Game-changing Market Trends…..Catalyzed by Materials Science Advances

Hello again and welcome to another post,

At the outset, I wish readers A Happy & Prosperous 2012 !

GLOBAL ECONOMY & EUROZONE

As we usher in the New Year with cautious optimism (bordering on trepidation, for some ?) of the global economy, it would perhaps be prudent to focus on each Quarter at a time. December 2011 was a mixed bag of sorts with the major surprise being the possible renaissance of the U.S. economy through a slight jump in manufacturing activity and hence predictions of a relatively strong Q1. Asian factory output remained sluggish in December with China, Korea, Taiwan registering weak industrial activity. Economic pundits state that the eurozone is already in a recession that could extend through Q2,2012.

2012 could well be termed the year of M&A (Mergers & Acquisitions) as industries across a broad spectrum could  witness consolidation. We have already seen the beginning of this trend from Q3, 2011 in the plastics and composites sector which could gather further momentum in the coming months. Capacity expansion through organic growth would still continue; albeit at a relatively slower pace, from a M&A perspective.

SPEED – THE DRIVING FORCE

“Faster than a speeding bullet” was the screaming Dec 27 headline [Mail Online] heralding China’s super-speed train scorching speeds up to 300mph (100mph quicker than its current bullet train), reportedly made possible by liberal use of lightweight CFRP. The spate of  announcements related to the carbon fiber industry…be it related to new JVs for the  fiber or downstream units by auto majors jointly with carbon fiber producers adds credence to the growing demand for CF in automotive, aerospace and infrastructure (offshore wind energy, CNG tanks….). Weight reduction is of paramount importance and carbon fiber could well emerge as the material of choice this decade for high-end applications where premium is on performance (superior mechanical properties vis-a-vis glass fiber).

ELECTRIC VEHICLES – STAR OF 2012

The forecast for the automotive sector this year is that electric vehicles (includes hybrids) will be more widely available than ever. It is also predicted that this could be the year where mass market vehicles adopt CFRP parts [Plastics Today]. We heard the news at IAA 2011 on the development and successful commercialization of a 33% GF reinforced polyamide 66 lithium ion battery module frame for GM‘s hybrid extended range electric drive cars [European Plastics News]. The composite frames support and align the battery cells. Replacement of metal battery housings by plastics is the new trend. The low thermal conductivity of plastics eliminates the foam sheet sheet thermal insulation required for metal housings. Connectors integrated in the housing provide a thermal barrier, protecting batteries from overheating while charging and against cold temperatures in the winter.

As we all realize, plastics & composites in automotive is not just about weight reduction alone…..

The concept of failure strain (elongation at break) in design of composites is well known, as also the role of the matrix in achieving this objective. Studies on hybrid composites with interplied carbon fiber reinforced polypropylene (CFRPP) between self-reinforced polypropylene (SRPP) layers have shown that the failure strain of the hybrid composite is improved in comparison with CFRPP. One of the contributing factors to improved tensile strength has been to utilize the intrinsic behavior of shrinkage under high temperatures of SRPP, to introduce a compressive pre-strain in CFRPP [Sciencia].

SCIENCE TO THE FORE

Relentless pursuit of technological advances continue to expand the range of applications for composites. Recent studies indicate that Polyamide 6 composites reinforced with surface-treated glass fibers and including a small amount of clay-like mineral as an inexpensive filler could yield the best performance of injection molded parts because the glass fibers enhance the mechanical properties and the clay-like filler accelerates the crystallization rate. The presence of a small amount of nucleating agent favors the isothermal crystallization rate of the reinforced polyamide. Microstructural features of the composites and interfacial interactions between filler and polyamide phases, quantified by rheological measurements served to substantiate the findings [Sciencia].

NATURAL GAS  vs. CRUDE OIL

Driven by surging natural gas consumption in Asia and the U.S.( primarily due to shale gas), global use has rebounded to new highs. The world’s largest incremental increase  occurred in the U.S. where low prices (an all-time low as we speak) triggered a 1.3 trillion cubic feet increase to 24.1 trillion cubic feet – just over 1/5th of global natural gas consumption [Environmental News Network]. The Asia Pacific region experienced the strongest growth with China, India, South Korea, Taiwan experiencing demand growth of over 20 % (over 2009 levels). Sinopec’s increased stake in a U.S. energy company last week with a view to gain technology through partnerships is a recognition of China’s focus on shale gas reserves that exceed that of the U.S. Taking cognizance of this rapid shift in natural gas economics, several leading petrochemical majors have announced new plants for ethylene and industries are planning to boost fertilizer production made from gas.

The fallout…PP demand through 2015 in North America is expected to grow at less than GDP growth. Interesting  2011 stats… PP sales declined by 6.8%, while HDPE and PS grew 2.7% and 11% respectively [Plastics Engineering]. With the current natural gas pricing advantage (ethane cracking yields more ethylene !); this trend is definitely likely to continue into the foreseeable future….unless crude oil price drops dramatically!

The resin market in North America is predicted to sport a healthy look this year with distributors eyeing higher sales volumes. PE is expected to make greater inroads through technological innovations and advances in resin properties, possibly displacing PP in the process in many applications. Will LFRT applications using PP take a hit ? Only time will tell.

Significant changing market dynamics ? You bet.  

DREAM METALS COMBO

Ever considered combination of metals to result in a material with the strength of aluminum, density of steel and greater than 1.5 times the energy of TNT…. that is the new innovative revolutionary material that increases the explosive force and lethality on enemy targets. With the HDRM acronym (High Density Reactive Material); this material is designed to replace steel in warhead casings with little or no compromise in strength or design [Materials Insight].  

