3.1 DESCRIPCIÓN DE LAS FACILIDADES DE PRODUCCIÓN DEL
3.1.12 SISTEMA DE LEVANTAMIENTO ARTIFICIAL HIDRÁULICO
Our central research and development
To support our central research and development “Technology & Innovation” (T&I) in Meitingen (Germany), a state-of-the- art, comprehensive research infrastructure is available. The laboratories for developing composites and energy storage systems and a standard-setting carbon fiber pilot plant have been used to the full extent since 2012. This allows us to focus on our development projects under the best possi- ble technical conditions. T&I’s product and process develop- ments are aligned to SGL Group’s strategic objectives and fall into the following development areas: synthetic graphite, energy storage systems, precursor and carbon fibers, carbon composites as well as ceramic fibers and composites. Our research expenditure totaled €42.8 million in the past fiscal year (2012: €46.5 million), which means that research costs account for 2.9% of consolidated sales revenues (2012: 2.8%). At the end of 2013, there were 147 T&I employees (2012: 153).
Highlights from our development areas
In R&D for synthetic graphite, we use our long-standing process knowledge combined with current modeling meth- ods to further improve energy, material and cost efficiency in our products and production processes. We were able to develop, in particular, cost efficient processes for graphite production. For example, we designed a new production process for furnace lining blocs with extended life-time. The responsible Business Unit then qualified this process in cooperation with T&I and launched the product on the market. Application modeling of graphite electrodes and cathodes provided us with key findings on further optimiz- ing performance during customer use. New sources for raw materials were tested in order to further improve our cost situation and safeguard of our supply of raw materials for fine and coarse grain graphite.
T&I develops components for future energy storage systems
such as redox flow batteries, which can store electrical energy in chemical compounds, as well as for lithium ion batteries and for fuel cells. In 2013 we expanded our technical competence for lithium ion batteries. In our long-standing strategic development alliance with Hitachi Chemical, the global market leader for anode materials for lithium ion batteries, we are working on optimizing costs while consis- tently maintaining high quality. In order to meet the future requirements for electromobility, we are already working on the next generation of lithium ion batteries as part of funded projects. Both in the Alpha-Laion project, in which companies including Bosch, BASF, Wacker Chemie, BMW and Daimler rank among the project partners, and also in the MaLiSu project (NanoMaterials for future generation lithium sulphur batteries), we recorded initial technical progress in increasing storage capacity. We are contributing our graphite expertise to a new joint project (TOPBatt) to improve the thermal management of batteries.
In producing gas diffusion layers for fuel cells, T&I has built up expertise and consulting competence over many years. In 2013 we reacted to a substantial increase in demand with initial activities to increase capacity.
T&I made excellent progress in optimizing processes to manufacture carbon fibers. In particular it was possible to substantially improve the textile characteristics. Knowl- edge obtained in the pilot plant has already been trans- ferred to the production lines in Muir of Ord (UK) and Evan- ston, Wyoming (USA) and will simultaneously be included in the precursor development at the Portuguese Fisipe location.
For the development of carbon fiber in aviation applica- tions, the publicly funded development project “AirCarbon I” with partners in the European aerospace industry was extended through to the end of 2013 with additional funding, and successfully completed. A follow-on project has already been approved.
In Carbon Composites, the development program started in 2012 for thermoplastic carbon fiber composite materials was successfully continued last year. This group of materi- als offers advantages compared to duroplastic matrix sys- tems, such as shorter cycle times and improved recycling which should better enable industrial series application and which makes them particularly interesting for use in auto- motive construction. In 2013 several customers were sam- pled with semi-finished products – unidirectional tapes and organic sheets – for material qualification. T&I has devel- oped carbon fibers with an adapted fiber surface specially for thermoplastic matrix systems. Thermoplastic compos- ites and recycling were also key topics for the activities in the MAI Carbon cluster of excellence, where we are involved in several projects.
In 2013, state-of-the-art coating and measurement technology was used to further develop stretch-broken carbon fiber yarns for applications in the automotive sector and these were produced as small series in the pilot phase. In addition to the characteristics which are typical for carbon fibers, these particularly fine yarns are characterized by excellent knot and loop strength. They can thus be used in sewing and knitting processes, as well as resistance heating ele- ments. Development experience and experience from cus- tomer feedback has been considered when constructing serial production equipment in Muir of Ord, thus creating the conditions for production starting successfully and on-time at the end of 2013.
Together with European partners from research and indus- try, SGL Group started work on an EU-funded project at the end of 2013, which aims to develop flexible, cost-efficient production methods for CFK components, thereby linking several key technologies such as automated production methods, intelligent tool concepts, simulation and custom- ized material systems.
