TECHTECHITALYITALY20122012Brussels, 2-4 October 2012
Advanced Materials and New Technologies for Sustainable Development:High Performance Polymers for Energy Application with Low Environmental ImpactHigh Performance Polymers for Energy Application with Low Environmental Impact
V. Arcella
Agenda
Solvay Group OverviewSolvay Group Overview
Solvay developments in Alternative Energyy p gy
- Fuel Cells
- Li Battery
- Photo VoltaicPhoto Voltaic
- Wind Mills
Conclusions
2 © 2012 Solvay Specialty Polymers2
Solvay History
Solvay was Founded in 1863 by Ernest Solvay
Ernest Solvay promotedErnest Solvay promoted in 1911 the first
“International Council on Physics”
Solvay
Solvay
The first Solvay Physics Conference in 1911, included 8 Nobel prize winning chemists and physicists: Marie Curie, Albert Einstein, Onnes Kamerlingh, Hendrik Lorentz, Walther Nernst, Max Planck, Ernest Rutherford, Jean Perrin
4 © 2012 Solvay Specialty Polymers
, ,
Solvay, an International Chemicals Group
Key FactsAcquired Rhodia, September 2011
Offers a broad range of products that contribute to improving quality of lifeand the performance of its customers
I th ld l d ith 90%Is among the world leaders with 90% of its sales in markets where it is among the top three globala o g t e top t ee g oba
Possesses a strong commitment to sustainable development and pa clear focus on innovation & operational excellence
5 © 2012 Solvay Specialty Polymers
Solvay Specialty Polymers
Grouped in one Company Top high performing products
Four Leading Companies create One Global Business Unit
Solvay Solexis
Solvay Advanced Polymers
Solvay Padanaplast
SolVin PVDC
6 © 2012 Solvay Specialty Polymers
Solvay Specialty Polymers
Key Figures
1+ Global Business Unit1+
1,25+
11+
Global Business Unit
Bn€ in Sales, 2011
RD&T Centers Worldwide11+
14+
40+
RD&T Centers Worldwide
Industrial Sites
Proprietar Technologies40+
300+
450+
Proprietary Technologies
Commercial Employees
RD&T S i li t450+
1500+
2500
RD&T Specialists
Products
E l W ld id2500+
2900+
6000
Employees Worldwide
Patents in Force
C t
7 © 2012 Solvay Specialty Polymers
6000+ Customers
International Presence
Newark Ulsan Seoul
Tavaux Rheinberg RoccabiancaNOHOudenaarde
Marshallton
West Deptford
Tokyo Fuji City
São Paulo Düsseldorf Spinetta
Greenville
Augusta
Shanghai Changshu
Taiwan
BollateMarietta
Alpharetta
Taiwan
PanoliVadodaraMumbaiAlpharetta
Orange
Mumbai
Singapore
Bay St. Louis Pretoria
= Headquarters = Plant = Sales & Administration = Research Development & Technology
8 © 2012 Solvay Specialty Polymers
= Headquarters = Plant = Sales & Administration = Research, Development & Technology
RD&T STRATEGY MEETING, Bollate 14 December 2009
Creation of theCreation of the
ALTERNATIVE ENERGYArea
ALTERNATIVE ENERGYArea
Fi d d i fFind synergy and increase focus on Alternative Energy Technology
9 © 2012 Solvay Specialty Polymers
FC T h l
Solvay developments in Alternative Energy
FC Technology
10 © 2012 Solvay Specialty Polymers
Solvay developments in FC Technology
Th FC t f H d i El t i E
Fuel cell: applications and working principle
The FC transforms Hydrogen in Electric Energy producing water as the only emission
