elements29 S c i e n c e N e w s l e t t e r |2 6 |2 7 |2 8 | | 2 0 0 9

i n t e r FA c i A L t e c H N O L OG i e S Chemical Umbrella for Buildings

C OA t i n GS Green Art for a Kick: New Coating Transforms Used Tires into Long-Lasting Artificial Turf E D i t O r i A L

Encouraging Signs

Would you hang wallpaper in the bathroom? Paper that could curl up on you and become water- logged when you take a shower, not to mention make an ideal spawning ground for mildew? These problems are a thing of the past, as Evonik has proven with its new ccflex® ceramic wall covering. ccflex® can be handled as easy as wallpaper, is as water-repellent and durable as a tile, and com­pared to tiles, takes one-tenth the energy to produce. The Initiativkreis Ruhr, an association for promoting commerce in the Ruhr Valley, billed ccflex® “an outstanding innovation,” and has now honored it with the Ruhr2030Award, which carries prize money of €50,000. And now for a different topic, but from the jury‘s perspective, one just as innovative: our co­­­oper­­ ation with Daimler AG in the research, development, and production of lithium-ion batteries in Germany. The two companies are now distinguished winners of the ÖkoGlobe, the first internation­al environmental award for the automobile industry and its suppliers. This award, which we have received in the Innovative Energy Source category, also has its roots in our research—in the separ­a­tor Patrik Wohlhauser Evonik developed that makes batteries exceptionally efficient and safe. Chairman of the Board Our researchers and engineers can chalk up yet another success for themselves. They have devel­­­ of Management of Evonik Degussa GmbH oped a process to be used in a new plant we just commissioned to produce 2-PH (2-propyl heptanol), a starting material for the manufacture of PVC plasticizers. With this new plant, we are fostering the trend toward high-molecular-weight plasticizers, which pose no risk to human health, according to a rigorous EU risk assessment. This has been well-received on the market: The plant is complete- ly booked from the start. These three encouraging signs convince us that we can’t afford to shortchange research and development, even in times of crisis. The economy also looks less gloomy these days. The situation is beginning to stabilize, if at a low level, and we are now standing on solid ground at the bottom of the valley. Next begins the long, slow ascent back up. And we have our first signals of confidence for the climb—the number of our employees in short-time work has dropped from its high of 3,700 to less than half that number. Another encouraging sign!

elements29 | 2009 n e w s C OA t i n GS 4 Supply partnership for novel battery materials 22 Green art for a kick: new coating transforms used 4 Polyphthalamide is used for the first time to tires into long-lasting artificial turf manufacture filaments contents 5 International environmental award for Evonik and Daimler n e w s 27 “Area of Competence Days” point to perspectives i n n O V A t i O N M A N AG E M e n t in biotechnology 6 Technology foresight: 27 CyPlus® commissions Cold Caro’s Acid systems in Brazil in search of the needle in the haystack 28 New license agreement for vanadium-doped precious metal powder catalysts i n t e r FAc i A L t e c H N O LOG i e S 28 High-pressure for VESTAMID® PA 12 10 Chemical umbrella for buildings D E S I G n i n G w i t H P O LYM e r S E vo n i k F o u n dat i o n 30 PLEXIGLAS®: innovative light management with The cover photo shows 15 A radar screen for good people high-precision microstructures artificial turf—because it not only entertains C ATA LYS I S n e w s soccer fans but keeps 18 CENTOPRIME®: highly selective hydrogenation 35 Ruhr2030Award for ccflex® researchers in Evonik’s of nitriles to primary amines Functional Films & 36 e v e n t s a n d c r e d i t s Surfaces Project House on their toes

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+++ New Chief Human Resources Officer of Evonik Degussa GmbH

The Supervisory Board of Evonik Degussa GmbH nal term of office. He was appointed to the has appointed Thomas Wessel (46), Chairman of Executive Board of Evonik Industries AG as Chief the Board of Management of RAG Bildung Human Resources Officer with effect from July 1, GmbH, to the Board of Management of Evonik 2009. Degussa GmbH as Chief Human Resources Officer thomas Wessel, who became Chairman of effective November 1, 2009. He succeeded Ralf the Board of Management of RAG Bildung GmbH Blauth (58) who held this position at Evonik in September 2006, will hold his current position, Degussa GmbH in addition to his role as a mem- in addition to his new post, until the end of 2009. ber of the Executive Board and Chief Human under his leadership, this company has been Resources Of­ficer of Evonik Industries AG. As reorganized to make it more competitive. Wessel planned, Ralf Blauth relinquished his post on the previously held a number of posts at the former Board of Management of Degussa Evonik GmbH RAG Aktiengesellschaft, including latterly Head on October 31, 2009, before the end of his origi- of the Human Resources Division.

+++ Plant for production of the plasticizer alcohol 2-PH commissioned

Evonik Industries has expanded its product range Two hundred fifty for high-molecular-weight plasticizer alcohols metric tons of steel, 260 instruments and commissioned a plant for the production of and machines, and the plasticizer alcohol 2-propyl heptanol (2-PH) 1,500 pipelines with at the Marl Chemical Park. The company’s invest- a total length of twelve kilometers: Evonik‘s ment in the plant, which is in the high double-di- new 2-PH plant git million Euro range, makes it the largest produ- cer of C9/C10 alcohols in Europe. The plant has an annual capacity of 60,000 metric tons, and has brought twelve new jobs to Marl. “With this new product, we are actively promoting the market trend toward high-molecular-weight plasticizers and offering our customers attractive and com­ petitive solutions for plastics production,“ said Dr. Thomas Haeberle, member of the Management Board of High-molecular-weight plasticizers are also among the most stu- Evonik Degussa GmbH at the opening ceremony. died chemical substances and have been declared risk-free in tests 2-PH is used as a raw material for the production of a PVC conducted by the European Union. This is why more and more plasticizer, which transforms PVC, a naturally brittle plastic, into a PVC processors prefer to use high-molecular-weight plasticizers, flexible material. Plasticized PVC based on 2-PH is used for appli- which show above-average growth. cations such as cable insulation, tarpaulin fabrics, elastic floor cov­ evonik currently produces annually 340,000 metric tons of erings, and in various automobile parts. the C9 plasticizer alcohol isononanol (INA) at its Marl plant, the market for plasticized PVC has a volume of approximate- which is the largest INA plant in the world. INA and 2-PH com- ly twelve million metric tons per year. The demand for plasticizers plement each other very well, as the plasticizers made from them amounts to several million metric tons per year. In the past, both can be used to vary the properties of plasticized PVC over a wider have grown roughly 4 percent annually, with the highest demand range. coming from Asia. The economic crisis has been hard on the market with the new plant, Evonik is also optimizing its production for plasticized PVC, but “like our customers, we are expecting fu- network for C4 chemistry, an area in which the company has ture growth of worldwide 3 to 4 percent per year, because PVC many years of experience. The Marl production network, which is one of the most versatile and, at the same time, cost efficient is unique in the world, converts Crude C4, a by-product of the plastics,” explained Haeberle. “Another indicator is the fact that Naphtha cracking process, to high-quality products such as buta- our new plant is completely booked from the start.” diene, MTBE, isobutene, butene-1 and isononanol. Nearly all pro- Following increasing technical and environmental require- cesses were developed by the C4 Chemistry Business Line and ments for plasticized PVC applications, the “high-molecular- make best possible use of raw materials and energy within an weight” plasticizers, which are based on C9 or C10 alcohols such as integrated network. Evonik processes a total of approximately 2-PH with its ten carbon atoms, are in particularly high demand. 1.5 million metric tons of Crude C4 per year in its C4 Chemistry These plasticizers are remarkable for their excellent low-temper­ Business Line, and is therefore the most important processor in ature properties and low volatility, and are extremely versatile. this field in Europe. elements29 evonik science newsletter 3 +++ Supply partnership for novel battery materials

Süd-Chemie AG, Munich (Germay) and Evonik Industries have energy storage material lithium iron phosphate (LiFePO4, also agreed to enter into a supply partnership aimed at using novel referred to as LFP), to be used in rechargeable lithium-ion batte- mat­erials in the next generation of lithium-ion batteries for auto- ries. The use of lithium iron phosphate in lithium-ion batteries will mobiles and other industrial applications. By entering into this significantly improve the conditions for a swift and wide-scale agreement, both enterprises have laid the foundation for the pre- introduction of more powerful electric drives for the next genera- ferred delivery by Süd-Chemie to Evonik of the high performance tion of hybrid and electric-drive vehicles. Süd-Chemie will be responsible for manufacturing the high- grade lithium iron phosphate in line with the required specifica- tions, and for technical customer service. With the aid of the cathode material lithium iron phosphate, Evonik intends to develop to market maturity high-powered cell components for both mobile and stationary applications via its subsidiary Evonik Litarion GmbH, focusing initially on the European market. the main features of lithium iron phosphate which make it espe­cially suitable for use in lithium-ion batteries are its high energy density, its high cycle stability, long life and above all, the intrinsic safety of the material. under the LITARION® brand, Evonik Litarion GmbH produces electrodes that make a significant contribution to enhancing the performance of lithium-ion batteries. Evonik has also developed a novel ceramic separator named SEPARION® to significantly boost both the efficiency and safety of large-scale lithium-ion cells. Li- Tec – a joint venture operated by Evonik Industries (50.1%) and Daimler AG (49.9%) – makes use of the key chemical cell com- ponents supplied by Evonik Litarion to produce large-scale lithi- Electrodes production at Evonik um-ion battery cells for automotive and industrial applications at Litarion GmbH in Kamenz (Germany) the partners´ joint production site in Kamenz, Saxony (Germany).

+++ Polyphthalamide is used for the first time to manufacture filaments

Polyphthalamide (PPA) is always used whenever metal has to be Since the melting point of VESTAMID® HTplus F1001 is above substituted with a different material, or when other plastics such 320°C, the filaments are suitable for use at elevated tempera­ as PA 6 and PA 66 can no longer do the job. Evonik Industries has tures. The monofilaments show a stress at break of over 300 MPa found a new application for the high-performance polymer: and a strain at break of over 150 percent, so they are almost pre- Evonik’s VESTAMID® HTplus F1001 is the first polyphthalamide destined for manufacture into special bristles for tough applica- that can be drawn into filaments. The material can be easily pro- tions. Other applications are mono- and multifilaments for filters, cessed into different varieties of filaments, and modifications in as reinforcements, or as fabrics. geometry and color are possible, too. users like polyphthalamide because of its outstand­ ing performance at high temperatures and its excel- lent mechanical properties. Parts made of VESTAMID® HTplus F1001 are highly dimensionally stable and wear-resistant. Because of its crystallinity, the materi- al is incredibly resistant to chemicals, so it can be used in aggressive media and demanding environments. until recently, polyphthalamide was not used to make filaments. Evonik, however, has now filled in this gap. With its VESTAMID® HTplus F1001, the company succeeded in extruding PPA into monofila- ments, which were then made into special brushes. For the first time, Customers have found preliminary tests for heat Evonik has extruded PPA into resistance and mechanical properties to be very monofilaments prom­ising.