Innovations are not confined to lightweight plastics and composites, but the heavier stuff as well…which is required at times, necessitated by the nature of the application !

Brace yourselves for another innovative material….that matches the malleability of glass while retaining the toughness and stability of thermoset plastics. With potential applications in the aerospace and auto sectors; the material is recyclable while scratches and small breaks can be repaired by heating [Plastics News]. This unique organic material that mimics malleability of inorganic glass is being taken up for commercial production in France.

Are venture capitalists listening ?

The Word Future Energy Summit [WFES] convenes in Abu Dhabi in the Middle East later this month with a lot of discussion on renewable energy (in its various forms) in general. It would be interesting to note the valedictory comments at the conclusion of the Summit and the message that it conveys.

 TIME RUNNING OUT ?

I end this post with people referring to the Mayan calendar’s prophecy of the world ending in 2012. The Cassandras may be pitching for it; but much will depend on policymakers’ (politicians’) response. As a noted economist recently pointed out that “politicians should get out in front…right now they are running behind”.

Apocalypse and end of the world….Bah !

Till the next post,

Cheers,

S. Sundaram

Email: SS@essjaycomposites.com

Twitter: @essjaycomposite

Website: www.essjaycomposites.com

Composites & Plastics – Foraying further into Metals domain

Hello everyone,

I write the opening para of this post wearing my economist hat and in a pensive mood on the happenings in 2011.

  Q1, 2012 – light at end of tunnel ?

Per recent column in CNBC, “the world economy is on a slippery slope with the eurozone appearing to have tipped into a mild recession and the rest of the global economy struggling to hold on to firm ground. China is slowing, Japan’s exports are tumbling. The U.S. Q3 growth was revised to 2.0%, though a stronger Q4 is forecast”. The OECD has similar warnings of an European recession. It’s report revised global economic growth down to 3.8 % this year and 3.4 % in 2012.

Would even the die-hard optimistic economist sport a wry smile ? Close call….

Metals & Composites – clash of the Titans !

Composites outperforming aluminum and vice – versa always merits industry’s riveting attention. The announcement of commercial lightweight aluminum alloys last summer was news to designers on exciting options for potential and existing applications in different market sectors. The recent introduction of a 30% carbon fiber reinforced polyamide (Nylon 66) motorcycle engine cover at the IPF show in Japan was a revelation, insofar it was a replacement for an aluminum piece.The composite weighed 130 grams versus 263 grams for the traditional aluminum counterpart and outmassed even a magnesium alternative [Plastics Today]. The resultant tensile strength of 250MPa which was on par or even better, lay in preserving the length/ integrity of the 7 – 8 mm long CF used in the injection molding process [IPF].

 Composites supremacy over Metals…one upmanship

Composite access covers could emerge as the material of choice in the UK (currently more than 10 million access covers in use & generally in metal). These covers are placed at points where utility companies need to change the direction of pipes and drainage – usually at corners and often on the crown of the road [Construction News Portal]. Worn, cracked, displaced or pilfered metal access covers pose a hazard to motorcyclists in terms of stability and traction, especially when the road is wet. Composite covers have the advantage of  anti-slip properties remaining at consistently high levels throughout the cover’s life. The manner in which the aggregate is impregnated in the mix results in the composite cover having the added advantage of a tread pattern which is omni-directional; so it cannot be approached from an angle that diminishes grip level. The Motorcycle Action Group [MAG] is actively promoting the “Get a Grip” campaign that could possibly promote greater use of composite covers.

Are SMC/BMC processors and glass fiber producers listening?

  Thermoplastics – untiring & to the fore !

The thermoplastics sector received a fillip on the opening day of December with Bridgestone Corp. announcing a prototype non-pneumatic car tire that uses thermoplastic ribs (with a higher aspect ratio than earlier versions from others) as load bearing elements. Even the tread is made of a thermoplastic material and the material is claimed to be easier to recycle [Plastics News].

More news on the automotive front…. combining the advantages of classic SAN co-polymer with improved temperature and weathering resistance has resulted in a modified SAN with higher HDT (heat deflection temperature), greater transparency and gloss than PMMA. The modified SAN, which is an amorphous plastic; is also claimed to be chemically resistant, stiff and resistant to scratches & lends itself to exterior applications such as mirror bodies, spoilers, decorative trim and in vehicle interiors such as frames and radio face plates [Plastics Today].

The moral of such developments.. automotive is not just about lightweighting, but the accompanying paraphernalia too ! 

Fight global warming… focus on wind energy

Amsterdam was in the news last week…it hosted the  EWEA 2011 Offshore Wind Energy Conference. The timing could not have been more opportune, considering the giant strides being taken in this sector. According to EWEA, over 141 GW of offshore wind energy capacity (enough to provide 13.1% of Europe’s total electricity production)  is built, under construction, or planned in Europe; compared to the 4GW installed today. The potential risk of a high-voltage subsea cable shortage over the next few years is being addressed…trust the EU to tackle this effectively. Did they not plan for the Supergrid well in advance ?

Carbon fiber and thermoset resin producers would be rubbing their hands in glee at the projected GW of offshore wind energy.

Epoxies : eternally reliable

Epoxy functional group modifiers have been reported to improve the mechanical properties of short glass fiber reinforced PBT. Morphological observations  by SEM reveal a thin layer of polymer adhering to the surface of glass fibers, indicating that epoxy functional group reacts with fiber surface and PBT matrix[Sciencia].

PP resin prices dipped in both the U.S. and Europe in November. Unlike the U.S. however, demand in Europe was at more normal levels as converters returned to rebuild inventories. Demand for propylene derivatives such as acrylonitrile remained weak in the U.S. Further PP pricing volatility in the U.S. has created opportunities for HDPE and polystyrene.Titanium dioxide price continues to be firm and the pigment industry has entered a period of renewed profitability with further price increases on the anvil in 2012.