Automotive
ForkliftAquivion®
Membrane
Fuel cell stackPower generation
11 © 2012 Solvay Specialty Polymers
Solvay developments in FC Technology
Competitive advantage of Aquivion®
O
---CF(CF2 )k-(CF2CF2)j---
O
CF
---CF(CF2 )k-(CF2CF2)J---
®CF2CF-CF3
O
CF2
SO3H
CF2Aquivion®
Nafion®CF2CF2
Nafion®
The shortest side-chain ionomer available
SO3H
Short side chain means1 Very high proton conductivity2 Maintain performance on a broad temperature range (-40 + 120°C)3 Limited membrane humidification needs
12 © 2012 Solvay Specialty Polymers
3 Limited membrane humidification needs
Solvay developments in FC Technology
The Aquivion® development
Solvay owns a very favorable process for vinyl ethersproduction available at the industrial scale
CF2=CF2
SO3 CF2 CF2 F-FOC-CF2-SO2FCF2=CF2
SO3 CF2 CF2 F-FOC-CF2-SO2F
The traditional process
O SO2
ClCF2 CF CF2
O
Na2CO3
Cl CF CF O CF CF SO FNa
O SO2
ClCF2 CF CF2
O
ClCF2 CF CF2
O
Na2CO3
Cl CF CF O CF CF SO FNa
SO3 CF2 CF2[CsF] / F2SO3 CF2 CF2[CsF] / F2
The hypofluorite process(Solvay proprietary process)
FOC-CF-O-CF2CF2SO2F
CF2ClΔ
Cl-CF2-CF-O-CF2CF2-SO2F
CF2=CF-O-CF2-CF2-SO2F
- NaCl
FOC-CF-O-CF2CF2SO2F
CF2ClΔ
Cl-CF2-CF-O-CF2CF2-SO2F
CF2=CF-O-CF2-CF2-SO2F
- NaCl
CF2=CF2
SO3 CF2 CF2
O SO2
[ ] 2
Gaseous phase
FO-CF2-CF2-SO2F
ClFC=CFCl
One process step
CF2=CF2
SO3 CF2 CF2
O SO2
[ ] 2
Gaseous phase
FO-CF2-CF2-SO2F
ClFC=CFCl
One process stepOne process step
ClCF2-CFCl-O-CF2-CF2-SO2FCF2=CF-O-CF2-CF2-SO2F
One process step
ClCF2-CFCl-O-CF2-CF2-SO2FCF2=CF-O-CF2-CF2-SO2F
One process stepOne process step
13 © 2012 Solvay Specialty Polymers
Solvay developments in FC Technology
20.000 h durability demonstrated with minimal membrane degradation
Membrane: E87-05 (50 micron)
14 © 2012 Solvay Specialty Polymers
Solvay developments in FC Technology
Aquivion® for the emerging FC Automotive Industry
We have developed a proprietary process for “ultrathin”reinforced FC Membranes available at industrial scale
15 © 2012 Solvay Specialty Polymers
Solvay developments in FC Technology
Aquivion® for the emerging FC Automotive Industry
“Ultrathin” Aquivion® reinforced membranes can operate at high Temperature (120 C) and in Dry conditions
Avoid humidification of gas reactants to the FC stack (i.e. avoid complex Engine humidification systems)Increase stack working temperature (i e avoid large Engine heat exchangers)
0,8
1,0
Increase stack working temperature (i.e. avoid large Engine heat exchangers)
0 2
0,4
0,6
Cel
l Vol
tage
(V)
EXTREME DRY CONDITIONS:Tcell=95°CStoic 1,5 / 2 Ultrathin Aquivion® membrane
0,0
0,2
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6Current density (A/cm²)
ULTRATHIN membrane - low EW 25 micron membrane - low EW
Anode RH: 18% - Cathode RH: 18%1,5 bar
Ultrathin Aquivion membrane
16 © 2012 Solvay Specialty Polymers
50 micron membrane - high EW
Solvay developments in FC Technology
Aquivion® demonstration plant
For a continuous power of 1 MW
168 stacks: 12600 MEAs
Lillo 1 Mw plant: the largest PEM plant in the world
168 stacks: 12600 MEAs
Membrane: 18x18 cm (total 400m2)
V=0.67, A=120, W=80 (Total 1MW)
