Arizona Researchers to Widen Methods for Producing Bio-based Styrene

Styrene is one of the major building-block chemicals used to make many of the rubbery polymers and plastic materials we use today. More than 6 billion tons of it is manufactured each year in the United States alone, most of which goes into producing insulating materials, automobile tires, footwear, medical devices and hundreds of other widely used products. The problem is that all styrene is currently derived from a dwindling resource petroleum and its production requires one of the most energy-intensive processes in the petrochemical manufacturing industry. More than three metric tons of steam is necessary to produce just one metric ton of styrene. That excessive energy consumption also produces significant amounts of carbon dioxide, contributing to the detrimental buildup of greenhouses gases in the atmosphere.

At Arizona State University, David Nielsen and Rebekah McKenna are seeking ways to make styrene and other common petrochemicals using renewable resources. They want to produce materials that are more sustainable, require less energy to produce, and alleviate negative environmental impacts when they are manufactured. Nielsen is an assistant professor of Chemical Engineering in the School for Engineering of Matter, Transportation and Energy, one of ASU's Ira A. Fulton Schools of Engineering. McKenna is studying to earn a doctoral degree in chemical engineering. They're experimenting with engineering microorganisms to act as catalysts for making styrene from renewable resources in this case biological materials, like sugars from plants.

The bacteria they have genetically engineered for that purpose has drawn attention from peers in their field. A report on their work was first published in the international science and engineering journal Metabolic Engineering, and then later appeared in Nature Chemical Biology as a featured "research highlight". This past summer, McKenna was one of only a handful of student researchers selected by the Society for Industrial Microbiology to give a presentation at its annual meeting. Her report, "Styrene Biosynthesis from Renewable Resources," earned the conference's Best Student Oral Presentation award. "What we've done is create a new metabolic pathway," Nielsen explains. "We've found the particular genes and enzymes required to achieve the necessary chemistry, and we have strung them together in a way that enables our engineered bacteria to function as a sort of biological catalyst. In this way the cells can perform all of the biochemical reactions required to convert sugars like glucose into styrene".

He and McKenna are doing what he describes as building "microscopic microbial chemical factories," designed to synthesize the raw ingredients required to make products with characteristics identical to those that in the past have been derived only from petroleum. If that is achieved, it could be possible for these chemicals produced from renewable materials to "plug directly into existing infrastructure, and be ready to use in current manufacturing systems that provide many of the products we use every day," Nielsen says.

The next leap a particularly challenging one involves further improving the bacteria and scaling up the process to where styrene yields can be produced from renewable resources in as economically viable a way as styrene made from petroleum. Nielsen sees potential for his and McKenna's research to contribute to engineering efforts to develop other commonly used chemicals, fuels, and materials from renewable resources that would "create whole new markets for renewable biochemicals and biopolymers". At the very least, "we hope to be able to develop viable renewable alternatives for the bio-plastics industry," he says. "From there, we might be able to begin making all sorts of new products from renewable, biological materials," including new kinds of fuels.

Molecular Solar's Organic Photovoltaics Used for Charging Electronic Device Shines at Lord Stafford Awards

Molecular Solar is pioneering ultra-thin, flexible solar panels that can be used in portable chargers for mobile phones and other handheld devices, allowing devices to be recharged without needing to be connected to a mains power supply. As well as being a convenient way to charge electronic equipment, the technology will also help to reduce an individual's carbon footprint.

The Lord Stafford Awards showcase collaboration between business and academia in the Midlands and Molecular Solar was recognised for its very successful partnership with Warwick Ventures, the University of Warwick's technology commercialisation company.

Warwick Ventures helped set the company up in 2008 and has been instrumental in securing funding to enable Molecular Solar to translate the research done in the University's Department of Chemistry into marketable products.

Most recently, Molecular Solar announced that its solar cells, which are made from organic photovoltaic materials, can now produce voltages of over 4 volts, making its technology suitable for recharging the lithium ion batteries used in many handheld devices. This means the cells are now ready to be developed for commercial use.