After a project in ceramic fibers and composites was devel- oped through to commercial maturity for the first time in 2012 and transferred to the Business Unit Graphite Special- ties, we want to develop additional applications and mar- kets. As a result, in 2013 a steel-ceramic hybrid system for automotive applications was developed together with Ben- teler Automobiltechnik.
Silicon carbide fibers are an additional development target for ceramics. In the joint project “SicTec2”, together with partners including the Fraunhofer Institut für Silicat- forschung ISC Würzburg, MTU Aero Engines and Wacker Chemie, we are working on developing silicon carbide fibers for high-performance turbines. In 2013 we produced the first kilometers of SiC fibers on spools, and presented these to the project partners for testing.
Strategic industry alliances and research networks
In 2013 SGL Group was honored for the fourth time as one of the top 100 innovators in the German SME segment. The jury was particularly convinced by our involvement in industry associations and research networks as one of our particular strengths – and this is a key element in our R&D strategy. As part of the strategic alliance for synthetic graphite with the Technical University AGH in Krakow, several Masters and Doctoral candidates are working on long term topics for raw material and process development. Setting up an “International Carbon Center” at the AGH has been further driven by building up a laboratory and an auditorium. As a co-founder of the competence network for lithium ion batteries (KLiB), we are working together with companies including BASF, Bosch, Daimler, Evonik and BMW on the development and market launch of lithium ion batteries for e-mobility and stationary energy storage. In order to take the new cell production process out of the laboratory and into industrial scale production, a pilot plant for industrial scale production of battery cells has been built at the ZSW (Zentrum für Sonnenenergie- und Wasserstoffforschung
67 Combined Management Report The SGL Group
Baden-Württemberg) in Ulm using a substantial government support. SGL Group is one of the first users of this new, research production line. A corresponding declaration of intent was signed in May 2013 as part of the foundation ceremony.
Together with all of our partners, we want to drive the development of carbon fiber and fiber composite technolo- gies via the Carbon Composites e.V. (CCeV). The key results include developments as part of the MAI Carbon cluster of excellence, in which SGL Group is also active in several leading projects. CCeV, an association of companies and research institutions, spans the entire value chain for high-performance composite materials in Germany, Austria and Switzerland, and also wants to establish itself interna- tionally as a recognized association. The association has been awarded the “Gold” label in the “European Cluster Excellence Initiative”, which marks a further milestone on this path.
The professorship of Carbon Composites (LCC) endowed by SGL Group at the Technical University of Munich (TUM) has developed to become a hub for multinational projects with industrial partners. The existing networks, in partic- ular with universities in Singapore, helped us to interna- tionalize our own Asian development activities in 2013. Sin- gapore is one of Asia’s knowledge hubs, and has grown to become a center of applied product research with its tech- nology subsidies while simultaneously highly protected intellectual property rights and recognized certification standards. Together with other industrial partners, we want to support a project at the universities of Singapore Polytechnic, TUM Asia and LCC, to establish a technology center for composite materials in Singapore.
Scientists at TUM Asia and Nanyang Technological Univer- sity (NTU) in Singapore have developed the world’s first electric taxi for tropical mega-cities. In so doing, they use top technology for battery development, and also state-of- the-art lightweight construction with carbon fiber compos- ite materials. SGL Group supplied the material for light- weight, and high strength CFRP-chassis and supported with technological know-how. The electric taxi was pre- sented at the 43rd Tokyo Motor Show in November 2013. A series of seminars for future construction applications was conducted with external experts. We presented leading rep- resentatives from the Institute for Energy Research at the NTU and the construction authorities in Singapore with the current status and the future possibilities offered by carbon fiber reinforced concrete. For Redox-Flow batteries, the network with the renowned NTU in Singapore is also a key step in internationalizing our research.
We registered 17 new patents in 2013, further developing our portfolio of patents in a targeted manner, and we have consistently geared the existing portfolio of patents to the current technology areas. SGL Group is active in the man- agement bodies of national (Arbeitskreis Kohlenstoff AKK) and international scientific carbon societies and regularly lectures at the annual Carbon Conference.
T&I is SGL Group’s talent pool
Again in 2013, SGL Group worked intensively to develop new talent, thus training up-and-coming specialists and managers for the Company. T&I employees regularly attend the leading HR recruiting fairs. A key instrument in devel- oping junior talents for engineering and materials sciences continues to be our program for masters and doctoral can- didates. In 2013 a total of 61 students were supported by T&I for their theses, in internships or in work study (2012: 69). During the past fiscal year, five employees left T&I in order to take over new positions within the Business Units, three new employees joined T&I from other areas of SGL Group, and one external employee and six apprentices were hired.