Solvay has investrd over 5 M€ in the construction of a test fuel cell with a total electric power of 1 megawatt (MW) at the SolVin plant in Lillo Antwerp Belgium
17 © 2012 Solvay Specialty Polymers
the SolVin plant in Lillo, Antwerp, Belgium
Solvay developments in Li-Battery
Solvay products in a lithium ion battery
Liquid Electrolytecontaining fluorinated solvent and Li salts
for improving safety and performances(Solvay Special Chemicals F1EC, TAB,
GALDEN® PFPE Rhodia LiTFSI)
Polymeric Binderfor higher electrode adhesion,
increasing cycle and calendar life(PVDF SOLEF®, PAI TORLON®) GALDEN PFPE, Rhodia LiTFSI)
Non-toxic solventfor polymer dissolution during slurry preparation
(Rh di l ® IRIS)Polymeric Binder
for higher electrode adhesion, increasing cycle and calendar life
(PVDF SOLEF®)
(Rhodiasolv® IRIS)
( )
P iti El t d A ti M t i lPositive Electrode Active Materialfor higher energy density and
improved safety(Solvay Special Chemicals)
Polymeric Separatorfor improving safety
and power performances
19 © 2012 Solvay Specialty Polymers
(PVDF SOLEF®, PAI TORLON®)
Solvay developments in Li-Battery
A recent development of PVDF for Li Batteries
Cathode:- Li metal oxide (active material)- Carbon Black (conductive carbon)- PVDF (binder)
Separator: - PVDF based Gel polymer (electrolyte: Li+ salts in organic carbonates)
Anode:- Graphite (active material)
g )
- Carbon Black (conductive)- PVDF/other polymers (binder)
20 © 2012 Solvay Specialty Polymers
Solvay developments in Li-Battery
Synthesis of a new modified PVDF for the cathode Binder
First Step: Very High Molecular Weight Polymer DevelopmentImproves cohesion of active materials and adhesion to metalImproves cohesion of active materials and adhesion to metal collector
21 © 2012 Solvay Specialty Polymers
Solvay developments in Li-Battery
Synthesis of a new modified PVDF for the cathode Binder
Second Step: Very High Molecular + Adhesion PromoterPolar functional groups as adhesion promoter in the polymerPolar functional groups as adhesion promoter in the polymer backbone
Very good Cohesion Between binder & active materialsVery good Adhesion to metal collectors
22 © 2012 Solvay Specialty Polymers
Solvay developments in Li-Battery
Synthesis of a new modified PVDF for the cathode Binder
Resulted in:
The new product SOLEF® 5130
Better cohesion and adhesion to metal collector
80
120
mAh
/g]
SOLEF® 5130, 3%
Outstanding chemical resistanceImproved energy and Power
40
80
arge
Cap
acity
[m
SOLEF® 5130, 8%homo PVDF, 8%
Improved energy and Power performances
00 50 100 150 200 250 300
Disc
ha
longer cycle life!! Cycle number
23 © 2012 Solvay Specialty Polymers
Electrode composition: PVDF binder, 10% super P, LiFePO4
Solvay developments in Li-Battery
The AMELIE Project – FP7 European Founded N.265910
Fluorinated Polymers
A new advanced Li-Battery project, fully based on Fluorinated materials to overcome safety
issues and increase the battery specific energyFluorinated
SaltsFluorinatedSolvents
issues and increase the battery specific energySolvay Coordinator
Project full title: Advanced Fluorinated Materials for High SafetyProject full title: Advanced Fluorinated Materials for High Safety, Energy and Calendar Life Li Ion BattEries.