Welcome to the northward pricebound elite club…much to the chagrin of plastics processors and compounders.

Transition time –  Metals to Plastics

As NA and Europe brace for a cold winter, news of the commercial development of thermoplastic polyurethane (TPU) snow chains (in lieu of metal) is something to cheer about. The most treacherous winter driving requires placement of metal chains on cars and truck tires beneath the treads, forcing drivers to kneel in frozen muck. TPU facilitates a plastic alternative that eases installation ( light weight) and offering outstanding wear [Plastics Today]. Another star to TPU’s proven & inherent wear resistance characteristic.

The next generation batteries and shock absorbers may well be made of a material [developed at the University of Carolina] that is 100 times lighter than polystyrene foam with extraordinary high energy absorption properties. The substance is made of tiny hollow metallic tubes arranged into a micro-lattice..a criss-crossing diagonal pattern with small open spaces between the tubes. The resulting material has a density of just 0.9mg/cc compared to silica aerogel (1.0mg/cc). The material’s strength is derived from the ordered nature of the lattice design that consists of 99.99 % air and 0.01 % solids [BBC News/Technology].

A concept even difficult to imagine? Maybe so; but the commercial prospects in practical applications, if and when that hurdle is crossed, seem fascinating.

It is with a sense of pride and satisfaction that we at Essjay Composites sign off this holiday season… our readership now spans 25 countries and across all continents, embracing the polymers and composites fraternity worldwide.

We will be back with our next post on January 9, 2012.

Till then…

Happy Holidays !

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Winds of Change – Blowing strong for Polymers & Composites

Hello again,

The stock market crests and troughs have left most of us bewildered and bemused as to what factors really drive the rollercoaster trends. Undoubtedly, the eurozone has been the focus in recent times. The G20 leaders ended their summit with a communique that spoke of plans to boost growth and rebalance the global economy. Political rhetoric ?

ECONOMY – GOING ROUND IN CIRCLES ?

GDP grew in most countries in Europe in H1 2011 in spite of marked differences in performance, with Germany being the most sprightly. But sluggish growth and the prospect of renewed recession means  joblessness could be rising again in Britain & Germany [The Economist].

The U.S. economy on the other hand continues to flummox economists with the common man swinging between despair and hope depending on the  tidings of the weekly stats. The latest weekly update indicates light at the end of the tunnel -however seemingly distant it may be. A faint glimmer of hope that manufacturing activity is witnessing a renaissance ? Let’s hope so !

COMPOSITE REBAR – CONCRETE FOUNDATION

At its October meeting, the American Concrete Institute Committee 440 (FRP) updated design examples for the design guidelines for FRP rebar reinforcement of concrete, test protocols for durability assessment of FRP products in concrete and a state-of-the practice document on use of stay-in-place structural formwork used for bridge decks [ACMA]. Such updates should be beneficial to the construction sector at large and provide a greater degree of confidence to designers and architects worldwide.

MOLECULES – RAISING THE  BENCHMARK

With global demand for carbon fiber on an upward trajectory; developments on PAN precursor continue unabated.Latest studies indicate positive results in coating modification of PAN fibers with boric acid to enhance the controllability of the oxidation stabilization process. Microscopic analyses showed that the coating was effective to avoid skin – core heterogeneity on the cross section apart from boric acid tending to act as a cross-linking agent leading to formation of uniform oxidized structures favorable for enhanced tensile properties of carbon fiber [Sciencia].

Do such positive results ring a bell for composites veterans….similar to what the glass fiber industry witnessed for decades on  progressive enhancement of mechanicals through sustained  development work ? Therein lies the challenge for researchers in the field of composites.

Metals, in general and stainless steel, in particular  are not about to give in to composites that easily! Recent studies indicate that implantation of Titanium ion avoids intergranular corrosion and mitigates pitting on 316SS as the outer surface becomes completely amorphized, thereby avoiding localized corrosion [Sciencia]. This should be great news for designers as they now have more options in the choice of materials…no wonder Material Sciences is attracting so much attention and drawing students in droves.

Hitherto, the use of fragrance in plastics has been limited, as traditional technologies using EVA particles find it difficult to withstand temperatures of 200C plus. Not so anymore… spherical particle technology offers more robust ways to add complex fragrances to thermoplastics at 280C processing temperatures without issues [Compounding World]. Better still, this innovative technology controls the release of fragrance from the finished polymer for in excess of 18 months.The spherical particles are reportedly a co-polymer produced by polycondensation of methyl pyrrole and squaric acid.

Will plastics with a ( sweet smelling) fragrance be a commercial reality ? Let’s hope so…the script has been written !

RESINS MARKET – THE BALANCING ACT ?

Though financial turmoil weighs on the global economy, chemical makers are more cautious than earlier this year, but there are no signs of a major downturn [Chemical Week]. Some of the demand slowdown reflects inventory adjustments as lower energy and feedstock costs and uncertainty push buyers and consumers to more defensive positions. Though inventories are being squeezed, producers say underlying demand and orders are holding, albeit at a more subdued pace than early 2011. An analysis of PP, PE, styrene, PC, thermoset resin price trends reflect the aforesaid market sentiments.