Professor Shipman says: "Molecular Solar is founded on the strength of its partnerships with Warwick Ventures, the University of Warwick's Department of Chemistry, and other companies with whom we are working closely. We are delighted that the success of those partnerships has been recognised by the Lord Stafford team."

Quentin Compton Bishop, CEO of Warwick Ventures, says: "Warwick Ventures has spun out more than 50 companies over the past 11 years and it is always a great honour to be recognised in the Lord Stafford Awards. We are delighted with Molecular Solar's achievement and look forward to working with them as they continue to grow and develop a truly groundbreaking technology."

PolyOne Utilizes Sanitized's Antimicrobial Solutions to Produce Medical Device for Healthcare Applications

PolyOne Corporation, a premier global provider of specialized polymer materials, services and solutions, announced an alliance with Sanitized AG, one of the leading producers of antimicrobials with over 50 years of experience, to provide innovative, customizable polymer solutions for specialized healthcare and medical device applications.

PolyOne will utilize Sanitized® MedX antimicrobials in select formulations of WithStand™ Antimicrobial Solutions, which consist of active ingredients developed using proprietary technology that helps to inhibit the growth of bacteria, viruses and fungi on plastic surfaces.

"PolyOne continues to align with leading global and innovative companies that help us better serve our customers," said Craig M. Nikrant, Senior Vice President and President, Global Specialty Engineered Materials, PolyOne Corporation. "This alliance gives Sanitized the benefit of PolyOne's expertise in medical polymer formulation and our penetration in the healthcare market. In turn, PolyOne gains from Sanitized's unique bacteria protection technology."

PolyOne WithStand™ solutions are ideal for healthcare applications, such as minimally invasive surgical device housings, respiratory and anesthesia devices, catheters, hospital furnishings and medical packaging.

Sequana Selects Evonik's PEEK to Design its Pump Implant for Medical Applications

The newly-developed ALFAPump™ System from Sequana Medical Switzerland helps patients suffering from excessive fluid in their abdomen: the battery-operated pump implant is based on the PEEK polymer VESTAKEEP® from Evonik Industries and has received CE approval. It pumps the excessive fluid from the abdominal cavity into the bladder, from which it can be excreted by the patient in the natural manner. Up to now, the water has had to be drained using painful paracentesis during regular doctor's appointments. Patients with liver disorders, congestive heart failure and certain types of cancer are particularly affected by ascites. The new system consists of a subcutaneously implanted pump and a catheter system: one catheter connects the abdomen to the pump, while the second connects the pump to the bladder.


The new technology is made possible thanks to the use of VESTAKEEP® PEEK, a polyether ether ketone which is particularly characterized by its biocompatibility and biostability. In contrast to metal, the ion content of VESTAKEEP® PEEK is virtually zero, thus preventing shift reactions with the body. What's more, the PEEK implant is considerably lighter than a comparable metal implant. The VESTAKEEP® PEEK iGrades are specifically suited to long-term use in the human body and can also be made transparent to X-ray on request, so that they cannot be seen on X-rays.

"The ALFAPump™ System not only improves the quality of life for patients but also represents a cost-effective solution," explains Dr. Noel Johnson, CEO at Sequana Medical. Marc Knebel, Business Management Director at VESTAKEEP® Medical & Implants, adds:

"The ALFAPump™ System is a perfect example of the many benefits of PEEK compared to metal in this field. Other areas, such as spinal implants, can also benefit from these advantages."

The high processability of PEEK is a further advantage of its use: VESTAKEEP® PEEK polymer can be manufactured using either the injection molding or cutting procedures, thereby supporting freedom of design in the development of new implant technology.

Teijin to Open CFRTP Pilot Plant for Producing Composites from Carbon Fiber for Japan's Automotive Industry

Teijin Limited has announced that it will establish the world's first pilot plant for fully integrated production of carbon fiber reinforced thermoplastic (CFRTP) components from carbon fiber on the premises of its Matsuyama Factory in Ehime Prefecture, Japan. The new plant will feature Teijin's unprecedented mass production technology for CFRTP components, which significantly reduces cycle times required for molding composite products to under a minute, enabling rapid production of various prototypes and performance evaluation tests.