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+++ International environmental award for Evonik and Daimler

Evonik and Daimler’s strategic partnership in electric power trains r­ator, the battery boasts outstanding safety and high energy densi- has chalked up yet another success: The companies are co-recipi- ty in a compact size. According to predictions, the market volume ents of the ÖkoGlobe, the first international environmental award for high-performance lithium-ion batteries will cross the €10 bil- for the automobile industry and its suppliers, for their collabora­ lion mark in the next decade, with that of battery materials exceed­ tion on lithium-ion battery technology. The partnership between ing €4 billion. The German federal government plans to fill city Evonik Industries and Daimler, which was established about ten streets with at least one million e-cars by 2020. months ago, made it to first place in the category Innovative in July 2009, Evonik and Daimler announced the next stage in Power Systems. Their alliance has allowed both of these German their strategic partnership for the electrification of the passenger companies to promote e-mobility along the entire value-added car. In the future, Deutsche Accumotive GmbH & Co. KG, like­ chain in Germany. wise jointly owned by Daimler (90%) and Evonik (10%), will Advanced, safe, and affordable lithium-ion batteries are con- produce battery systems based on lithium-ion technology in Ka­ sidered a key technology for making environmentally friendly menz. Construction of the new production facilities is scheduled electronic cars suitable for everyday use. Combined since Decem­ to begin this year. The first lithium-ion battery systems will then ber 2008, the competencies of Evonik and Daimler in this field be installed in vehicles produced by Mercedes-Benz Cars as early impressed ÖkoGlobe’s jury. The jury comprises Prof. Fer­dinand as 2012. With the manufacture of lithium-ion battery systems in Dudenhöffer, who is the chairman and an automotive industry Kamenz, Deutsche Accumotive will begin industrializing the key expert, and HA Schult, who is an environmental artist, as well as technology for the electrification of the automobile. Matthias Machnig, State Secretary of the Federal En­ vironment Ministry; Prof. Claudia Kemfert, an energy and sustainability scientist; Prof. Bruno O. Braun, pres­ i­­dent of the As­so­ciation of German Engineers (VDI); and Engelbert Fassbender, member of the DEVK in- surance company’s management board. The name “ÖkoGlobe” comes from the institute of the same name, which is headed by Prof. Dudenhöffer at the University of Duisburg-Essen. ralf Blauth, member of Evonik Industries Executive Board, regards the receipt of the internati- onal environmental award as an incentive to further consolidate the expertise of Evonik and Daimler in the companies Li-Tec Battery GmbH and Deutsche Accu­ ­ motive GmbH. “Advanced batteries are the key to the success of e-vehicles. Everyone is trying his hand at this right now,“ said Blauth. “We don’t consider the ÖkoGlobe a laurel to rest on. The award shows us that At the ÖkoGlobe award we and our Made-in-Germany exper­tise are top per- ceremony: Ralf Blauth, member of formers on the international stage. That makes us the Executive Board of proud and hugely pleased. But the ÖkoGlobe also en- Evonik Industries AG courages us not to let up in the race for top solutions (left), and Prof. Herbert Kohler, head of E-Drive for the car of the future. As a location for industry, & Future Mobility at Ger­many has scored—with team-oriented, highly Daimler AG trained, and motivated employees.” evonik and Daimler forged their strategic alliance to develop and manufacture lithium-ion batteries in December 2008. A key player in the partnership is bat­tery specialist Li-Tec Battery GmbH in Kamenz, near the city of Dresden. Evonik holds a 50.1 percent stake in Li-Tec Battery, Daimler 49.9 percent. Based on Evonik’s lithium-ion technology, and with Daimler’s The heart of the large- format lithium-ion know-how, the two global giants advance the re- battery cells produced by search, development, and manufacture of battery Li-Tec is SEPARION®: cells and systems in Germany. a new type of ceramic separator from Evonik the worldwide leading lithium-ion battery flat-cell that separates the anode from Li-Tec has a lot to offer. With its ceramic sepa­- and cathode elements29 evonik science newsletter 5 T e c h n o l ogy F o r e s i gh t

In Search of the Needle in the Haystack

Dr. Friedrich Georg Schmidt

To survive in the markets of the “day after tomorrow,” a company must spot real innovation potential—and search for it in particular off the beaten path. To this end, Evonik’s Technology Foresight Team is deploying a network of experts to identify ideas and research findings of long-term importance to the company.

he future is when you regret not doing Low-cost airlines such as Ryanair, for example, what you could have done.” This saying have shaken the price structure of short-haul reflects the conflict that technology- flights to its foundation and have instilled fear in based companies face. While they must the established carriers. Here’s a second example. TgetT the maximum potential out of available tech- In the early 1980s, IT giant IBM completely under­ nologies and processes to satisfy the current needs estimated the importance of the PC and suffered of their customers, they often risk being too late one of the most financially difficult phases in its to identify newly emerging trends that are impor- corporate history. A third example: The big steel tant for their future market position. producers failed to recognize the potential of small The history of innovation proves that start-up steel mills—“mini-mills“—which initially pro­duced companies or niche players, more than any others, only simple construction steels from iron and steel develop „disruptive” technologies whose poten­ scrap, but then increasingly manufactured high- tial is either recognized not at all or only late by the quality steel for other applications and markedly large, established companies. Sometimes too late. re­duced the market share of established companies.

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In Search of the Needle in the Haystack

Timing is everything The art to the innovation process lies in identifying the potential for new markets and technologies as early as possible and selectively advancing This is why it’s important—indeed, a matter of sur­ highly promising developments at the right time vival over the long term—to recognize the poten- Signal intensity tial of new markets and technologies as early as possible. In the 21st century, this task will prove all the more difficult, because you have to do more than identify highly promising developments. You Sales

also have to select and advance them at the right Product announcement time. In 1995, Jackie Fenn, consultant with U.S. tech- Process development nology consulting firm Gartner, developed the idea

of the „hype cycle,” which illustrates this prob­lem Patents well. The hype cycle describes the phases of pub- lic attention that a new technology goes through R&D alliances when it’s launched. The first phase is the “technol­

ogy trigger,” which generates significant interest Scientific papers Discussions Crazy literature only among specialists. In the next phase, im­ proved and faster global sources of information jostle with one another to spread word of the new technology, often generating unrealistic expecta- tions. Media reporting on the technology then be- Years before first sales Market entry gins to wane as it fails to fulfill the initial inflated expectations. This is followed, however, by a

deeper understanding of the practical application Long before a technology has reached market maturity, the number of of the technology, as well as its limitations. Only scientific publications and patents peaks slightly. This can be identified and when its benefits are widely demonstrated and ac- interpreted, however, only in retrospect cepted does the technology then reach its “plateau Patent applications Scientific literature

of productivity.” The height of this plateau largely Number depends on whether the technology plays a role 400 in mass or niche markets. If a technology company doesn’t enter this kind 350 of market before the plateau phase, it could spell extremely high costs or loss of market share. On 300 the other hand, if the company invests in a technol­

ogy prematurely, as it is first emerging, the com- 250 pany had better have a lot of stamina and factor

the risk of failure. No one can say for sure what 200 will ultimately succeed on the market—and when. Even so, studies show that long before a tech- 150 nology has reached market maturity, the number of scientific publications and patents peaks slight- 100 ly. This is identified, however, only in retrospect. To put it another way, only in hindsight can we 50 judge which of the many pre-peaks in the “back- ground noise” of new developments actually point­ ed to a successful technology. This is why spot- 0 ting disruptive technologies is like searching for Time (years) the proverbial needle in the haystack. >>>

elements29 evonik science newsletter 7 The Next Big Thing is still not a practical strategy Evonik’s Technology Foresight Team

But a company with technology foresight should Dr. Masayuki Arai, Innovation Management Chemicals Japan not move at the level of the so-called Next Big Dr. Wolfgang Benesch, Evonik Energy Services Thing. It’s an open secret that globalization, cli- Dr. Klaus Dorn, Performance Polymers Business Unit mate change, and demographic developments will Dr. Jing Feng, Innovation Management Chemicals China have an impact on a number of markets, but this Dr. Stefan Buchholz, Industrial Chemicals Business Unit realization alone cannot point to any specific strat­ Dr. Doris Holland, IPM Innovationsagentur egies. To be sure, extrapolating and retropolating Dr. Norbert Kern, Creavis Technologies & Innovation existing scenarios, on the other hand, is important Dr. Friedrich Georg Schmidt, Coatings & Additives Business Unit for short-term technology developments, but it Dr. Peter Schwab, Consumer Specialties Business Unit provides little help in developing a long-term ap- Dr. Manfred Stickler, Innovation Management Chemicals & Creavis proach. Dr. Christoph Tontrup, Inorganic Materials Business Unit The best opportunities for increasing a com­ Dr. Christoph Weckbecker, Health & Nutrition Business Unit pany‘s ability to innovate are at the very beginning and associated partners. of a new development. Indeed, scientific studies The Technology Foresight Team views itself as a network within the have shown that investment in advance develop- Group and began its work in September 2008. ment through shorter development times pays off and that the way in which an advance develop- ment is pursued is a decisive factor in its success. The value of genuine innovations compared to incremental On average, companies have spent twice as much improvements can be seen most clearly in the income-to-expenses on advance development in successful projects ratio—but more often in the medium term than the short term! than in unsuccessful projects. So when it comes to Creating new offerings/markets/industries innovation management, only he who sows will Incremental innovations to existing offerings reap. But he who sows earlier can reap more. 14 One phase of the innovation process is the 38 “fuzzy front end,“ which is generally the stage in 61 which future technologies are identified. Evonik has been working this fuzzy front end since late 86 2008 with its Technology Foresight Team, an in- 62 ternal network of experts from all the business 39 units, main service units, and Innovation Manage­ ­ ment Chemicals & Creavis. The network is the log­ical continuation of earlier foresight activities R&D-effort Revenue Margine of the Group and its predecessor companies. The Source: Harvard Business Review, October 2004 main focus of this collaboration­ is the realization that while normal management processes identify Open innovation: To have the best possible chance of success, and implement technological developments that companies must experiment and react flexibly to changed conditions. lead to new businesses vital to the company’s Expanding the business model and integrating sources of external future, the signs pointing to completely new in- know-how, for example, creates an opportunity for successful innovation in new business fields novation potential are rather difficult to read.