The potential opportunities that polymers & composites offer the automotive industry are widely recognized. The thumb rule is that a 10% reduction in vehicle weight increase fuel efficiency ( and reduces reduces emissions) by 6-8%. The increased interest in multifunctional components  is calling for new material solutions that can accommodate actions such as thermal/vibration energy harvesting (an efficient energy harvesting system is estimated to have the potential to generate 10% fuel saving), active NVH control or conductive surfaces to remove physical wiring. These new materials are either polymeric in structure or need to be embedded in a polymer matrix to be  turned into cost-effective and usable components in automotive parlance [Injection World]. Future structural applications could witness a glass fiber-reinforced polyolefin with a steel tubing structure or developing TPO combined with SMC for car doors and liftgates [Plastics News].

AUTOMOTIVE – GLOSS & GLAZE !

The automotive glazing market is poised to witness a major shift to Polycarbonate (PC) from traditional glass resulting in a weight saving of around 20%. A new hard coat system that will further improve the scratch resistance and UV protection of PC is a major reason for the successful switch in many European & Japanese cars from 2012[Teijin]. The glazing concept is likely to extend to high gloss or transparent body components in vehicles in the next five years. PC’s growing popularity received another shot in the arm with Shell announcing its low cost, greener process for making Diphenyl carbonate (DPC) – a key intermediate for producing PC [Chemical Week].

COMPOSITES  -   SAFE INVESTMENT !

For the wind energy sector, the winds of change appear to be blowing stronger than ever ( pun intended). According to a recent study, the market for advanced composites is set to grow @16% per annum through 2020… the difference being, that, while aerospace has been the biggest consumer of new structural materials; wind turbines will replace the industry as the leading advanced composites market, owing to the growth of global offshore installations. By 2020, wind is expected to account for $15.4 billion in advanced composites compared to just $6.3 billion for aerospace [Aviation & Aerospace News].

Little wonder that the CF market is headed for a golden decade and flying sky high (Boeing 787 and Airbus 350) whilst simultaneously funneling winds of change in the ocean through massive turbines.

Are composites in general and CFRP in particular having the best of both worlds ? Apparently so, if one were to go by number crunching stats on commercial demand ! Raw material producers (fibers, resins) and processors should be laughing all the way to the bank from 2012-13.

Amidst the prevailing economic uncertainty, are we composites professionals not (justifiably ) entitled to bask on the bright prospects in the coming years?

The seeds of growth have been sown….it’s time to think of reaping a rich harvest !

Till the next post,

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Paradigm Shift – Morphology to play Key Role in Polymers/Composites Design

Hello all,

European leaders at the ongoing summit meeting appear to be focusing intensely on resolving the eurozone crisis. At the same time, U.S. efforts to resolve its own imbroglio seems to be fraught with issues that tend to get more complex. With China’s industrial output temporarily losing steam (a blessing in disguise ?), the global economy is probably in the “pause” mode for the time being.

 For those who revel in crystal ball gazing, these are testing times.

COMPOSITES : HITTING THE BULL’S-EYE

The best advertisement this month on successful use of composites in the automotive sector was UPS‘s new shipment van. It was truly  ”composite ” in character in that the side panels were  made from polyethylene skins with a honeycomb core for strength & stiffness; flooring was in a urethane foam core + PE panels, with rubber from recycled tires being used on rear side bumpers [Composites Manufacturing]. Vehicle weight saving was to the tune of 600 lbs. with an annual carbon footprint reduction of up to 11 Tons. The design ultimately had something for everyone…lesser dependence on fossil fuel (35% better fuel economy), environmentalists’ delight (additional outlet for recycled rubber) and thermoplastics back as a strong contender for sandwich facings.

The extensive use of carbon fiber in the Boeing 787 Dreamliner,the Airbus A350 and the military’s stealth jet fighter planes appears to be coming down to Earth with a slew of energy- saving automobiles expected to hit the roads in the next few years [Materials Insight]. In spite of the projected higher prime cost, the life-cycle-cost-benefit-analysis through energy saving is being touted a strong plus point by electric and hybrid car makers. No wonder automajors such as Toyota, Daimler, BMW are all in the fray. Global resin majors (Dow, Huntsman, BASF,  3M) are not far behind in their efforts to develop resins that have the best compatibility and processing characteristics (short molding cycle times…) to result in  CFRP parts with requisite aesthetics and mechanical properties required in service [Chemical & Engineering News].

 WEIGHT REDUCTION : THE DRIVING FORCE

When leading auto, resin and carbon fiber majors pool  their resources, the end result has to have success written all over.

More interesting news on CF development. Carbon fiber made from PAN with 5% acrylamide (dry-jet wet spinning process using solvent-free coagulation bath) reportedly has the highest Young’s modulus of 5.54 GPa compared with homopolymer PAN [SPE/Polymer Engineering & Science]. Will the higher modulus translate into more exotic applications for CFRP where additional stiffness is a key criterion?

Glass fiber has been the workhorse reinforcement for the composites industry spanning several decades. Carbon fiber may be the (relatively) new exciting  kid on the block, but GFRP continues to hold sway when it comes to cost-performance combine for an application. SABIC recently announced an industry first of sorts – an one-piece reusable concrete form made from long – glass fiber reinforced thermoplastic composite. Advantages claimed are weight reduction up to 40%, cycle times of only a few minutes plus all the added peripherals of reduced transportation & installation costs, durability for repeated use [Composites World].

For the composites industry as a whole, such exciting applications  provide the necessary adrenaline and vehicle for growth.

PE PIPES : MAKING AGGRESSIVE INROADS

Polyethylene (PE) may be one of the earliest thermoplastics to be commercially launched, but it continues to make significant inroads with new grades having improved performance and potential to rival thermoset composites. This has been especially so in pipe applications. New grades (having an extremely tough molecular structure) involve improved high stress-cracking resistance in harsh conditions from freezing cold to high acidity that find extensive use in the gas sector  for pipe diameters in the 100-1200mm range. The high resistance to slow crack growth allows the latest high-speed, lower-cost techniques such as sandless bedding & no-dig installation, without risk of pipe being damaged during installation or in use [Pipe &Profile Extrusion].