Construction of the new plant will begin shortly, with operations expected to commence in mid 2012. The new plant will enable Teijin to further accelerate its commercialization of CFRTP components for mass-produced automobiles and other industrial uses. Capital expenditure for the establishment of the pilot plant will total over two billion yen.

Teijin's proprietary mass production technology for CFRTP enables the integrated production of carbon fiber to composite products within one minute, the ideal tact time required by automakers for mass-produced vehicles. The technology, which promises to realize revolutionary weight-reduction, is expected to find a wide range of applications in addition to automobiles, where certain levels of structural strength are required. CFRTP components are also highly recyclable, as technically its thermoplastic resins can be converted into desired shapes when heated.

To introduce this cutting-edge technology to automakers, Teijin developed an electric-vehicle concept car earlier this year featuring a body structure made entirely of CFRTP components and weighing only 47 kilograms or roughly one-fifth the weight of a conventional automobile body structure.

Through the new pilot plant, Teijin aims to accelerate its market development and further its position as a global leader in carbon fiber composite products.

Global wind power set for steady growth to 2020

Global wind energy installed capacity increased at a compound annual growth rate (CAGR) of 27.9% from 74.1 GW in 2006 to 198.2 GW in 2010, of which 36.1 GW came online in 2010. There was a fall in annual additions in 2010 by 10.9%, however, as major wind markets such as the US, Germany and Spain were hit by the global economic crisis.

The global wind power markets are expected to recover in 2011 with the huge order intake by major wind manufacturers, the growing Asia-Pacific region, emerging South America and Africa regions, steady European wind markets and recovery in North America, GlobalData says.

The growing Asia-Pacific wind power market powered by India, China and other emerging countries such as Republic of Korea, Thailand and Philippines will continue to drive the wind power market as well as emerging South America and Africa countries such as Brazil, Columbia, Argentina and South Africa.

China largest in 2010

China was the global leader with a cumulative installed wind power capacity share of 22.6% in 2010, overtaking the US as the number one wind power market in terms of new installations in 2009 following the addition of 13.8 GW of wind capacity in that year.

China has doubled its cumulative capacity every year during 2006-2009 and grew by 72.4% in 2010 after the addition of 18.8 GW of new capacity. Supportive government policies which include an attractive concessional programme and the availability of low cost financing from government banks are critical reasons for the success of the Chinese wind power market, the analyst says.

It is expected that China will continue to promote wind power in order to reduce its carbon footprint and increase rural electrification.

US comes in second

The US is the second largest wind power market with a cumulative share of 20.3% of the global wind power market. Its share decreased by 1.4% in 2010 which lost the US its market supremacy.

Germany is the third largest wind power market in the world with a share of 13.7%. Germany maintained its ranking in 2010 but lost 2.2% to competing nations. Spain, which is the fourth largest wind power market with a cumulative share of 10.4%, lost 1.4% in 2010 as it continued to face economic problems. The other major wind power markets include India with a share of 6.6%, Italy and France with a share of 2.9% each, the UK with 2.6%, Portugal with 2.1% and Canada with 2%.

Offshore wind gains momentum from 2015

The offshore wind market is expected to become one of the major market segments of wind power generation during the forecast period. Offshore wind power installations accounted for 1.6% of the global wind power market in 2010.

The UK, Germany, the Netherlands, the US and China are the biggest offshore wind power markets in the world with a number of projects currently in planning and under construction. With an increasing number of countries exploiting offshore wind potential during the forecast period 2010-2020 it is expected that its share in the global wind power market will reach 9% by 2020.

Vestas largest manufacturer in 2010

The global wind turbine market is a consolidated market with the top 10 players accounting for 80.4% of the market. Vestas Wind Systems A/S dominated the global market in 2010 with a 12.5% share and a total of 4719 MW of new turbines installed. The company however lost a share of 0.9% in 2010. Vestas is the industry leader and one of the strongest vertically integrated wind turbine manufacturers.

Chinese giant Sinovel Wind Group Co Ltd was the second largest wind turbine manufacturer in 2010 with a share of 11.6%. The company installed 4386 MW of wind turbines and gained a 2.3% market share. Sinovel is followed by another Chinese turbine manufacturer, Xinjiang GoldWind Science & Technology Co Ltd, which accounted for 9.9% of the market in 2010. The company installed over 3.7 GW of turbines in 2010 and gained a share of 2.7%.