Starting Date: 01 Jan 2011Ending Date: 01 Jan 2014g
Budget Total/Funding: 5,2 MEUR / 3,5 MEURPartners: 12 Organizations from 6 Countries
24 © 2012 Solvay Specialty Polymers
Solvay developments in Li-Battery
The AMELIE Project – FP7 European Founded N.265910
LNMO (LiNi0.4Mn1.604) LNMO (LiNi0.4Mn1.604)
25 © 2012 Solvay Specialty Polymers
Solvay developments in Photo Voltaics
Composite solutions and semi-finites for PV
Barrier LayerHalar®ECTFE
with organic/inorganic multilayers
FrontsheetHalar®ECTFE with UV scavenger and Advanced compounds
Fluorinated Polymers
Specialty Polymers
Rhodia
Encapsulant and Backsheet P lidi ® XL PO S l f PVDF
Trasparent Conductive electrodePolidiemme® XL-PO, Solef PVDFBased on Halar®ECTFE
27 © 2012 Solvay Specialty Polymers
Solvay developments in Photo Voltaics
Halar with UV Scavengers:
Special film construction capable to block UV and protect EVA substrates
Transmittance vs. wavelength
0 hours
QUV 1000 hours
28 © 2012 Solvay Specialty Polymers
Solvay developments in Photo Voltaics
Building Integrated PV Low Energy Harvesting
Third generation PV – OPV/DSSC
Building Integrated PV Low Energy Harvesting
Light and Flexible
Works in diffuse light
29 © 2012 Solvay Specialty Polymers
Flexible diffuse light
Solvay developments in Wind Mills
Windmill Gearbox Lubrication
Two big concerns of Wind Mills areMaintenance and risk of firesMaintenance and risk of fires
Fire due to the presence of high amount of hydrogenated lubricant
31 © 2012 Solvay Specialty Polymers
Solvay developments in Wind Mills
Windmill Gearbox Lubrication
Develop a stable PFPE Fluorinatedlubricant for WM gear drives:
Wind Diameter: 120mPower: 5 MW
Objective
lubricant for WM gear drives:
■ Extended lifetime of the gearbox (10+ years vs. 5-6 years)R d d f il f
Power: 5 MWOil for lubrication: 2 t
■ Reduced failure frequency■ Reduced scheduled/non scheduled maintenance■ Improve wind Mill safety, No risk of fire (Lower
costs of insurance)
32 © 2012 Solvay Specialty Polymers
Alternative Energy Cycle: the Solar Impulse way
ProductionProduction StorageStorage UtilizationUtilizationPhotovoltaic Photovoltaic
12’000 cells12’000 cells
lithium ion batterylithium ion battery
400 kg400 kg
4 electric motor4 electric motor
10CV each10CV each
th i f i bthe size of an airbus
the weight of a carthe weight of a car
the power of a scooter
34 © 2012 Solvay Specialty Polymers
Solar Impulse is the archetype of a new economy wholly based on solar energy
Solvay: a global payer in Solar energyThrottlehousing
Radel RRadel R®®
T lT l ®®
Bushingscontrol system
TorlonTorlon®®
Circuitboardsspacers
Lubricant
F bliF bli ®®
BearingsTorlonTorlon®®
Bolts scews
washers
Primospire®Primospire®
Instrument panel
housing
Radel RRadel R®®
Glue : •for honeycomb
in structure•for strain gaugesTorlonTorlon®®
KetaspireKetaspire®®
PrimospirePrimospire®®
AmodelAmodel®®
TorlonTorlon®®Ketaspire®Ketaspire®
p
Primospire®Primospire®FomblinFomblin®® Radel RRadel R®® •for strain gauges
TorlonTorlon®®
N i l
Enginebench test
IxefIxef®®
EpichlorhydrinNumerical simulations in• Solar panels• Wing ribs• Wing leading edge
Tape for PV cells(Kynstick)Foam for pilot seat
SolefSolef®®
p y200 kg of epoxy resins
(all parts)
Air data booms (antennes)Attachment system
Radel RRadel R®®
TorlonTorlon®®
PrimospirePrimospire®®
Batterybinder
SolefSolef®®
Leds
Amodel®Amodel®
Foammotor
gondola,PV cell
Film encapsulationElectrolyte
additiveLanding gear
P i i ®P i i ®
Intrados filmLaminated on PA
Mobile parts
35 © 2012 Solvay Specialty Polymers
SolefSolef Amodel®Amodel®gondola,cockpit
SolkaneSolkane®®Halar®®for batteries
FIECFIECPrimospire®Primospire®
Ixef®Ixef®
pSolefSolef®®