Technology licensing Other firm’s market

Firm Spin-off boundary New market

Current Internal market innovation projects

Technologyechnolog TechScout acquisitionacqu Search Field Technology Ventureenture in-licensing ExternaExternall investmentinvestment Front end of innovation innovation project Idea realization and development Commercialization

Source: Herzog (2008)

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Communication is pivotal Open innovation is the in the matter key to success

As an everyday affair, technology foresight is a For this long-term innovation strategy to succeed, communication task—both within the Group and Evonik must also be more open to third parties in with organizations outside the Group. Only when its innovation process. Collaboration with aca­ information flows freely among participants can demic partners, which is already happening in the foundation be laid for future developments. In many areas of interest, is just the first step. Ex­ this regard, openness to new ideas and technol- ternal innovation projects, in-licensing or sale of ogies outside one’s own core business is vital. The technol­ogies (for example, through start-ups) can paths of innovation are not linear, as we know be fur­ther steps. For this reason, technology this from the example of the security checkpoints scouts from the individual units concerned with for people at airports. The metal detectors used innovation should have these wide-ranging op- there are based on a sawing machine develop- tions on their radar screens if they are genuinely ment in the lumber industry. on the lookout for attractive new methods and As part of the innovation process, individual, ideas. perhaps abstruse-seeming ideas must be measured Technology foresight calls for a long-term against market realities time and again with the perspective. It’s not about technologies that can help of experts inside and outside the network, be developed rapidly. Moreover, real innovation and increasingly, highly specialized colleagues. doesn’t travel familiar roads but often occurs as a Ultimately, then, technology foresight is broken disruptive development—with proportionately down into short-term processes without losing its greater consequences for the companies in that long-term perspective. market. And although this is about long-term On the other hand, it’s not enough to focus strategies, the individual steps of the innovation only on what the customer wants or to shelve an process must be designed for the short-term, be- idea only because it lies outside current business cause in the end, as the saying goes, „the future activities. On the contrary, markets, needs, and so­ will be here before we know it.“ l ciety change, and no one now can say with cer- tainty what opportunities will open up in five, ten or twenty years. The Internet is a vivid example of this. Until well into the 1990s, it was a technol­ ogy for a select few specialists. Today, it plays a vital role in the commercial success of several com­panies. In the process of selecting highly promising in­ novations, network participants will also inevi­ tably produce “false negatives,” or misjudge the potential of ideas. This is why the Technology Fore­sight Team also sees the need to continue monitoring the ideas and research findings gleaned from the innovation process, so it can present them to experts from the business units again at a later date, if needed. Viewing a new technology DR. FRIEDRICH GEORG SCHMIDT with a long-term perspective is essential to inno- Born in 1956 vative capability. And as experience shows, the Schmidt has been head of Innovation Management, disruptive technologies tend to be found among New Technologies, in Evonik’s Coatings & Additives Business Unit since 2008. He studied chemistry at the false negatives. the Universities of Göttingen and Freiburg. After obtaining his doctorate and an assistantship at the University of Karlsruhe, he began his career in 1985 in the central research department of the former Hüls AG in Marl. He moved to the Engineering Plastics Business Unit in 1986, where he was in charge of such products as VESTORAN® and VESTOBLEND®, and also directed the pilot plant for polymer blends. In 1996 he was a member of the Screening Committee at Hüls, which evaluated research topics for new business options. Beginning in 1997, he was a member of the management team at the then newly established Creavis unit, where he headed a variety of projects until 2002, when he took charge of product development in the former Coatings & Colorants Business Unit. +49 2365 49-4272, [email protected] elements29 evonik science newsletter 9 Chemical Umbrella for Buildings

Frank König, Dr. Ralph Scheuermann

Each year, moisture in buildings is responsible for billions of euros in commercial losses. Much of this damage can be avoided, how- ever, because interfacial chemistry has a recipe to protect buildings from penetrating moisture. Experts from Evonik’s Consumer Specialties Business Unit have developed additives for drymix materials that make buildings water-repellent from day one.

10 elements29 evonik science newsletter i n t e r FA c i A L t e c H N O L OG i e S

ydrophobizing building materials is not a recent invention. The ancient Egyptians treated their papyrus boats with salt so- lutions, and Alexander the Great had HwoodenH bridge piers dipped in olive oil before they were erected. Then and now, the objective was the same: protect the material proactively against the incursion of moisture. The purpose of Ways in which buildings this „chemical umbrella“ is to prevent or at least can take up water greatly delay moisture damage to the building. Today, moisture in facades, masonry, bridges, Driving rain and other architecture is considered as one of the Condensation in capillary most important factors contributing to building Condensation damage. Virtually no material is immune to the de­ above dew-point structive power of moisture penetration. Wheth­er Hygroscopic water retention masonry or cement, concrete, thermal insulations­ Osmosis or natural stone, whether brick or composite­ Technical faults structures—water destroys the inner cohesion of the material. As a result, precious monuments Infiltration of leak water crumble, bridges lose their bearing capacity, and masonry becomes unstable. Each year, moisture in buildings is responsible for billions of euros in Moisture on buildings can result in Rising damp commercial losses. microcracks through frost-thaw cycles (above), the efflorescence of The effects of water in the material vary. Mois­ mineral salts (middle), as well as ture settles into the pores, freezes in the colder reduced thermal insulation, or months, and blows open microcracks in the stone. growth of microorganisms (below) Water promotes the growth of certain fungi and other microorganisms that cover facades with fouling and attack the stability of the structures with their mycelium. Moisture washes out certain salts that then effloresce on the surface. Water Prevention instead of repair also carries contaminants such as sulfur dioxide and nitrogen oxides from the outside air into the In general, protecting existing buildings at a later masonry and promotes the formation of corrosive stage is complicated and expensive. Cologne Ca­ acids. Not least, moisture reduces the insulating thedral and the well-known Church of the Holy effect of walls, thereby increasing the energy Family in Barcelona are two outstanding examples consumption of buildings. of how long and difficult the fight against the destructive power of water is. Here, experts are try­ing to impregnate the natural stone with water- repellent and sorption-inhibiting coatings based on silicon. An ounce of prevention is worth a pound of cure, so goes the saying, but the same is true for buildings and facades, too. In the past ten years,

Integrating water-repellence in the preventive measures against moisture have be- construction of new buildings can save come increasingly relevant. Modern buildings are billions of euros, thus preventing often planned with moisture protection in mind, damage from moisture. This way, the time for the first renovation measures since the selection of building materials can keep can be moved up significantly moisture damage to a minimum. >>>

elements29 evonik science newsletter 11 Higher quality through finished products Above all, drymix products can meet the sharp increase in quality standards. Today’s materials Thanks to the growing importance of drymix tech­ must be “formula-proof,” so that expectations for nology, this trend is gaining significant momen- the longevity of objects and warranty protection tum. The selection of dry ready-mixed products can be fulfilled. Ready-made formulations pay off has grown enormously in the past few years, be- over the long haul: They reduce renovation costs, cause of the many key advantages of these formu- because the integrated water repellence works lations. They are easy to process and have long far longer than surface coatings. storage times. The properties of the finished build­ Today’s mortars are complex products. Manu­ ing material are consistent and reliable, and easy facturers mix anhydrous formulations that con- processing at the construction site saves time and, tain 15 to 20 individual components. In addition to therefore, costs. fillers and pigments, these mainly include additives that simplify workability, improve mechanical strength, shorten drying time, or control the air pore content as the prevention of tiny air holes.

High standards for water-proofing agents

Waterproofing agents play an increasingly im­ portant role in these complex formulations. The advantages are clear: If these water-repelling ad- ditives are added to the dry mortar during formul­ ­ ation, the material and, later, the structural ele­ ment receive a kind of “inner” compact and ho­ mogeneous protection. High demands are placed on the waterproofing agent, however. Capillary water uptake must be ruled out or at least greatly reduced—and permanently. If this is not the case, the first rehabilitation measures for a building can become necessary after only a few years. Drymix mixtures with water-repellent prop­ erties have been fixtures on the market for sever­ al years. But products that contain the impreg­ nating additives based on stearates or oleates show limit­ed water repellency and work only tem­ ­porarily.

A key advantage of drymix products: After they are mixed with water, they can be worked easily as flowing screed or with the trowel

12 elements29 evonik science newsletter i n t e r FA c i A L t e c H N O L OG i e S

Siloxanes: sustainable protection show an excellent beading effect and the desired through covalent binding high stability, even in a strongly alkaline medium, because cementitious systems often have a high Experts from Evonik’s Consumer Specialties Busi­ pH value. ness Unit, on the other hand, have developed But above all, they provide structural compo- powdered impregnating materials based on or­ nents with long-term protection against moisture gano­modified siloxanes that can give the structural and the damage it can cause. The reason is that, component optimal water-repellence over the unlike conventional metal soaps, SITREN® addi­ long term. Organomodified siloxanes are chemi- tives form permanent bonds with basic compo- cal com­pounds that also contain, in addition to di- nents of the mortar. This means they cannot be methylsiloxy units [Me2SiO-], different organic washed out later on. endgroups. On the one hand, the silicon-oxygen Test blocks containing a 0.25 percent dose of back­bone of these compounds gives them a high SITREN® additive were poured to verify long- affinity­ for the mineral construction material, and term protection. For comparison purposes, the on the other hand, their organic endgroups im- exact same blocks were produced from drymix part a strong water repellency. As compounds, mortar with conventional water-repellent metal they are relatively inert chemically, and there-­ soaps. The samples were pre-conditioned for sev­ fore offer ideal protection for the building over eral days in a humid environment, and then dried de­cades. ­ in an oven. For the actual test, the blocks were set Because the siloxane-based materials them­ on a water-saturated PU sponge, and the quantity selves are liquid, they are mixed into drymix for- of absorbed water was measured at defined time mulations and applied to porous, primarily inor- intervals (10 minutes to 72 hours). A sample with­ ganic substrates. The end result is a fine, white out water repellency was used as the control. powder that is easy to dispense and work. Behind The water-absorption tests were repeated in four their modest appearance lie true specialties opti- cy­cles. Between cycles, each of the mortar blocks mally tailored to your area of application. was dried in an oven at 80°C. Marketed under the brandname SITREN® this In the tests, the samples impregnated with product family has proven its outstanding proper- metal soaps showed an acceptable water-repel- ties in countless studies. They preserve the natural lent effect. After the fourth cycle, however, the water vapor permeability of the structural com­ impregnation had more or less disappeared, be- ponent, because it does not change the open pore cause it had been washed out with the water. On structure of the material. They also leave the the other hand, the samples hydrophobized with structure and color of the material unaffected—an SITREN® not only showed more effective im­ extremely important factor for today‘s architec- pregnation at the very beginning but remained ture. They allow surface treatment, such as paint­ water-repellent throughout all cycles. SITREN® ing with conventional dispersion paints. They ad­ditives, therefore, ensure reliable and >>>

Comparison between a brick water-proofed with SITREN® (background) and an untreated brick (foreground). In the untreated brick, moisture has caused mineral salts to float and effloresce on the surface

The powdered impregnating materials of Evonik are based on organomodified siloxanes (left) elements29 evonik science newsletter 13 With SITREN®, hydro- long-term protection against damage caused by phobized construction moisture penetration. materials show very good beading effect The development of innovative hydrophobiz­ without impairing the ing agents serves current developments in the natural water vapor construction market: drymix products based on permeability formulas that allow long-term and high-quality construction are quite common today, and will be used even more widely in the future. Worldwide, about 85 million metric tons of drymix construc- tion materials were sold in 2006. Experts predict that the market will more than double to 180 mil- lion metric tons by 2011. Particularly strong growth is expected in Asia, Eastern Europe, and Drymix products con- taining organomodified South America. siloxanes-based addi­ Growth is driven by the constantly rising de- tive developed by mands for materials. The primary catalysts are Evonik offer very good long-term protection grow­ing productivity along the entire value-added against moisture. Even chain in the construction industry, and the increas­ conventional dispersion ing importance of design and aesthetic aspects. paints can be easily applied. Now nothing Moreover, the demand for sustainable construc- stands in the way tion requires high longevity for buildings, innova- of a colorful cityscape tive materials, and optimal energy efficiency. These, in turn, prevent costly rehabilitation or com­­promises in quality from the outset. l

