-integrated plants. In the volves foaming granulated PMI first step, methylmercaptan into the desired mold for the and acrolein react to give MMP, finished foam core, thus saving which is then converted to material and process steps. methionine using hydrocyanic Embedded metal components acid. Hydrocyanic acid has a Martin Steurenthaler, such as threaded inserts can be Dr. Kay Bernhard, low boiling point (25°C) and spokesperson of the nominated integrated during the foaming spokesperson of the nominated

Photography: Evonik (7), Shutterstock (7), Evonik Photography: must be liquefied by cooling. methionine team process. ROHACELL® Triple F team

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE WISHLIST:RUBRIK: RENÉE THEMA SCHROEDER

Prof. Renée Schroeder, 62, is a biochemist and a professor at the Depart- ment of Biochemistry at Max F. Perutz Labora- tories, a joint venture of the University of Vienna and the Medical Univer- sity of Vienna.

Prof. Schroeder is an expert in the field of RNA biology and a recipient of the renowned Witt- genstein Award. She is a prominent advocate of measures to ensure a wider acceptance of science.

Her most recent book is Von Menschen, Zellen und Waschmaschinen. Anstiftung zur Rettung der Welt (Of People, Cells, and Washing Ma- chines: An Incitement to Save the World) (Residenz-Verlag 2014).

WHAT I HOPE FOR FROM SCIENCE Renée Schroeder AN OPEN MIND There is nothing that says that simply being new makes something valuable. Just because something is new doesn’t mean it is good or even better. Established things are tried, tested, and familiar. Evolution, on the other hand, requires constant new impetus and new things to try out. My hope is for science and innovation to make the world better and to ensure that it develops further. The most important thing above all is freedom, and freedom begins in the mind. Ideologies restrict this freedom—they are prisons of the mind.

Education is therefore the most important prerequisite for a free mind. And so my wish is for everyone to have education, specifically education in the sense of freedom of thought. On the basis of the realization that our level of knowledge is low but that we are capable of expanding it, I define education as training our abilities: to be unbiased, to ask critical questions, and to be creative. No question is off-limits. Everything can be and should be questioned. This is not easy, of course. But, as we all know, taking the easy way is not what drives evolution.

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE RECOMMENDED READING

Masthead

Publisher Evonik Industries AG Dr. Ulrich Küsthardt, Rüdiger Oppers Rellinghauser Str. 1-11 45128 Essen, Germany

PATHS TO GREATER INNOVATION Publication Manager Useful information on culture and markets Urs Schnabel Consulting and Concept Manfred Bissinger

Scientific Advisory Board Innovation is a What inhibits Dr. Felix Müller Dr. Friedrich Georg key matter innovation ? Schmidt

he question of how compa- new study commissioned by Editor in Chief Tnies can further increase their Athe German chemical industry Dr. Karin Aßmann innovative capabilities is addressed association VCI and conducted by (responsible) karin.assmann in the Innovation Report by Price- Who gets what IW Consult and Santiago Advisors @evonik.com waterhouseCoopers. According to provides answers to this ques- Annette Locher the results of a survey of 246 CEOs and why? tion. Nearly 200 companies from annette.locher worldwide, innovation has become Germany’s third-largest indus- @evonik.com a function of senior management. S economist Alvin Roth, who try participated. The results show The report concludes that the way received the Nobel Prize in that internal and external hurdles Contributing Editors U Christa Friedl a company is managed and the Economics in 2012, has written a impede research and development Björn Lohmann company’s culture are the most book that the Washington Post has to the same degree. First, we must Michael Vogel important ingredients for innova- described as recommended read- remove unnecessary bureaucracy Dr. Caroline Zörlein tion success—this includes room ing for “all innovation junkies.” and simplify complex regulations. Editorial Consulting for creativity, a willingness to Between the market economy and Second, further promotion of the Tom Rademacher work together, and the readiness to legislative frameworks, Roth looks culture of innovation within the Dr. Edda Schulze challenge the status quo. The key to for the key factors that shape to- company must be a priority. One Dr. Petra Thorbrietz 39 greater innovation, said one CEO, day’s markets, the “matchmaking” of the recommendations of the speaking for many others, is in between consumers and offerings. study’s authors is a stronger focus Managing Editor Dr. Sebastian Kaiser creating an organizational culture Roth, a game theorist, cites college on disruptive innovation and new that encourages and strengthens admissions and the market in or- business models. Companies should Picture Editing innovation at all levels. gan transplants as examples of the venture into more partnerships and and Layout fact that the days when price deter- participate in attractive start-ups. C3 Creative Code and How the role of innovation within business Content GmbH and the way companies innovate are being transformed. mined everything are long over. Agency Unleashing the power of BISSINGER[+] GmbH innovation Medien und Kommunikation INNOVATIONEN An der Alster 1 Alvin Roth, DEN WEG EBNEN 20099 Hamburg,

Eine Studie von IW Consult und SANTIAGO Who Gets What—and für den Verband der Chemischen Industrie Germany Why: [email protected] The New Economics of www.pwc.com Matchmaking and Market Printing Design, Eamon Dolan/ iStockphoto Foto Titel: Griebsch & Rochol Houghton Mifflin Har- Druck GmbH & Co. pwc.to/1Fsx8Z2 court, New York 2015 bit.ly/2088FPQ KG, Oberhausen

Industries AG, Essen. BIOCATALYSIS: MORE BIO REACTION TECHNOLOGY: IN PRODUCTION NETWORKS GOING MOBILE WITH MICRO Reprinting only with the permission of the agency. The content ELEMENTSDECEMBER 2015 # 53 does not necessarily reflect the opinion of the publisher.

Contact THE COVER #53 [email protected] From the creativity of the researcher in the laboratory Evonik Industries is a to operation of a large-scale plant: Digital technologies worldwide manufacturer of DATA STREAMS: generate enormous amounts of data from experiments, PMMA products sold under BIG DATA MEANS process development, production monitoring, material the PLEXIGLAS® trademark BIG BUSINESS * on the European, Asian, Afri- ELEMENTS #53 DECEMBER 2015 flows, sales, logistics, and marketing. Big Data analysis can, and Australian continents

* …DIGITAL INTELLIGENCE MAKES CHEMISTRY MORE EFFICIENT THE INNOVATION MAGAZINE turns this data into a valuable raw material for the and under the ACRYLITE®

Photography: Ingo Pertramer Ingo Photography: optimization of processes. trademark in the Americas.

EV_E053_EN_0101_Titel [e].indd Alle Seiten 24.11.15 11:53

ELEMENTS #53 THE EVONIK INNOVATION MAGAZINE ELEMENTS #53 DECEMBER 2015

* …DIGITAL INTELLIGENCE MAKES CHEMISTRY MORE EFFICIENT