GE Energy, which was the second largest turbine manufacturer in 2009, slipped down to fourth position after losing 2.8% of its market share in 2010. The company accounted for 9.4% of the market in 2010 compared to 12.2% in 2009.

Gamesa Corporacion Tecnologica S.A. accounted for 7.5%, Dongfang Electric Corporation Limited accounted for 6.9%, Enercon GmbH accounted for 6.8%,Guodian United Power Technology accounted for 6.5%, Suzlon Energyaccounted for 4.8% and Siemens accounted for 4.6% of the global annual capacity in 2010.

Consolidations on the horizon

The major business strategies adopted by the global manufacturers for long term sustainability in the market are investments in research and development (R&D) to expand existing product portfolios to meet changing market needs, capacity expansions and setting up manufacturing units across regions to cater to local demand.

Consolidation is on the cards as the US market is undergoing correction and the Chinese wind market is expected to stabilise during the forecast period. Companies have modest expectations of growth for 2011 as major markets have slowed down but are expected to pick up in the second half of year.

ESPCI Researchers Develop Light-weight Thermoset Plastic for Demanding Applications

French scientists have created a new lightweight plastic that is as strong and stable as other thermoset materials such as Bakelite, yet can be easily reworked and reshaped when heated. The team suggests the material could be used in many applications, from aviation to electronics, while being recyclable and repairable.

Typically, the atoms in thermoset polymers are permanently crosslinked giving them excellent mechanical properties and solvent resistance. However, unlike thermoplastics, which can be repeatedly melted and moulded, thermosets remain fixed in shape once made and cannot be reprocessed.

Now, Damien Montarnal and colleagues led by Ludwik Leibler at the Industrial Physics and Chemistry Higher Educational Institution in Paris have created a thermosetting material that can be repeatedly reshaped like a silica glass using heat. According to the team the reworked material retains the mechanical properties of the original material.

'These materials are thermoset organic resins but they can be worked by techniques similar to blowing and smithing hitherto available solely for metals and glass,' says Leibler. 'Compared with metal and glass, they bring lightness, ease of implementation and a wide range of hardness and extensibility. Compared to other thermoset organic resins, they can be reshaped, recycled, repaired and still present solvent resistance and good mechanical properties.'

The material was made like a conventional epoxy resin by mixing a liquid resin, hardener and catalyst and then heating it between two hot plates. After complete curing, the material was cut and shaped in an oven or by using a heat gun. By applying sufficient heat, the material can be reshaped and remoulded. The team also demonstrated that it can be ground down into a powder and then remoulded or injected.

It works because the material is able to flow when heated thanks to reversible exchange reactions by transesterification. These allow some of the crosslinks in the molecular network to change the topology of the material without breaking bonds in the molecular network hence maintaining its integrity as a solid and preventing depolymerisation. During cooling exchange reactions become so sluggish that the network appears to be a solid just like silica glass.

It works because the material is able to flow when heated thanks to reversible exchange reactions mediated by transesterification. These allow some of the crosslinks in the molecular network to temporarily break which changes the topology of the molecular network while maintaining its integrity as a solid and preventing depolymerisation. The broken crosslinks then reconnect during cooling.

'By implementing the concept of crosslink exchange they have created a novel polymer network with unique capabilities,' comments Christopher Bowman who investigates synthetic polymers at the University of Colorado in Boulder, US. 'It is similar to other covalent adaptable networks that exist but implements a distinct reaction mechanism that utilises a non-radical mediated exchange reaction to enable the adaptation process. This reaction keeps the material in its polymer state but allows for reprocessing and recycling.' Bowman expects the principle applications will be in healable and recyclable composite materials.

'Possible applications include coatings, furniture, propellers and, more generally, any complex part in the fields where one wishes to combine lightness with mechanical and chemical resistance such as aviation, automotive, portable electronics, etc,' says Leibler. He suggests the new material, once reinforced by fibres, might even compete with metals in the most demanding applications.