Comparison of the water uptake of drymix blocks that have been hydrophobized with SITREN® and with metal soaps. While water uptake significantly increases after the fourth cycle with metal soaps, it remains at the same low level throughout all cycles with SITREN®

Control Metal soaps 1st cycle 4th cycle Sitren® P 750 1st cycle 4th cycle Water up-take (mg/cm2) 350

300

250

200

150

100

50

0 10 min 20 min 30 min 60 min 4 h 6 h 24 h 48 h 72 h

FRANK KÖNIG DR. RALPH SCHEUERMANN Born in 1965 Born in 1972 Frank König heads the Innovation Ralph Scheuermann has been Management Industrial Formu­la­tors respon­sible for development in unit in Evonik’s Industrial Specialties the Industrial Formulators and Business Line. He started his career Functional Materials segments at Evonik Goldschmidt GmbH in since 2008. He studied chemis­try Essen in 1981, holding several posi- at the Technical University of tions in various R&D units, Tech­- Clausthal. After graduation, he ni­cal Services, and in Sales & Mar­ began his career in 2003 as an keting before assuming his current R&D employee in the Consumer responsibilities. Specialties Business Unit. +49 201 173-2988, [email protected] +49 201 173-2195, [email protected]

14 elements29 evonik science newsletter E v o n i k F o u n da t i o n

The foundation’s team: Susanne Peitzmann (advisor, left), Prof. Wolfgang Leuchtenberger (scientific consultant) and Managing Director Erika Sticht A Radar Screen for Good People

New name, new logo, new program: the Evonik Foundation promotes select young talent and awards annual scholarships, especially for scientific research.

elanie Thoß is a true child of the reactions faster than natural enzymes. “But we’re Ruhr Valley. Born into a mining fam­ talking about basic research. Specific applications ily in Bochum, raised in Watten­ are not the main focus.” scheid, she initially attended middle Her work is scheduled for three years. To con- MschoolM (Realschule), then passed her qualifying centrate on it completely—aside from some work exam for university entrance (Abitur) with the for the institute, such as advising Diplom candi­ goal of studying medicine. The numerus clausus dates—she looked around for scholarships and ap- pre­­vented a direct path to her goal, so she chose plied to Evonik Foundation (at that time Degussa biology instead, which meant she had to take Foundation). The jury found everything—her abil­ chem­istry. “I really liked it. It‘s so logical and, at ities, achievements, study plan—to its liking. And the same time, aesthetic.“ She was certain now: so Thoß received the Werner Schwarze Scholar­ ­ she would stay in biology but write her thesis on ship, which is fitting, since the long-time Degussa a chemistry topic. researcher Werner Schwarze (1913-2007) is the That was three years ago. And because she father of methionine, an essential amino acid vital fin­ished her thesis with the perfect grade of 1.0, it to modern animal nutrition. Now Thoß can con- is no surprise that she is now working on her doc- centrate entirely on her degree, thanks to the sti- torate, and should be finished in July 2010. The pend of €1,050 a month, which she thinks is “very subject of her dissertation is “Synthesis of Folda­ ­ good” and absolutely sufficient. mers from Chiral Binaphthyl Amino Acids.” Thoß is one of a total of 24 scholarship recip­ Foldamers are folded molecules that imitate the ients who have been supported by Evonik Foun­ tertiary structure of proteins in their size and dation. The foundation has been active under this structural complexity but are made up exclusively name and with its new logo since the beginning of of synthetic components. The basic idea is to po- the year. Its goal is to promote young talent who tentially recreate enzymes that carry out certain are unable to finance their intended scien- >>>

elements29 evonik science newsletter 15 Scholarship recipient Fascinated by the “Even though I was a Oliver Busse works beauty and logic of clear standout as a busi- with vegetable oils as chemistry: Melanie ness student among all substitutes for gasoline Thoß researches those natural scientists, in his laboratory in synthetic amino acids I really enjoyed the foun- Dresden. “Regenerative at the University of dation meetings, and my This meant some very concrete changes. chemistry,” he says, Bochum—and without horizons are continually “Instead of supporting 24 scholarship recipients “fits Evonik.” (left) financial worries, expanding thanks to my for one year, with the option of extending the thanks to a scholarship fellow scholarship recip­ from Evonik Foundation ients, who are really nice. scholarship one or two more years,“ says Peitz­ (middle) Thank you for the won- mann, „we’ll have ten recipients in the future derful time!” Henrik who’ll receive a solid two years of funding, with Matthies, former scholar- ship recipient (right) the option of a one-time extension. This will offer our doctoral candidates greater planning securi- ty.” In the future, the foundation will also limit itself to fields that fit Evonik Industries. Cultural scholarships will be discontinued. But the changes don’t stop there. In the future, tific education from their own funds, parental each scholarship recipient will be given a mentor. subsidies or donations from third-parties, and Dr. Stefan Buchholz, head of Innovation Manage­ who are ineligible or no longer eligible for public ment in the Industrial Chemicals Business Unit, funding options such as BAföG (Federal Training will become the first mentor and offer scholarship Assistance Act). recipients the opportunity to get an inside look at the company. They will also receive assistance in Active sponsor procuring technical literature and attending sci- entific meetings. In addition, scholarship recip­ Erika Sticht is the managing director of the foun- ients will be able to participate in the Evonik Per­ dation. Together with Susanne Peitzmann, the ad- spectives program, which helps young talent stay visor, and Prof. Wolfgang Leuchtenberger, the in contact with Evonik and strengthens their loyal­ scientific consultant, she has created a new model ty to the company. for the foundation: “We want to transform our- “But everything is voluntary. There are no selves from a passive into an active sponsor,” says strings attached to the award of the scholarship,“ Sticht. “We not only want to distribute money but says Sticht. What kind of applicants are consid­ to offer our scholarship recipients all-round sup- ered? “We’re assisting really excellent people,” port, as it were.“ The Executive Board agreed. In raves Leuchtenberger. The task of finding the right June, Executive Board Chairman Dr. Klaus Engel, ones from the mountain of applications falls to him. Chief Human Resources Officer Ralf Blauth, and “It‘s not enough to write a letter that says‚ I need Dr. Peter Nagler, head of Innovation Management your help.‘ The applicant must show what he has Chemicals & Creavis, approved the realignment already accomplished, describe his topic clearly, of the endowment. and present a detailed working plan,” explains

16 elements29 evonik science newsletter E v o n i k S t i f t u n g

Evonik Foundation is continuing the activities of Degussa Foundation, which was originally endowed with €2.5 million. In two additional steps, the Degussa-Hermann-Schlosser Foundation and the Degussa- Konrad-Henkel Foundation were integrated into the foundation in September and October 2003. Evonik Foundation currently controls as- sets totaling over €7.2 million. Compared with the large foundations such as Bosch or VW, Evonik Foundation is a pretty small flower in the garden of German foundations. The Association of German Founda­ tions estimates the total number of foundations in Germany to be about 16,500. Like almost all other foundations, Evonik Foundation also has to accept losses. In 2009, the endowment awarded scholarships exclu- sively for master’s theses and dissertations for the following chemistry majors: organic chemistry, physical chemistry, chemical technology, macro-molecular chemistry, material sciences, and process engineering.

For further informationen: www.evonik-stiftung.de

Leuchtenberger, who is in close touch with the basic research „but is not purely theoretical re- scientific community and, in addition to eval­ search.“ Despite his scientific ambitions, applied uating the application materials, also makes ver­ research is important to Lygin, who can see him­ bal inquiries. This is how applicants are screened self in corporate research in the future, rather than before the Executive Board makes its decision. at the university. A wel­come side effect: the foundation functions, This is also the goal of Oliver Busse, who according to Sticht, as a „radar screen for good works with vegetable oils at the Dresdner Institute people.“ for Technical Chemistry, and studies how they People like Alexander Lygin. Alexander is 25. react on porous, bi-functional catalyst systems. Born near Lake Baikal and raised in Moscow The goal is to use them in place of fossil fuels. His (Rus­sia) he attended Lomonossov University and, chemistry teacher (“I’m still in close contact with at the tender age of 21, received his master’s de- him”) kindled his love for these molecules. Busse, gree in chemistry, graduating with a “red diplo- too, earned his master’s degree with a grade of 1.3 ma,” the Russian equivalent of high honors or and began his doctoral research in October 2008. Summa Cum Laude. Unable to speak a word of “Regenerative chemistry,” he says, “fits Evonik.” German, he decided in consultation with his wife, His dissertation also lends itself to applied re- who is also a chemist, to go to Germany to work on search, and like Lygin, he can see himself work­ his doctorate. He has worked in Göttingen (“The ing in research and development. City of Science”) now since 2006, has long since He has also spent some time getting to know spoken fluent German, and feels very at home. Evonik. The scholarship recipients meet once a The thing that impressed him the most when he year. This year Busse and the others met in Ha­ saw Germany for the first time from the air was nau-Wolfgang; last year they met in Berlin. These “the orderliness.” “All the fields were neatly­ ar- meetings afford not only a glimpse inside the com­ ranged. Everything in this country is quadratic, pany but an introduction to some of the disserta- practical, good.” tion projects in roundtable discussions. And so here are three of a total of 24 scholar- A collaborator on six patents ship recipients, who showed up on the radar screen of the Evonik Foundation by word of mouth, In­ Despite his young age, Lygin already has a sub­ ternet research or the recommendation of their stantial list of publications under his belt. He has pro­fessors, and all with the greatest chances of collaborated on six patents. He came to Evonik fulfilling their goals—hopefully, with Evonik in the Foundation through his doctoral advisor. His dis- near future. l sertation—on synthesis of heterocyclical com- pounds with potential biological activity—benefits elements29 evonik science newsletter 17 c e n t OP r i M E ®

Highly Selective Hydrogenation of Nitriles to Primary Amines

Dr. Jürgen Krauter, Dr. Daniel Ostgard

The new CENTOPRIME® technology from Evonik allows the direct and highly selective conversion of nitriles to primary amines with a new type of catalyst developed by the Catalysts Business Line. Already used successfully in such processes as the synthesis of vitamin B1, this is a technology that lives up to its claims.