Whilst thermoplastics have generally been considered versatile for non-structural applications, advancements in technology over the last decade have seen vast improvements in performance – be it plain, elastomer modified or fiber reinforced. Global demand for Thermoplastic Elastomers (TPE) is forecast to rise 6.3 % per year to 5.6 million Tons in 2015 aided, in part, by the ongoing push to reduce motor vehicle weight [European Plastics News].

The most fascinating aspect, from a designer’s perspective; is the multifarious options available for a given application from a materials selection viewpoint.

FUTURE SHOCK : ELECTRICITY COST

According to a recent report, wind farms could produce as much as 49% of EU (European Union) electricity by 2050 , up from 5% today [Financial Times]. The report states that EU businesses and consumers face at least 20 years of electricity price rises. Dubbed as  “Energy Roadmap to 2050″ and due for release by the year – end; the assessment analyses different scenarios to make the EU less dependent on conventional fossil fuels.With China (having the highest installed wind power capacity) seeking to challenge GE and other Western firms in the wind turbine market, Bloomberg suggests wind power could become competitive with fossil fuel, as a shift to Chinese suppliers could nudge down the cost and enable competing with coal and natural gas [The Diplomat].

COMBATING CORROSION: NEW ALLOY

Recent studies indicate that the corrosion rate of zinc is significantly reduced by alloying it with nickel. Increasing the Ni content increases the barrier of activation energy- a higher value of corrosion resistance is obtained at 10% Ni [Sciencia].

In the field of corrosion, metal researchers rarely like to be second best – alloying is such a boon !

Smart metals are essentially high-tech materials that can remember their cold-forged shape, returning the pre-deformed shape by heating. Shape memory alloys using a 50:50 combination of titanium and nickel are expensive. Hence work is in progress to produce a less expensive smart alloy using copper and aluminum and having potential large-volume applications in electronics and mechanical industries [Materials Insight].

Polymers, composites, metallic alloys….all have their pros and cons in applications. New developments in their respective fields  have a lot to do with  morphology (evident from above new developments in PE and CF). In the ultimate analysis, such technological advancements are extremely rewarding.

Let us  continue to partake in this exciting adventure and keep challenging ourselves in raising the bar when it comes to designing products for applications using polymers & composites.

Till the next post,

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Partnerships in Innovation…the new Mantra to survive & prosper

Hello once again,

The past five weeks were eventful in more ways than one. The  glittering MTV Video Music and Emmy Awards ( that threw in a few surprises and led one to believe that we should lead with our hearts and passion, not our heads, in predicting the winners) provided enough excitement, in spite of the stockmarket mayhem.

A semblance of sanity in the midst of apparently inexplicable market jitters ? Definitely not, if you are a naysayer.

GOLD – WILL IT  UPSTAGE  PLATINUM?

In one of my earlier posts , I had stated that platinum prices could well test the $2000 mark by the year end. For a fleeting tenure, gold came tantalizingly close to platinum‘s current price of $1700, before dropping off. Copper,which was riding high a few months back, fell sharply to a 52-week low last week. Gold’s glitter may well wane if one were to go by the the latest craze for titanium jewellery – it’s versatility such as lightness, rigidity, antiallergenic qualities and ability to be transformed into bold colors. In view of its lightness (vis-a-vis gold), the earrings could just become larger as designs would permit a larger surface area. Italian jewellery designers have already taken the lead.

All that glitters is not gold… how true  this could  be in the not-so-distant future !

A team from an University in the Netherlands has designed and developed a composites solar car that makes extensive use of carbon fibers, incorporating a sandwich structure featuring an aerospace grade structural foam. Since the car was very big, stiffness was the key to design. A special durable and tough polymer from DSM was the choice of the matrix resin. The car is targeting a first place finish at the 2011 World Solar Challenge in Australia in October [Design News]. Good luck!

CARBON FIBER – ON CLOUD NINE ?

Elsewhere, Boeing  is reportedly nearing the implementation of a carbon fiber recycling program for the 787 Dreamliner in order to reduce weight further and use scraps to develop secondary aircraft structures- such as interior parts  and passenger seat backs, thereby achieving an additional potential weight saving of 450-900kgs.[Aviation News].

Resting on laurels…that is equivalent to complacency in general and the composites business, in particular. Don’t we all realize that metals are just waiting in the wings, literally and figuratively; with a chance to swoop in on any potential commercially viable application.

GROWING CLUSTERS – MIND BLOWING !

Offshore wind energy continues to makes waves across continents. Europe (read U.K.) has made rapid strides in this sector and is the undisputable global leader,as we speak. With Germany also viewing offshore as the country’s nuclear energy  exit strategy, talks of an Anglo-German co-operation has gained credence in recent times. Between the two countries,there are potential plans to deploy over 40GW of offshore wind energy, equivalent to around 8,000 wind turbines. The objective seems to be to reduce costs through collaborative innovation, especially in turbine foundation technology, as the traditional monopole design becomes a tad too expensive in deep waters. In addition, optimizing wind farms layout is also crucial. While the biggest wind farms today have about 300 turbines, a site being developed in the middle of the North Sea can have as many as 2,500 ! [Science Business]. New onshore turbines have blades as long as a football field.

They keep getting bigger and synergistic collaboration is the key – be it between companies or nations.  Are ivory towers a thing of the past in this sector? Apparently so !

