Bayer MaterialScience Opens Pilot Nanotube Manufacturing Plant in Germany

---

Researched by Industrial Info Resources (Sugar Land, Texas)--Bayer MaterialScience AG (Leverkusen, Germany) , a subsidiary of Bayer AG (ETR:BAYN) (Leverkusen), recently began operations at its carbon nanotubes (CNT) production facility at its chemical complex in Leverkusen. The 200-ton-per-year pilot manufacturing unit, built for 22 million euros, is considered to be the largest of its kind in the world. In 2007, Bayer MaterialScience commenced operations of a 60-ton-per-year pilot CNT plant at Laufenberg, in Baden-Württemberg in Germany.

Company officials are optimistic that the Leverkusen facility would open doors for new applications and markets for CNT. The North Rhine-Westphalia region, where Bayer's facility is located, has become the hub for nanotechnology projects. State-of-the-art infrastructure, the availability of raw materials, excellent waste management systems, and skilled manpower have helped in the development of CNT production facilities in the region.

CNT is emerging as a popular specialty material that can be used in several applications. Depending on its molecular structure, CNT can be a very good conductor of electricity, with its ability exceeding the conducting capacity of copper. CNT is also a good heat-resistant material, with its thermal resistance properties comparable to that of diamond, which is considered to be the best natural thermal conductor. CNT is available in various forms including single-walled, cup-shaped, multi-walled, and doughnut-shaped.

Baytubes, Bayer MaterialScience's product, are clusters of multi-walled CNTs in the shape of hexagonal rings. The product has high levels of tenacity. When subject to mechanical loading, it exhibits five times greater strength than steel of the same mass. According to Dr. Joachim Wolff, member of Bayer MaterialScience's Executive Committee, demand for CNT is forecast to grow at an average of 25% per year. Dr. Wolff predicts that in the next ten years, the global CNT market will be about $2 billion. The growth of the nanotechnology sector is estimated to create 10,000 jobs in Germany.

Baytubes is produced from ethylene in a high-temperature reactor using catalysts. This process is called catalytic chemical vapor deposition (CCVD). Globally, CCVD is a popular method for production for CNT. In this process, a metallic catalytic layer consisting of iron, cobalt, nickel or a combination of all three is prepared. CNT is produced by mixing a carbon gas such as ethylene, methane, ethane or acetylene with a process gas such as hydrogen, ammonia or nitrogen. The carbon gas is broken down and the carbon produced attaches itself to the edges of the catalytic particles to form CNT. Depending on the application, further processing of CNT is undertaken. Several global players including Bayer, Mitsui & Company (TYO:8031) (Tokyo, Japan), Hyperion Catalysis International (Cambridge, Massachusetts), Nanocyl SA (Sambreville, Belgium) and Arkema S.A. (EPA:AKE) (Colombes, France), use the CCVD process to produce CNT. Nanocyl recently announced plans to begin operations of its new 400-ton-per-year CNT reactor by July 2010.

Applications of Baytubes vary, depending on molecular structure and properties. Some of the applications include:

• Production of antistatic products from polyether ketone
• Cost-effective manufacture of large-scale storage units in explosion-protection zones. These units are used instead of conventional steel drums.
• Marine coatings, which help in reducing resistance between water and the vessel's hull. This helps to significantly reduce fuel consumption.
• Applications in the automotive, shipbuilding and wind power industries. The load-bearing capacity and strength of Baytubes, in combination with special epoxy resins, finds several uses in these industries.
• Manufacture of stronger and lighter sports goods, including baseball bats, skies, hockey sticks and surfboards.

Baytubes is expected to find several new applications in the future. These include:

• High-performance materials
• Increased energy storage and performance of lithium-ion batteries
• Lighter and stronger rotor blades in wind turbines. This is expected to optimize energy production.
• Secure packaging for computer peripherals and chips

Bayer MaterialScience employs 15,100 people in 30 locations, and operates three business units. The divisions are polyurethanes, polycarbonates and coatings, and specialties and adhesives. The company has planned large-scale investments, especially in China. In Shanghai, the firm is expected to spend 2.1 billion euros through 2012 to set up an advanced integrated manufacturing site.

In a related development, the firm signed an agreement with Hyperion Verwaltug GmbH (Frankfurt, Germany) to acquire usage and marketing rights of the Durflex track superstructure system. The system, which helps to optimize railway network operations, was jointly developed by the two firms using the Bayflex polyurethane foam process.

Industrial Info Resources (IIR) is the leading provider of global market intelligence specializing in the industrial process, heavy manufacturing and energy related markets. For more than 26 years, Industrial Info has provided plant and project spending opportunity databases, market forecasts, high resolution maps, and daily industry news.