he catalytic hydrogenation of nitriles to If commercial-quality activated nickel catalysts their corresponding primary amines plays are used in the hydrogenation of nitriles, second­ an important role in the commercial sec- ary and tertiary amines also form as undesired by- tor. The chemical industry, for example, products. Figure 1 illustrates this for the example Tuses nitriles to produce nylon (from adiponitrile), of benzonitrile hydrogenation. high-performance plastics (from diaminobutane), In the past, this problem was solved by adding surfactants, emulsifiers, and numerous medicines amonia or alkali to the reaction mixture, which such as the cholesterol-lowering drug Lipitor and would promote formation of the primary amine by the anti-convulsive Gabapentin for treatment of interfering with the chemical equilibrium. A draw­ epilepsy. Based on a Murray Raney (patent 1927) back of this method, especially with more com- development, the activated metal catalysts used in plex molecules, is that undesired reactions with the reaction are powdered full-contact catalysts the other functional groups can occur in these made of a transitional metal aluminum alloy from molecules. Furthermore, the use of ammonia is which the aluminum has been leached with caus- critical, particularly in terms of the technical reac- tic soda to a content of about seven percent by tion conditions, but also from the standpoint of weight. Nickel is used most often as the transi- safety, and the use of alkali shortens the lifespan tional metal, but copper and cobalt are also used, of the catalyst. But even if these drawbacks are ac- albeit far less frequently. The catalysts obtained in cepted, sel­ectivity for conversion to the primary this process are comparable to highly porous amine can be increased to more than 95 percent sponges saturated with hydrogen on the surface. only in exceptional cases. >>>

Figure 1 Hydrogenation of benzonitrile to the primary amine using a Desired primary amine commercial-quality activated nickel catalyst. The secondary reaction to the undesired secondary amine can be partially suppressed by adding ammonia or alkali

Undesired secondary amine

18 elements29 evonik science newsletter C A T A L YS I S

Highly Selective Hydrogenation of Nitriles to Primary Amines

elements29 evonik science newsletter 19 Up to 99 percent selectivity with new catalyst technology Figure 3 Vitamin B1 synthesis: the selectivity of various catalysts in the hydrogenation of pynitrile to the primary amine, as compared to CENTOPRIME® technology To remove this weakness, Evonik’s Catalysts Busi­ Primary amine Secondary amine Other products ness Line has developed a completely new gen- % Selectivity from pynitrile hydrogenation eration of catalysts. Even without the addition of 100 1.7 1.0 1.3 0.2 ammonia, it offers selectivities of more than 80 0.1 percent in the hydrogenation of nitriles to prima- 99.7 ry amines. Small amounts of ammonia allow these 99 2.2 values to climb to as high as 99 percent. Previous 1.9 catalysts could achieve a selectivity of between 1.9 only 50 and 60 percent without ammonia. Evonik 98 markets the patented technology under the trade- mark CENTOPRIME® (Patent WO 2006050749 of 97 Evonik). 96.8 96.8 The key to the success of this technology is in 96.4 the systematic surface treatment of the catalyst, 96 Activiated Ni Activiated Co Ni/SiO2 Centoprime® which creates defined nickel ensembles with a catalyst precise geometry. These are created through tar- technology geted application of carbonaceous precursors that ensure that parts of the surface are artificially “carbonized” at the end of catalyst production. This makes the catalytically active centers on the surface smaller than they are on the untreated cat­ alyst. The result is steric effects that ensure the ca­talysts are far more selective than the non- treat­ed catalysts. Both nickel and cobalt can be used in this method of surface modification.

Evonik´s Catalyis Competence Center in Hanau (Germany)

Figure 2 In vitamin B1 synthesis, pynitrile is hydrogenated to the corre­ Desired Grewe diamine sponding primary amine, the “Grewe diamine.” About four percent byproduct is produced with conventional catalysts

Undesired secondary amine

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20 element evonik science newsletter C A T A L YS I S

Yields increased in more fluid the product is, and the better suited Contact the synthesis of vitamin B1 the surfactants produced from them are for the above-named applications. In the synthetic production of vitamin B1, pynitrile Typically, up to six percent secondary and ter- is hydrogenated to the corresponding primary tiary fatty amines are produced during the hydro- amine, the “Grewe diamine.” The mechanism genation; 40 to 80 percent of the double bonds shown in Figure 2 forms the undesired secondary are retained. CENTOPRIME® technology also scores amine. Typically, about four percent byproduct is in this regard: It reduces the share of secondary produced in the presence of ammonia. This loss in and tertiary fatty amines to below three percent, yield is not an insignificant cost factor for the while alkene retention increases to over 90 per- commercial scale. cent. This ensures that the fatty amines are color- When CENTOPRIME® technology is used, less, clear and display good fluid properties, DR. JÜRGEN KRAUTER Grewe amine yields increase to more than 99 per- which not only allow the production of high-qual­ Head of Marketing & Business Development cent (Fig. 3). This selectivity advantage has re- ity products but also open up other new applica- Catalysts Business Line sulted in use of the new technology in the com- tions for fatty amines. With the conventional Evonik Industries mercial manufacture of vitamin B1. Another ad- technology, this was not possible. +49 6181 59-8714 [email protected] vantage is the flexibility: because CENTOPRIME® Also in this case the special structure of the technology can be transferred easily to other sub- nickel ensembles that determine the surface of strates, there are now numerous applications in the catalyst is the reason for the high selectivity of fine chemicals. this technology. Steric effects prevent the forma- tion of secondary and tertiary amines through the A new route to high-quality fatty amines same mechanism as in the hydrogenation of the pynitrile in vitamin B1 production. Likewise, the A host of surfactants, such as those used as soft­ high retention of the double bonds can be traced eners, dyeing aids, disinfectants, bactericides and back to steric effects and the preference they detergents, are based on fatty amines, which are create for absorption of the nitrile over the dou­ obtained through the selective hydrogenation of ble bonds. DR. DANIEL OSTGARD fatty nitriles in the presence of ammonia (see Both examples show that continuous innova- Senior Business Figure 4). The selectivity of the reaction can be tions are possible, even in the field of apparently Development Manager Catalysts Business Line judged with the naked eye: the clarity and fluid­ity mature nickel-catalyst technology. New technol­ Evonik Industries of the fatty amines that form depend on how many ogies such as CENTOPRIME® help meet the con­ +49 6181 59-4138 secondary, tertiary and saturated fatty amines stant challenges faced by industrial chemistry [email protected] were produced as byproducts. The more double with regard to more efficient processes and im- bonds are retained, and the higher the selectivity proved products, and thereby provide the user a to the primary fatty amines is, the clearer and higher added value. l

Figure 4 Production of fatty amines

A solid fatty amine with a low melting point

elements29 evonik science newsletter 21 The construction of new playing fields reveals a trend away from natural grass in favor of artificial turf. The German national soccer team had its debut on artificial turf in a match against Russia in Luschniki Stadium, Moscow, in October 2009. Germany won 1:0, securing early qualification for the World Cup 2010

Green Art for a Kick

New Coating Transforms Used Tires into Long-Lasting Artificial Turf

Dr. Rainer Fuchs, Dr. Andreas Berlineanu

Sports fields with artificial turf are growing in number and have definite advantages over fields with natural grass and hard courts: They are easy to maintain, usable year round, and elastic—easy on the bones and ligaments of the athletes. So it is no surprise that the International Federation of Association Football (FIFA) is now actively considering artificial turf as the ideal playing surface for big tournaments. A vital element of an artificial grass field is the infill, a centimeter-thick layer of rubber granulate between the grass fibers, whose properties have now been drastically improved by Evonik with a newly developed two-component coating.

22 elements29 evonik science newsletter C OA t i n G S

he Salzburg Stadium has it, so does the A number of German soccer clubs, including Swiss Stadium in Bern, as well as the from the upper leagues, now have training fields Luschniki Stadium in Moscow, where the made of artificial turf because they are playable German National Soccer Team held its no matter what the weather is like. According to TTWorld Cup qualification match against Russia: ar- FIFA, there are currently 184 FIFA 1-star fields and tificial turf. Once decried as inferior and cursed 141 FIFA 2-star fields made of artificial turf, world- by players and trainers alike, artificial turf has wide. Two-star fields are approved for the now advanced so far that FIFA is actively prom­ Champions League. oting it globally. As a big advantage it creates play­ing fields of uniform quality standards world- Man-made beats nature, even wide, in a great variety of climate zones—some­ when it comes to costs thing natural grass cannot do, or can do only at great expense. Costs are another strong argument in favor of ar- In the countries of northern and southern tificial turf. The landscape architecture company Europe, the construction of artificial grass fields is G. & L. Hoppe from Bremerhaven conducted a driven more by climate than it is in Central Eu­ comparison study and determined that one hour rope. Cold weather and too much rain in northern­ of use on a natural grass field costs €100, on a Europe, or too little precipitation in southern Eu­ “hard court“ almost €29, and on an artificial turf

The third, most recent Short-piled turf with High-piled turf with generation of artificial bound elastic base high infill layer turf systems: the short- piled variety needs a bound elastic base course made of rubber granulate, and contains comparatively little Blade infill. With the high- height: piled variety, on the 1.5–2cm other hand, only the infill provides the Infill: required elasticity. 1–1.5cm; This is why it contains Infill: 5kg/m2 significantly more 3–4cm; rubber granulate as 12–15kg/m2 Sand: infill 1cm; 15kg/m2

Bound elastic base 5–35mm Sand: (GTR 1cm; Ø 2–7mm) 2 Soil, asphalt, or concrete 15kg/m

rope make it difficult—and expensive—to maintain field only €20. The study took into consideration the same level of quality of a natural grass field. both the construction and maintenance costs, as But the general trend towards expensive high- well as the potential utilization of the surface over tech stadiums, which are increasingly be­coming the course of the year. multiple-event venues, makes an artificial turf The fibers of artificial grass are made of poly- surface more attractive and economical. Today a propylene, polyethylene, or polyamide. A layer of soccer field, next week a rock concert—with a na- sand is scattered between the fibers to weigh tural grass field, the only option is complete re- down the artificial grass carpet, and then a layer placement. With artificial turf, however, the field of rubber granulate, the „infill,“ is applied to im- can even be covered and overlaid with an ice rink. part the required elasticity. The quantities are Only a few days after the ice rink is melted off and considerable: depending on the type of artificial the covering is removed, the artificial grass is play­ turf, 5 to 15 kg of rubber granulate is required per ­able again—as was the case recently at the Salzburg square meter. The entire structure is permeable to Stadium. water, so even large amounts of rainwater >>>

elements29 evonik science newsletter 23 The UV test developed by the Project House Functional Films & Surfaces and the Tech- nology Service Center of the Wolfgang Industrial Park provides reliable data on the long-term stability of the infill. From left to right: Frank-Dieter Kuhn, Rainer Fuchs, Doris Schneider, Marisa Cruz

do not form puddles but instead flow out through environmental standpoint, are not a sustainable the drainage system located under the turf. product because they are not made from recycled Artificial turf infill is made predominantly from materials. recycled scrap tires, which accrue worldwide at Moreover, once they are used in artificial turf the rate of twelve million metric tons per year—or fields, EPDM infills have shown little aging resis- about 1.6 billion used tires. Ground tire rubber tance, and as observed in many cases in the recent (GTR) has several drawbacks that make it unpop­ past, are not abrasion-resistant. TPE infills also dis­ ular among many artificial turf owners and play- play weaknesses in this regard, and are extremely ers: it heats up strongly in the sun, makes both the expensive. One alternative on the market is poly- ball and the goal posts black over time, and smells urethane-coated GTR infills. But because of their strongly. Little by little, rainwater also washes UV sensitivity, they darken severely over time zinc ions out of the GTR infill. Zinc ions originate and therefore are not weather-resistant. from the zinc oxide in the rubber granulate, which acts as crosslinking catalyst during tire pro- The solution: POLYVEST® duction. This is why GTR infills are prohibited in Italy, for example. A manufacturer of artificial turf infills approached Other suppliers have reacted to these weaknes- Evonik and asked for a creative solution to the ses of GTR infill by marketing products made of problems with GTR. A coating was desired that ethylene-propylene-diene monomers (EPDM) or not only retains substances such as zinc ions or thermoplastic elastomers (TPE). They have three odors in the granules, but protects the ground tire to five times the cost of GTR infill, and from an rubber against UV light, water and reactive envi-