In my last post, I had mentioned the U.S. Congress announcing standards for vehicles to deliver 54.5mpg by 2025. Close on the heels of this came the Ford-Toyota partnership announcement to bring to market; faster and at lower cost, new hybrid gas-electric systems for pickups and sports utility vehicles. Another classic example of synergistic co-operation between peers to accelerate innovation.

If politics makes strange bedfellows; survival and the will to succeed through innovation can bring together equals to work for a common cause. The world is changing….for the betterment of one and all .

Join the bandwagon - carbon & glass fiber manufacturers, resin producers and processors. The pie is large enough for all to share…profitably !

FASTER CHARGING ? NO PROBLEM    

We all  love lithium-ion batteries for obvious reasons as it powers our laptops, cameras, mobile phones & MP3 players. Is it just possible that we could have the cake and eat it too? Would it not be great if the time to charge the batteries is dramatically reduced? The Chemical Sciences Division of the Department of Energy [DOE] in the U.S. has found that titanium dioxide creates a highly desirable material that increases surface area and features a fast charge-discharge capability for lithium-ion batteries, at its Oakridge Laboratory. This enables batteries to be charged up to 50% full capacity in six minutes while the traditional graphite based lithium-ion battery would be just 10% charged at the same current [R&D].

An amazing and often exciting “R” word is Research. It’s power in all spheres  can make our lives a wee bit more comfortable. The cumulative effect can, of course, be phenomenal.

PP price in Europe was down in September with demand being soft.Coupled to this was the slowing down of demand in China adding to price pressure. Benzene (feedstock for styrene monomer) prices in Asia , Europe and the U.S. moved south this month, aided in part by the dip in crude oil price. With natural fibers and bio-resins being increasingly used in automobiles , will PP-based LFRT (using glass fiber) witness a dent in its competitive edge in the long run? Not so for structural components ; where natural fibers can be a disadvantage, strengthwise.

Qatar (the world’s largest exporter of liquefied natural gas) in the GCC, surpassed Luxembourg as the world’s richest nation in 2010.With a GDP growth in 2011 projected at a staggering 16%, the IMF estimates the Persian Gulf Nation to have the world’s fastest growing economy for the second year in succession, with wealth that’s almost twice that of the U.S. For a country with a population of less than a million, these stats are mindblowing.

BRICK REVOLUTION ?  

Are bio-bricks the building blocks of the future? A researcher at the American University of Sharjah [AUS] is working on bio-bricks that consist of bacteria and waste products which are then dispersed over dry sand. Sand in lieu of clay for bricks? Considering the fact that sand is abundantly available in the region, the prototype 2-meter high wall, if successfully tested,could usher in a revolution as carbon emissions in the construction sector can reduce by more than 800 million tons /year.

Watch out for more bacteria-related potential path-breaking innovations in other market sectors in future posts on this blog.

While the U.S. may have lost it’s top ranking  on innovation ; the latest Social Network survey [Badoo] shows it topping the category on coolness (surpassing France, Italy, Spain) !!

That should cockle the hearts of Americans and be reason enough to smile.

Till the next post…

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Despite Economy Woes, Exciting Trends Ahead for Composites!

Hello again,

The world economy has been in the yo-yo zone awhile; frustrating economists worldwide, since many seem clueless and keep expounding their own pet theories, baffling folks even more. A recent column in Bloomberg Businessweek aptly summed the situation: “Economics isn’t rocket science, but the U.S. economy is a little like a rocket. If it has enough thrust, it can escape the tug of economic gravity – not enough and it might just go into a tailspin”. The dreaded “R” word (read Recession) is gaining credence nowadays with the global economic crisis leading to a “developed economy” recession in the U.S. and Europe. There is even talk of the emerging economies being the knight in shining armor and keeping the global economy afloat, albeit with a scaled-down growth forecast.

Concern about fiscal deterioration continues and any amount of crystal ball gazing is unlikely to predict a clear picture at least till Q2, 2012.

The show however needs to go on. The composites industry continues to keep making progress. ACMA‘s Pultrusion Industry Council (PIC) has developed a new industry document titled “Code of Standard Practice for Fabrication & Installation of Pultruded FRP Structures” which will provide recommendations for construction contract documents as well as procedures and practices for the the fabrication and installation of pultruded FRP structures. One more feather in the cap of ACMA’s Composites Growth Initiative (CGI) program.

AIR BOUND

Our spirits definitely soared last week when Boeing announced that it has achieved certification from the U.S. Federal Aviation Administration and European Aviation Safety Agency for the new Dreamliner 787 airplanes that authenticates the airplane’s readiness to enter into commercial service per Avionics Intelligence. The first commercial passenger flight of the Dreamliner is scheduled for October 26 this year. It was interesting to read a column in Seattle’s Puget Sound Business Journal which stated that the 787 would never have been completed in its current form without a unique collaboration at the University of Washington Center of Excellence for Advanced Materials in Transport Aircraft Structures. The key innovation that the UW center supported was the way to make compression molded small CFRP parts – a method far cheaper than the regular process of layering long carbon fibers used for components such as the  airframe hull and wing.

A classic example of successful innovation in commercializing a novel concept on extensive use of carbon fiber composites. For a moment, even Apple would pale in comparison, given the order of magnitude!

SOARING TO NEW HEIGHTS

Gasping in disbelief is a well known cliche. Those who thought that the Burj Khalifa in Dubai was the world’s tallest building at 828 meters would be in for a pleasant surprise. The Kingdom Tower at 1000 meters (1 kilometer) would be the world’s tallest tower in five years at a whopping $1.2 billion and part of a $20 billion mega project near Jeddah in Saudi Arabia to be built by the Saudi Bin Laden Group, as reported in Gulf Construction.

Jaw dropping awe; you could definitely say so!

