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Carbon fibers as raw material for light weight systems

Trans-Atlantic Workshop on Rare Earth Elements and Other Critical Materials for a Clean Energy Future. Carbon fibers as raw material for light weight systems in wind energy and automotive applications … Availability and challenges for the future. Dr. Michael H eine

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Carbon fibers as raw material for light weight systems

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  1. Trans-Atlantic Workshopon Rare Earth Elements and Other Critical Materials for a Clean Energy Future Carbon fibers as raw material for light weight systems in wind energy and automotive applications … Availability and challenges for the future Dr. Michael Heine MIT Cambridge/Massachusetts, Dec. 3, 2010

  2. Agenda • Fundamental global challenges • Competitive advantages of carbon fibers • Carbon fibers applications • Wind energy • Automotive • Carbon fiber market demand • Consequences • Future prospects Trans-Atlantic Workshop MIT Cambrige

  3. Key challenges Changed economic environment Climatechange Energy / raw materials availability General approach “Towards an ecologically sensitive world” Fundamental global challengesfoster the future economy Sustainable solutions Energyefficiency Alternativeenergies Lightweight Carbon fibers contributes to all three sustainable solutions Trans-Atlantic Workshop MIT Cambrige

  4. The competitive advantages of carbon fibers Energyefficiency Alternativeenergies Lightweight Sustainable solutions 7,9 Density(kg/l) 2,7 1,6 Steel Aluminium CFRP No other material is lighter … or stronger and stiffer Trans-Atlantic Workshop MIT Cambrige

  5. General technology trends: Fuel efficient cars Alternate fuels (CNG, LPG, E-10) Hybrid propulsion Plug in electrical vehicles General technology trends: On shore to off shore Increase of rotor-blade size Rotor-blades with higher strength to weight ratios Integrated systems such as wind-diesel, wind-SPV, wind-battery etc. Carbon fibers for wind energy and automotive Sustainable solutions Energyefficiency Alternativeenergies Lightweight Wind energy Automotive AudiR8 Trans-Atlantic Workshop MIT Cambrige

  6. main spar flange CFRP main spar web sandwich shell Wind energy:Carbon fibers for „Large Rotor-Blade Sizes“ approx. 0.7 mt CFRP / rotor blade approx. 2.1 mt CFRP / wind mill Nominal power Rotor diameter Axial height Annual energy harvest Trans-Atlantic Workshop MIT Cambrige

  7. benzine /diesel 170 g/km electricity conventional 90 g/km electricity wind energy 3 g/km Automotive:Carbon fibers for „Light Weight Car Design“ Electrified engine, transmission and storage system leads to an higher total mass „Compensation of electrical system mass by reduction of structural mass “ World Wind Energy Report 2009 Trans-Atlantic Workshop MIT Cambrige

  8. CF market demand [kt]Main drivers:Energy efficiency, renewable energy and light-weight systems 143 Sport Aerospace 87 77 66 55 Industry 45 38 38 ca. 15 % automotive 33 ca. 30 % wind Trans-Atlantic Workshop MIT Cambrige

  9. Investment in new carbon fibre capacities to follow the demand 140.000 t/a sports aerospace 100.000 t/a Edison carbon filament bulb other industrial applic. 60.000 t/a automotive 20.000 t/a PAN wind 1880 1900 1920 1940 1960 1980 2000 2020 2040 80 years 1000 to/a = 15 m€ 1500 m€ 900 m€ 300 m€ 2010 2020 Trans-Atlantic Workshop MIT Cambrige

  10. Investment in R&D of process technology, recycling and modelling Process chain carbon composites PANprecursor Carbon fiber CF Fabrics Preformsprepregs CF reinforced plastics CF reinforced carbon CF reinforcedSiC Development of enhanced process technology Polymerchemistry High temp.technology Textile technology Engineering components = additional CF capacities Recycling / Re-Use of CF x x x x Simulation / Modelling Trans-Atlantic Workshop MIT Cambrige

  11. Future prospects:Green energy for carbon fibre manufacturing JV SGL-BMW Moses Lake, WA http://www.energie-visions.de/wasserkraft.html Process chain carbon composites Stabilisation & carbonisation of PAN Trans-Atlantic Workshop MIT Cambrige

  12. Future prospects:Renewable raw material for carbon fibre production p.e. Cellulose p.e. Lignin Crude oil based Trans-Atlantic Workshop MIT Cambrige

  13. Trans-Atlantic Workshop MIT Cambrige

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