The coating developed by Evonik Water for ground tire rubber reliably protects against external influences and dependably retains odors and zinc ions. It is also non-toxic, has Ozone Sunlight (UV) the proper elasticity, does not dis­ color or darken, has a low heat up in sunlight, and lasts for five to ten years—at acceptable costs Oils Odor Zn++ Color

Abrasion

24 element30 evonik science newsletter C OA t i n G S

ronmental gases such as ozone or oxygen. It also had to be non-toxic, have the right elasticity, and ”Very close to natural grass“ adhere well to the rubber granulate. Moreover, it should not darken or discolor, and should have a As of 2008, the athletic field of the Marl Chemical Park has featured a lifetime of five to ten years. And absolutely essen- state-of-the-art artificial turf that meets the highest standards of quali- tial: the costs for this coating should remain rea- ty. The turf is the result of close cooperation between Infracor GmbH, sonable. a wholly owned subsidiary of Evonik that operates the Marl Chemical This is why the Functional Films & Surfaces Park, and the Functional Films & Surfaces Project House, which had Project House first scouted the Group to find worked intensively with infill materials for artificial turf in the prelimi- high­ly promising products. In the end, the key to nary stages. their success was a special product based on Today, well over 1,000 active members of works-related sports clubs POLYVEST®, a functionalized polybutadiene. Be­ train and play on the artificial turf. The popularity of the athletic ground cause of its similarity to rubber, it can adhere well extends well beyond the bounds of Marl. In September 2009, the U18 to the surface of GTR granules through chemical of the German national soccer team held an international match against reactions. Following application and curing, the Burkina Faso. Even the German Soccer Federation praised the athletic highly cross-linkable coating developed with these ground in front of the gates of the Marl Chemical Park. components is very flexible yet sufficiently hard, Jürgen Krakau of thus ensuring that GTR granules and coating form Infracor is responsible an elastic overall system that fully meets the high- for the athletic ground and gives his est demands. assessment of the The coating was developed by the Coatings & artificial turf Additives Business Unit. As part of the process, the Project House used a newly developed prac­ tice-oriented test system to study the coated rub- ber granulates. The obtained test results strongly influenced the further optimization of the coating formulation at the Coatings & Additives Business Unit. After more than 50 different, continuously optimized coating formulations, a coating has now been developed that optimally meets all the re- quirements for use on rubber granulates. The coating consists of a hardener and a bin- der component. The hardener component is a special product based on a functionalized polybu- tadiene. The binder component contains a binder, filler, pigments, and other products from Evonik. What’s so special about artificial turf? These are coating additives that stabilize the de- Krakau: Despite the mechanical demands of play and the stress of the gree of dispersion of the pigments necessary for sun, rain and frost, a field like that can be used 24 hours a day, 365 days coloration, ensure abrasion-resistance and anti- a year. You can’t do that with natural turf or with a conventional hard settling behavior. court (clay court). How hard is it to maintain? On the way to the market Krakau: The infill material is uniformly redistributed on the field through weekly removal with a Kleinschlepper and the proper cultiva­ In 2008, Evonik set up its first artificial turf field— tion equipment. The field also gets a thorough cleaning once a year. in the “Stadion am Badeweiher” belonging to the Natural turf or hard courts have to be regularly chalked and damage to Marl Chemical Park. The artificial turf is used the playing field repaired, not to mention the watering, mowing and year round, particularly for soccer training, and fertilizing required by natural grass. ex­­­perience has been completely positive: The ar- What do trainers and players have to say about artificial turf? tificial turf has the familiar advantages—highly Krakau: In Marl, we have the latest generation of artificial turf. It has elastic, easy to maintain, durable and playable in a reputation well beyond our city for high quality, and optimal and wind and weather. Encouraged by the positive re- consistent playing conditions. Players like it because the force dissipa­ sults with the field, Evonik has greatly stepped up tion and the damping of the playing field is nearly 70 percent. These the development work for a new artificial turf in- values exceed the requirements of FIFA 2-star quality by a wide fill material based on a new coating. The alterna- margin. A natural motion sequence, perfect grip, and protection of tive developed by Evonik is abrasion-resistant, musculature, joints, tendons, and ligaments are also highly praised by UV-resistant, non-toxic and reliably retains odors both players and trainers. and zinc ions. It has proven to be superior >>> elements29 evonik science newsletter 25 for artificial turf provided no clues to these require­ ments, since its standards for the infill material are often quite low. The abrasion test and the UV Evonik Industries test were important components of the self-devel­ oped test system, because both methods allow Installed artificial turf reliable conclusions to be drawn about the long- Coating Artificial turf system suppliers term stability of the infill. In addition to the Func­ tional Films & Surfaces Project House, the Tech­ nology Service Center of the Wolfgang In­dus­trial GTR Coated GTR GTR Park contributed significantly to the development production Infill of the UV test. Like the coating formulations, the test meth­ GTR coating ods are patented worldwide. Deliberations are al- Used tires ready underway to recommend one or more of Used tire recyclers the tests developed at Evonik as the future stan- dard for infills, so that more realistic and mean­ The path from used tire ingful specifications can be integrated into the to artificial turf. Begin- current norm. ning in 2010, Evonik will supply the two-com­- in virtually all properties to the traditional GTR in­ ­ponent coating for rub­- fills or other coatings or uncoated infill products — Good market prospects ­ber granulates, obtained ­and the base material, the ground rubber, is a re- from scrap tires (GTR, ground tire rubber), to cycled product. The market prospects for coated GTR are good, manufacturers of In line with Evonik’s philosophy of supplying as the trend away from natural turf and towards artificial turf infill not only components but a well-thought-out sys- artificial turf in the construction of new athletic tem, Creavis Technologies & Innovation, the strat­ fields continues. In Europe, GTR is still the most ­egic research unit of Evonik for its chemical activ­ popular choice for artificial turf. An infill made ities, will begin supplying the ready-made two- from coated used tire granulate is also currently component coating to artificial turf manufacturers used, but it has little UV resistance. There are also beginning in 2010. Several playing fields are sched­ EPDM and TPE infills in the market. uled to be equipped with this coated GTR infill as Depending on the type of artificial turf used, early as next year. between 35 and 100 metric tons of infill is re­ Crucial to this successful new development quired per field—a practical and, above all, sustain­ was a new test system that allowed a variety of able application for at least some of the used tires import­ant requirements for the product to be that accrue each year. Evonik’s use of the coating tested realistically,­ fast, and precisely. The DIN offers a “green future” for these used tires. l

DR. ANDREAS BERLINEANU DR. RAINER FUCHS Born in 1958 Born in 1958 Andreas Berlineanu (left) has worked for Rainer Fuchs has been an employee of various companies in the coatings industry for Evonik since 1990, and worked on several years. He has been responsible for the various active oxygen products and multi-faceted applications engineering­ for liquid environmental projects in R&D and polybutadienes in the Coatings & Additives applications engineering. He has Business Unit since September 2001. In the worked at Creavis Technologies & Coatings & Additives Business Unit, Andreas Innovation since late 2004, and has Berlineanu, Kirsten Luce, Siegfried Jittenmeier, been project manager of the Coated Nicole Dudek and Margit Bukohl (from l to r) GTR project in the Functional Films are responsible for development of the coating & Surfaces Project House in Hanau- system for rubber granulate infill. Wolfgang since July 2006. +49 2365 49-5497 +49 6181 59-6468 [email protected] [email protected]

26 elements29 evonik science newsletter news

+++ “Area of Competence Days” point to perspectives in Biotechnology

White biotechnology is becoming a major driver of growth and “White biotechnology means new methods, new possibilities, innovation in the chemical industry of the 21st century. This was and new markets based on nature,” said Patrik Wohlhauser, chair- the assessment recently made by one of Evonik Industries’ largest man of the Management Board at Evonik Degussa GmbH. “Fewer professional conferences on white biotechnology in Marl. The CO2 emissions, lower energy consumption, and higher efficiency event, Bio Business Perspectives, brought together some 150 com­ – these advantages of white biotechnology are particularly wel- pany employees, business leaders, and politicians in September come news in difficult times. The health, nutrition, and cosmetics 2009. The discussion centered on new biotech processes and markets continue to open up new growth opportunities for bio- products­ to meet the needs of tomorrow. Thanks to its low ener- based products,” Wohlhauser continued. “As one example Evonik gy and resource intensity, white biotechnology is already scoring has already established several products in the cosmetics market many points as an alternative to conventional contemporary that were made using biotech processes. This includes ceramides, chem­ical processes. The two Area of Com­petence Days held at which regulate the various cellular processes of the skin,“ added Evonik underscored, however, that the economic and ecological Dr. Peter Nagler, head of Innovation Management Chemicals & potential of this technology is far from exhausted. Creavis at Evonik. in their business unit presentations, Evonik’s experts discussed today’s biotechnology business, with all its opportunities and risks, and highlighted potential growth areas. Speakers from other companies and from the industry peer group analyzed the busi- ness perspectives of biotechnology from their views along the supply chain. Thus, Christophe Rupp-Dahlem, director of the vege­ tal-based chemistry program of the French company Roquette, introduced the fermentative production of succinic acid from glu- cose. The acid can be used in the manufacture of new materials, and a demo plant is scheduled to become operational this year, with a first production plant to follow two years later. “Industrial biotechnology will be a cornerstone of our future bio-product technologies,” Rupp-Dahlem emphasized. Patrik Wohlhauser (left), chairman of the Management Board at Evonik Degussa GmbH, and Dr. Peter Nagler, head of Innovation Management Chemicals & Creavis at Evonik