FREEZE!

Innovative developments in composites continue to abound. A company in the U.K. has developed an all-composite walk-in freezer that meets offshore blast standards. The lightweight composite panels are fixed to structural pultrusions to deliver low thermal conductivity and hence good insulation characteristics. The system reportedly meets all requirements for jet-fire, pool fire and blast protection, whilst simultaneously withstanding wind and wave load acceleration movements under extreme climatic conditions.

SUSTAINABILITY IN POWER

In early August, the U.S. administration announced the first fuel-efficiency and greenhouse gas standards for work trucks and other heavy duty vehicles. The regulations call for reductions in fuel consumption and greenhouse-gas emissions by 2018 of 9% and 23% depending on the type of vehicle. A 20% reduction in heavy vehicle emissions can boost fuel efficiency from the current 6mpg to an average of 8mpg. This announcement comes in the wake of an earlier one in July that unveiled new fuel economy rules for passenger vehicles that would boost fleet-wide average gas mileage to 54.5mpg by 2025 from the current 27.8mpg. The Center for Automotive Research (CAR) has already submitted a proposal to the Department of Energy (DOE) to study the issues involved in reducing auto weight by up to 40%.

Carbon fibers are poised to be used extensively in automotive applications as evidenced by CF producers forging strategic synergistic alliances with leading auto producers to achieve significant weight reduction in vehicles.

Brace yourselves for more groundbreaking news on wind power. Last week came the announcement of a Japanese breakthrough that will make windpower cheaper than nuclear via the Mother Nature Network. This involves a surprising aerodynamic innovation in wind turbine design called the “wind lens” that could triple the output of a typical wind turbine, making it less costly than nuclear power. “Down, but not out” …that is how one can describe Japan.In spite of a strong yen, battling the aftermath of the earthquake misfortune that prompted it to find an alternative to nuclear power and political uncertainty; the Japanese have few peers when it comes to innovation. The International Clean  Energy Analysis (ICEA) gateway estimates that the U.S. possesses 2.2 million square kms of high wind potential (Class 3-7 winds). By tripling wind energy output,the TOTAL energy needs of the U.S. could be met by just exploiting 20% of available wind resources. For that to happen, the Production Tax Credit has to be extended beyond 2012. In a Presidential year, will that happen? Fingers crossed, as always!

The last week of August also witnessed the installation of the world’s largest offshore wind turbines in the Irish sea that involved 30 turbines, each of  5MW capacity, that were manufactured in Germany and shipped in sections to Belfast as reported in Earth Techling.

Big IS beautiful. Will the Japanese ( who believe in miniature versions of everything) agree or scoff ?

…AND, DURING THE SUMMER HOLIDAYS…

Increasing cost of pigments (titanium dioxide in particular) is driving up gel coat prices with global thermoset resin producers announcing price increases last week. While polypropylene prices remained firm globally in early August, drastic reduction in feedstock price kept the PP market under pressure later on. Polystyrene prices in Europe surged in August in view of the monthly styrene contract price. Crude oil prices continue to be well below the $90 mark and has its own influence on resin prices-be it thermoplastics or thermosets.

I end this post with some more interesting news: Liquefied Natural Gas (LNG) will become the dominant fuel source for all merchant ships within 40 years as environmental pressures force all owners to use cleaner burning fuel according to Det Norske Veritas. Ships must cut emissions of sulfur oxides-a pollutant said to cause acid rain to 0.5% by 2020 from 4.5% today under rules from the International Maritime Organization. LNG, chilled to 1/600th  of its gaseous size costs $397 compared to bunker fuel oil that costs $475/Ton.

Do such comparisons ring a bell with respect to energy derived from wind power and coal? The bottomline is that we are becoming more aware of green, clean energy and the harmful effects of noxious emissions. The stage has been set for posterity to benefit from today’s decisions having far reaching ramifications. 

Clearly the aerospace, infrastructure (includes wind energy) and automotive sectors would be the main growth drivers for composites in the near future.

It was an awful  August global stockmarket roller coaster. Will it be a scary September? It will be foolhardy to even hazard a guess!

Keep smiling.

Till the next post…

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Bio-based Polymers & Composites: Dawn of a New Era?

Hello all,

As European leaders are engaged in discussions on how to prevent the Greek crisis contagion from spreading, the world looks for progress in Washington towards a vote to raise the debt ceiling and reduce the deficit by the August 2 deadline. No one would have ever imagined the current economic imbroglio at the start of the millennium year.

The heat is on in more ways than one.

With oil testing the $100 mark and continuing its roller coaster ride, leading multinationals have already begun charting a course that would make the world less dependent on the black gold. The current buzzwords are bio-polymers, bio-resins and, of course, bio-composites. Of special interest is the Dow-Mitsui partnership announced recently in becoming equal partners in Dow‘s sugarcane operation in Brazil; the JV will produce sugar cane-based ethanol which will then be used to make bio-polymers.

BIO-POLYMERS: PLANES, BICYCLES AND AUTOMOBILES

Image courtesy of Paramount Studios

Automakers (Ford, Toyota) are continuing their push into greater use of bio-resins for car parts. Plastics News reports that nylon, polypropylene, polyester and other resins made from natural resources such as sugar cane hold out the promise of a less expensive and stable source of raw material for plastics. Soy and castor-bean foam blends along with polylactic based plastics are used for interior parts in the Prius and other hybrids. The Prius also uses DuPont‘s Sorona bioresin (20-37% resin sourced from renewable plant sugar) for parts on the instrument panel air conditioning outlet.