+++ CyPlus® commissions Cold Caro’s Acid systems in Brazil

CyPlus GmbH, an Evonik subsidiary, has succeeded in commission­ “We require low cyanide discharge levels for our operations ing two Cold Caro’s Acid systems for Concord, New Hampshire, and it is essential to perform this economically. With the CyPlus® USA-based Jaguar Mining Inc. at their Turmalina and Paciencia Cold Caro’s Acid systems, we expect to reduce reagent consump- gold-mining operations in Brazil. The systems treat cyanide-con- tion by more than 30 percent, achieving the same low cyanide taining effluent. Cold Caro’s Acid is a powerful oxidant that is levels of 10 ppm or better. The results from the commissioning produced in situ by adding hydrogen peroxide to concentrated phase indicate that we made the right choice,” says Mauro Salim, sulfuric acid. It is used in gold extraction to convert cyanide into project manager for both of the Jaguar Mining operations. cyanate. “The CyPlus® system is a proven process that achieves a this CyPlus® process is es- yield of more than 80 percent of Cold Caro’s Acid,” says Stephen pecially suitable for treating Gos, manager of Technology Solutions at CyPlus GmbH in Hanau-­ cy­anide-containing effluents Wolfgang. The advantage of the CyPlus® system is that the heat from ore processing opera- from the reaction can be controlled and kept at low levels, thus tions in order to comply with ensuring safe operation. stringent limits such as those A feasibility study conducted by CyPlus® in its laboratories in set by the International Cya­ Germany shows that the Cold Caro’s Acid process outperforms nide Management Code, the other effluent-treatment systems. Basing its decision on the feasi- World Bank, and local author­ bility study and the basic engineering package, Jaguar choose to ities. install the CyPlus® system for generating Cold Caro’s Acid. Be­ sides keeping cyanide levels in check, the system is highly efficient CyPlus® Cold Caro’s Acid system at as regards hydrogen peroxide and sulfuric acid consumption. the Turmalina gold mine (Brazil) elements29 evonik science newsletter 27 +++ New license agreement for vanadium-doped precious metal powder catalysts

The Catalysts Business Line of Evonik Industries and Evonik’s Catalysts Business Line. “Additional license agreements and fees will the Swiss-based company Solvias AG have renewed no longer be necessary. What remains is a high-performing technology that their license agreement for vanadium-doped precious converts even complicated nitro compounds into amines reliably and with metal powder catalysts for the hydrogenation of nitro high yields.” compounds. Evonik will continue to market these cat­ the vanadium-doped precious metal powder catalysts can be used for se- alysts, which were developed by Solvias, on an exclu- lective hydrogenation of nitro aromatics. Their advantage compared with sive basis but the underlying business model has been other catalysts is that they do not target the halogen substituents in the target greatly simplified effective October 1, 2009. “Anyone molecule. That makes handling nitro compounds safer and generates fewer purchasing these catalysts from Evonik now automat­ by-products. ically acquires the right to utilize the technology,” For highly complex nitro aromatics Evonik offers a second form of this explains Dr. Jürgen Krauter, head of Marketing at cat­alyst which is additionally modified with hypophosphoric acid.T his is used where other catalysts reach their limits: When the target molecule contains reactive components such as double and triple bonds, carbonyl groups or highly reactive oxime groups as well as halogens. Here too, the catalyst en- sures selective hydrogenation of the nitro group only and thus obviates the need for time-consuming use of protective groups

Solvias uses technology for customized process optimization Solvias will continue to use this technology for customized process develop- ment and optimization. “This technology complements Solvias’ broadly based expertise in heterogeneous catalysis, which ranges from the development of heterogeneous catalysis technologies and high-pressure hydrogenation through the implementation of manufacturing processes to process develop- ment and scale-up in our GMP laboratories,” comments Dr. Stephan Haitz, head of Marketing & Sales at Solvias. This Swiss company thus retains access to the entire platform of technologies for hydrogenation of nitro groups with vanadium-based catalysts. Alongside the ready-to-use vanadium-doped cata- lysts marketed by Evonik, this includes in-situ variants comprising platinum catalysts to which a vanadium salt is added during the reaction.

Potential applications for vanadium-doped precious metal powder catalysts

+++ High-pressure for VESTAMID® PA 12

A new high performance thermoplastic polyamide (PA) pipe that Interstate 15 frontage roads outside Great Falls, agree. They are is less expensive to install and easier to maintain than traditional home to the first installation of VESTAMID® PA 12 gas pipe in an steel pipe has been introduced for the first time inN orth America. established public right of way in the United States. Evonik´s VESTAMID® LX9030 offers exceptional performance for high-pressure applications which helps gas companies effec- Less expensive to install tively design their underground infrastructure without sacrificing „There are numerous benefits to utilizing PA 12 pipe,“ said Ed flow capacity.R esearchers estimate that PA 12 pipe has significant Kacer, general manager of Energy West. „The material is light- labor and installation savings over steel. weight and allows for faster construction than steel, while main- „PA 12 is an excellent alternative to steel pipe in high-pressure taining higher volumes associated with higher pressures. Instal­la­ applications up to 18 bars for gas distribution lines,“ said Dennis tion can be accomplished using a smaller construction crew, saving Jarnecke, program manager at Gas Technology Institute (GTI), a time and money.“ research, development and training organization in USA serving in addition, Kacer said, very little initial investment is required energy and environmental markets. „It has been used as fuel lines for construction teams because the same equipment and processes in cars and for air brake tubing in trucks. Now we see great po- are used when installing VESTAMID® PA 12 pipe as other plastic tential for its use in gas delivery systems.“ pipe. „Today, it’s getting harder to find qualified welders and Officials at Energy West, a Montana-based (USA) gas utility many utilities contract their welding,“ he explains. „We used our and energy supplier that is laying three miles (about 4.8 km) of existing plastic fusion equipment and the fusions looked as good VESTAMID® PA 12 pipe for a natural gas distribution system along as a weld. Working with PA 12 was a very positive experience.“

28 elements29 evonik science newsletter news

to meet the needs of Energy West, Evonik—working jointly with GTI—coordinated a system of VESTAMID® PA 12 straight and coiled pipes and fittings. Extruded in diameters ranging from 32 to 160 mm, VESTAMID® PA 12 pipes can be manufactured as straight pipe and on coils, depending on the diameter and wall thickness. This flexibility in length—particularly for long stretches of installation—saves money by reducing time spent fusing pipe ends together. equipment used in the installation of both straight and coil pipe did not require any modification. The heat fusion process for joining two ends of VESTAMID® PA 12 is easier and faster than connecting steel pipes benefiting the bottom line. compliance with pipeline integrity regulations is also more cost-effective. „Traditional steel pipe must adhere to corrosion control and cathode protection requirements which add to a com­ pany’s expense,“ says Jarnecke. „PA 12 is corrosion resistant and has labor and installation savings over steel.“ Federal and State pipeline safety officials, including repre­ sentatives from the U.S. Department of Transportation, were in attendance in Great Falls to observe the installation, which went according to plans.

Easier to maintain More importantly, said Andreas Dowe, Evonik’s Market Development Manager for oil and gas applications, VESTAMID® PA 12 provides users with a comparable alternative to steel pipe for distribution of natural gas. „We believe this innovative mate- rial will revolutionize the gas transportation industry in the United States“, he says. „It’s less expensive to install, easier to handle, and maintenance over the long term is less than traditional steel pipe.“ And he completes: „We are sure that the benefits will prevail also in other regions worldwide.“ in research performed by GTI and sponsored by Operations Technology Development, NFP (OTD), PA 12 has been evaluated for use as gas-distribution piping in North America, and technical support necessary to obtain regulatory approval for its use in the U.S. was developed. Extensive testing of materials resulted in a comprehensive database of the physical properties of PA 12 pipe and demonstrated conformity to ASTM standards.

VESTAMID® PA 12 pipe ends are joined using a heat fusion process that is easier and faster than connecting steel pipes, benefiting the bottom line (above)

VESTAMID® PA 12 pipe coils reduce labor and installation costs (below) elements29 evonik science newsletter 29 P l e X I G L A S ®

Innovative Light Management with High-Precision Microstructures

Dr. Sandra Reemers, Dr. Heiko Rochholz, Grant Lafontaine, Pete Marks

Uniform room lighting with high light yield or solar concentrators that cost- effectively concentrate the sunlight onto smaller solar cells: The microstructuring of plastic surfaces offers a wide range of potential applications. Thanks to the joint efforts of the Functional Films & Surfaces Project House and the Perfor­ mance Polymers Business Unit, this pathbreaking technology is now available to Evonik Industries, and gives PLEXIGLAS®, the market leader among high- transparency, weather-resistant engineering plastics, new value-adding properties. PLEXIGLAS® covers with high-precision prismatic structures allow uniform room lighting without glare.

LEXIGLAS®, a transparent plastic made from Surfaces that are changing the world polymethyl methacrylate, boasts not only high stress cracking resistance and heat The functionality of a plastic like PLEXIGLAS® de- deflection temperature but also outstand­ pends, on the one hand, on the properties of the PPing optical properties. Accordingly, PLEXIGLAS® polymer itself, which define the mechanical and covers for lighting fixtures meet the highest stan- thermal characteristics of the material, as well as dards of functionality. But it does so without com- its color and transparency. On the other hand, it promising aesthetics: sophisticated designs for offers the opportunity to use the structure of the trans­parent diffusers can be realized for both the surface to direct the light that falls on it, thereby standard lighting and premium lighting sectors by selectively influencing the optical properties. forming PLEXIGLAS® molding compounds in the Here, the size, geometry, and distance of the injection-molding or profile extrusion process, or surface structures control the optical properties cutting them from extruded sheets. of the plastic. If the structure size lies within the Because of its outstanding optical properties, size of the visible light—a wavelength of 600 nm such as transparency and clarity, a major portion corresponds to a structure size of 0.0006 mm— of the acrylic produced each year is used in tech- diffractive effects occur. These optical effects are nical lighting applications, often for customers used, for example, to manufacture safety holo- from the lighting industry. About 8 percent of the grams and anti-reflective display cover films for acrylic glass in Western Europe is processed in mobile phones and laptops. the lighting market. The market for lighting, lamps Refractive effects occur with structures that and lighting control systems as a whole is about are larger than the optical wavelength—the size of €10 billion (2008) in Western Europe. a human hair, for example, but also much >>>

Influence of the structure size on optical properties, such as the transmission and reflection behavior of a transparent plastic (λ = wavelength)

Structure size >> λ Structure size = λ Structure size << λ

30 elements29 evonik science newsletter D E S I G n i n G w i t H P O L YM e r S

Innovative Light Management with High-Precision Microstructures

Precisely structured PLEXIGLAS® covers provide uniform illumination of rooms without glare

elements29 evonik science newsletter 31 larger structures. The light is refracted on the is why conventional grid lighting is equipped with sur­face—very much like light on the surface of special aluminum grids that direct light rays that water. radiate above an angle of 60° downward. To take this idea a step further, light can be To selectively direct, bundle and distribute directed in such a way that it spreads in a defined light, as well as minimize scatter losses, the sur- direction after it penetrates the surface. The action face structures must be precisely formed. This ex- is created through surface structures that function ceptionally high precision is a hallmark of quality like small prisms. Evenly arranged over the entire of the surface structures that Evonik produces surface, their individual light-deflecting actions with the help of its new technology platform. combine to create an overall effect observable on Accordingly, the areas of the structures here have the macroscopic scale. And this effect becomes very minimal edge roughness. Because the quality even stronger the more precisely the microstruc- of the pyramid edges determines the path the tures are formed and compatible with each other. light rays take when they hit them, rough surfaces Lighting designers, architects, and engineers in scatter light rays in all directions, causing scatter building and solar technology are particularly in- effects and losses. The smoother the edge surfaces terested in using these opportunities of selec- are, however, the more selectively they direct the tively distributing and directing light. light rays in a particular direction, no matter which Selectively and precisely structuring the sur- angle the light falls, and the better the effect and face gives developers the opportunity to direct, light yield. bundle or scatter light evenly. How polymer sur- faces can be technologically functionalized through Precision saves energy microstructuring is a research focus of the Func­ tional Films & Surfaces Project House, which For defined light direction, it is also important that Evonik started in Hanau in January 2007. An inno- the points of the pyramid are rounded as little as vative technology platform for high-precision possible, since rounded edges direct light im­pre­ microstructuring of PLEXIGLAS® films and sheets cisely and generate scatter losses. The pattern was also developed as part of the project. ma­nu­factured by Evonik scores in this regard too. The radii at the points of the internal edges are so Light management meets design small that no demonstrable scatter losses occur. The highly precise light redirection also ensures Ceiling lighting in offices should light the work- that less energy has to be used for lighting the place evenly without causing reflections on PC room—while simultaneously creating more com- monitors. This kind of glare is caused by lateral, fortable lighting conditions—than with conventional downwardly inclined rays from ceiling lights. This grid lighting, which simply blocks the light. >>>

Based on the standard for lighting New Plexiglas® workplaces, lights must be anti- covering glare for the sake of ergonomics. To this end, light rays that radiate above an angle of 60° must be directed downward No glare

Glare Glare

32 elements29 evonik science newsletter D E S I G n i n G w i t H P O L YM e r S

High-precision: a structured PLEXIGLAS® surface produced by Evonik. In lighting fixture covers, the material ensures that light that would otherwise shine in all directions (below left) is guided at a defined angle and thus causes no glare (below right)

High-precision structures are PLEXIGLAS® hight-precision structures required for efficient light 100% defined light distribution management. Roughness or curves in the structure lead to scatter effects—they also glare and lower light yields (below)

Poorly formed structures 40% undefined

60% defined

elements29 evonik science newsletter 33 A more efficient inline process DR. SANDRA REEMERS Born in 1977 As senior project manager in the Functional Films & Comparison with products already on the market Surfaces Project House, Sandra Reemers is respon- reveals that the microstructures produced by sible for the Structuring of Polymer Surfaces project. Evonik display a precision heretofore unrealized. In addition to building a technology platform, the aim of the project is production of demonstrators for This is possible thanks to a special process that optical applications. Reemers studied chemistry at also lends itself to inline extrusion. The option of RWTH Aachen and earned her doctorate there at the inline processing is a key competitive advantage, Institute for Technical and Macromolecular Chemistry, working with Prof. Martin Möller in the area of as is the fact that all chemicals, materials and pro- surface modification. She completed part of the work cesses used at Evonik are available in-house. on her degree in the Printable Electronics unit of the Nanotronics Science-to- Evonik has proven in an array of tests that the Business Center of Evonik Industries. In mid 2007 she began her career at Evonik as an employee of the project house in the field of surface functionalization, technology delivers on its promises. With this before accepting her current position in early 2008. tech­nology, the kinds of large formats that can no +49 6181 59-2439, [email protected] longer be achieved in the injection-molding pro- cess, for example, can be realized quite cost-effec­ DR. HEIKO ROCHHOLZ tively. This offers lighting manufacturers greater Born in 1977 design freedom because it allows them to cut flex­ Heiko Rochholz works in the Business Development ible formats, for example. unit of Evonik’s Performance Polymers Business Unit. Since early 2008, he has also taught optics and image In addition to pyramids, other prismatic struc- processing at Darmstadt University. Rochholz studied tures can be custom-engraved into the PLEXIGLAS® physics at Johannes Gutenberg University in Mainz, surface. The Performance Polymers Business Unit and in 2005, earned his doctorate at the Max Planck Institute for Polymer Research while simultaneously offers its customers assistance in the complete de- studying basic business administration at the University velopment of lighting—from conception of the tech­ of Mainz. He began his career in 2005, working in nical lighting design, through optical simulations, material testing in the Analytical Services unit at Evonik’s site in Darmstadt before moving to his current position in mid 2007. all the way to production of PLEXGLAS® sheet +49 6151 18-3754, [email protected] prod­ucts for light covers. With these special struc­ tures from Evonik, customers can equip their Grant Lafontaine lighting series with individual structures and spe- Born in 1960 cial effects, thereby creating a unique selling Grant LaFontaine is responsible for Business point in this increasingly competitive market. Film Develop­ment and R&D in North America for the acrylic sheet business of Evonik’s Performance and sheet strengths of fractions of a millimeter up Polymers Business Unit. LaFontaine studied chemical to 20 milli­meters are possible. engineering and applied chemistry at the University But the technology can serve more than just of Toronto (Canada), and in 1985, earned his masters degree. He began his career with Evonik’s affiliate the lighting market. There is also an array of pos- Evonik Cyro LLC, in 1985 as a production super­ sible applications that can be used to tap other intendent and progressed through a number of mar­ket segments. One highly attractive field of positions in production, technical service, and R&D within Evonik’s acrylic polymers business before moving to his current position. ap­plication is solar concentrator systems, which +1 207 490-4328, [email protected] use PLEXIGLAS® sheets with a microstructure that forms a linear or radial Fresnel lens to direct incident light to a small, highly efficient photovol- PETE MARKS taic element. With the development of the technol­ In his role as New Business Development Manager for Sheet Products in the Performance Polymers ogy platform for surface structuring, the project Business Unit NAFTA, Marks focuses primarily on house and the Performance Polymers Business solar, architectural lighting, and energy-efficient Unit have worked hand-in-hand to create the glazing markets. Marks earned his Bachelor of Science degree in Chemical Engineering from framework necessary for this technology. l Virginia Polytechnic Institute and State University, and started at Cyro Industries’ Wallingford, Connecticut site as a Process Engineer in 1992. Marks worked in Technical Services and Product Development for five years before moving to Cyro’s Osceola, Arkansas site. During his eleven years at the Osceola site, Marks held various production positions in sheet and molding compounds, and also served as Plant Manager prior to moving to the Sanford, Maine site in 2008 to fill his current role. Marks earned his Masters degree in Business Administration at the University of Memphis in 2002. +1 207 490-4371, [email protected]

34 elements29 evonik science newsletter news

+++ Ruhr2030Award for ccflex®

A team from Evonik has received the Ruhr2030Award for a new and revolutionary ceramic wall covering. The Initiativkreis Ruhr (Ruhr Area Initiative), which offers the award, praised ccflex® as an outstanding in- novation in the meta-competence field of Energy, Materials, and Logistics. Project manager Dr. Frank Weinelt accepted the €50,000 award at the Zeche Zollverein on behalf of his entire team. Dr. Klaus Engel, Chairman of the Executive Board of Evonik Industries AG, was the first to offer congratulations: ccflex® can be applied like wallpaper, but its ceramic properties make “We are delighted by this award. With our new tech- it as robust and waterproof as tile nologies we solve the problems of today and can al- ready provide answers for the pressing problems of tomorrow.” Production plant for ccflex®. the jury was particularly impressed by the func- The product will now be widely tional versatility of the ccflex® ceramic wall covering. launched by Marburger Tapeten­ fabrik, to which Evonik has “ccflex® combines the best properties of classic wall- awarded an exclu­sive license paper and conventional wall tiles,” explained Weinelt. Commercially available wallpaper is popular mainly because it is easy to apply and store. For sanitary ap­ plication, on the other hand, wall tiles are preferred; al­though they are very robust and waterproof, their application is much more laborious. ccflex®, on the other hand, is applied like wallpaper, and thanks to its cer­amic properties is as robust and waterproof as tile. It can be applied without joins on virtually any shape of wall, and even in the shower stall. The ceramic structure also creates a pleasant ambience. the wall covering has also won plaudits for its visual appeal. An international jury of 28 designers vot­ed ccflex® as the winner of the iF product design award for 2009, and Messe Frankfurt, in conjunction with the German Design Council, chose the wall cov­ ering for its Design Plus Award 2009. In addition, the Stardust design of ccflex®, created by interior designer Sylvia Leydecker, won the bronze medal of the Ger­ man Designer Club for 2008.

Exclusive license to Marburger Tapetenfabrik Following its successful development, the product is now being launched widely on the market. To this end Evonik has awarded an exclusive license for produc- tion and marketing of ccflex® to Marburger Tapeten­ fabrik J.B. Schaefer GmbH & Co. KG. This is the lead­ although simple, is highly effective. In the science-to- ing producer of technical wall coverings and, as Ger­ business centers and project houses, researchers from many‘s third largest manufacturer of wallpaper, also various disciplines work in the closest possible collab­ active throughout Europe. Marburger Tapetenfabrik will oration, jointly developing innovative solutions for the present ccflex® in its first appearance at the Heimtextil future. This collaboration is highly productive as well trade show in January 2010. as time-efficient. The aim is to develop an idea into a ccflex® was developed in Marl, where Evonik has market-ready product within three to five years. pooled its strategic research in Creavis. From its annu- “Already today, we generate 20 percent of our sales al R&D budget of more than €300 million, Evonik al- revenues from products less than five years old,” said locates about 15 percent to research and development Engel. “And we plan to increase this proportion for cross-disciplinary research projects. The concept, further with new products from our research.” elements29 evonik science newsletter 35 events

N ovember 0 9 D ecember 0 9

11/09–11/10/2009 16.12.–21.12.200711/26–11/27/2009 12/08/2009 Synthetic Bio(techno)logy International3rd Aachen-Dresden Symposium International on New Carbon Sources for frankfurt/main (germany) CatalysisTextile C onference& Fine Chemicals Biotechnology www.dechema.de/synbio aachensingapur (germany) frankfurt/main (germany) www.cfc2007.org/index.htmlwww.aachen-dresden-itc.de http://events.dechema.de/ feedstock.html january 1 0 F ebruary 1 0

01/20–01/21/2010 02/23–02/24/2010 ProcessNet Symposium: Industrial 10th Colloquium: Joint Research Utilization of Renewable Resources on Adhesive Technology frankfurt/main (germany) frankfurt/main (germany) www.processnet.org/bioraff2010.html events.dechema.de march 1 0 A pril 1 0

03/08–03/10/2010 03/10–03/12/2010 03/14–03/19/2010 04/07–04/10/2010 11th International Conference on 43rd Annual Conference of EUCHEM Conference on POLYCHAR 18 - World Forum for Microreaction Technology (IMRET 11) the German Catalysis Society Molten Salts and Ionic Liquids 2010 Advanced Materials kyoto (japan) weimar (germany) bamberg (germany) siegen (germany) www.cheme.kyoto-u.ac.jp/8koza/ www.processnet.org/ http://events.dechema.de/ http://polychar18.uni-siegen.de imret11 katalytiker2010.html euchem2010.html

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05/02–05/07/2010 06/07–06/11/2010 08/29–09/02/2010 EUCHEM Conference on Formula VI – Formulations 3rd EUCheMS Chemistry Congress Stereochemistry for the future nuremberg (germany) brunnen (switzerland) stockholm (sweden) www.euchems-congress2010.org www.stereochemistry- www.chemsoc.se/sidor/KK/ buergenstock.ch formulaVI/index.htm

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