In early July, KLM became the first airline in the world to operate a commercial flight on “biokerosene” which included renewable jet fuel. A 50/50 blend of conventional and  renewable jet fuel was used in both engines of a Boeing 737-800 aircraft that carried passengers from Amsterdam to Paris. On July 1, ASTM International that sets worldwide technical standards for the airline and other industries gave approval for carriers to mix fuel made from organic waste and non-food plants with kerosene, which is conveniently used to power planes. Airbus estimates, per Bloomberg, that by 2030, plant-derived formulas could make up as much as 30% of the market for aviation fuel.

With composites being used extensively in airplanes coupled with bio-fuels, travelers could be in for a unique flying experience in the near future.

Have you heard of the world’s lightest production two-wheeled electric vehicle? If not, please refer to Plastics & Rubber Weekly. It is an electrically assisted bicycle developed by a British company which used a 60% long glass-fiber reinforced nylon rear suspension unit with the main frame in magnesium. The surface finish was excellent in spite of the high glass content. More developments in LFT (long-fiber reinforced thermoplastics)….. European Plastics News reports a Dutch company having developed polypropylene based LFT (30 % glass content) solar photovoltaic modules to replace standard aluminum frames. Rapid assembly and disassembly, lower installation times and weight reduction are all the advantages that the composite offers for this application.

Ingenuity in design plus a yen for commercially viable applications is what makes composites such a fascinating proposition for numerous applications in a wide spectrum of market sectors.

OTHER INDUSTRY STARS: CARBON FIBER AND PLASTICS

More exciting news on carbon fiber composites awaits you! A revolutionary carbon-fiber aircraft (Solar Impulse HB-SIA) concluded its European tour in early July, marking a new era in terms of energy saving. The 12 1/2 hour flight was powered by solar energy alone! ” Another classic case of reduced dependence on fossil fuel”, was the statement issued by the European Commission. Thus far, three international flights have been completed in the European campaign. Around-the-world flights are scheduled in 2014.

An extraordinary example of what one can do with stored energy. And, of course, carbon fiber!

With natural gas in the news in a big way, the American government and industry plan to have a strategy for converting fleets to natural gas, including public transit and government fleets, heavy-duty freight fleets that currently rely on diesel, and light-vehicle fleets like taxis that can refuel at a single station. If passed, the NAT GAS Act would provide credits for companies to buy and manufacture natural gas vehicles and build refueling stations. Honda plans to sell its Civic Natural Gas in all 50 states in the U.S. this Fall.

Carbon fiber producers to a greater extent and glass fiber producers to a relatively lesser extent could reap significant benefits due to an increase in natural gas-powered vehicles through a big demand for cylinders for storing the gas.

Is fossil fuel exit more imminent and closer than we predicted? Not so fast…! This may just be the beginning (of the end)?

Engineering plastics demand in Europe grew by 30% in 2010 and poised for double-digit growth this year according to BASF. Excellent prospects have also been forecast for the U.K automotive industry according to the Society of Motor Manufacturers & Traders (SMMT) which states that the global shortage of some components caused by the tsunami in Japan has failed to dent the performance of the U.K. automotive sector.

Finally, light at the end of the tunnel ? Apparently so, judging by views of market pundits. Touch wood!

AND NOW FOR WIND POWER NEWS!

A new EWEA report shows that by 2020, most EU countries would have tripled their wind power capacity reaching a total installed capacity of 230GW, providing 15.7% of EU electricity, depending on demand. 190GW of this would be onshore and 40GW offshore, mainly driven by a strong EU regulatory framework to 2020. China plans to expand its offshore wind power to 5 GW by 2015 and 30 GW by 2020 according to the Chinese Renewable Energy Industries Association (CREIA).

The winds of change are blowing pretty strongly, particularly offshore wind power; and,that too, across all continents. A global revolution in green energy in the making in a planned , structured manner.

TIME: “INNOVATION IS AS AMERICAN AS APPLE PIE”

Aging infrastructure is a perennial problem in many countries, especially the U.S. Following observations made by the American Society of Civil Engineers (ASCE) a couple of years ago, a collaborative effort made between universities in Europe and the U.S. has resulted in a novel method for the electronic continual monitoring of structures using a sensing skin made of stretchable thermoplastic elastomer mixed with titanium dioxide that is highly sensitive to cracks, with painted patches of black carbon that measure the change in electrical charge of the skin[R&D]. The sensing skin has the advantage of knowing the damage location at a pre-defined level of precision apart from sensing a change in the general performance of the structure.

Essentially, it is extremely heartening news for ascertaining conditions of bridges, dams , schools world over and a shot in the arm for the safety of civil infrastructure as it entails real-time information on structural “health”.

The debate on the American economy can be endless. ”Innovation is as American as apple pie”, as described by Time. There can be no two opinions of the fact that America’s future growth will have to come from industries that create new products and processes. In short, encouraging American innovation and restoring it to its past glory. Two recent reports from the Boston Consulting Group and the Information Technology and Innovation Foundation (ITIF) found that, on the basis of innovation capacity (government funding for basic research, education and corporate-tax policies), the U.S. came last out of 40 countries analyzed.

Evidence that is neither startling nor surprising. Such has been the fall in America’s innovative capabilities – it’s forte until 2007.

A THIRD, AND ADDITIONAL MOVIE REFERENCE AS A CLOSING NOTE

Being vacation time at the ESSJAY offices, the next post will be published on September 5. Feel free to leave comments on the blog in the meantime, or send over an email or a tweet (contact details below).

We’d love to hear from our readers, and we’d like to thank  readers for our climbing readership numbers across 19 countries: we have DOUBLED over far less than a year’s time.

After Steve Martin’s Planes, Trains and Automobiles and the last decade’s teen hit American Pie, I’ll now remind you of yet another classic. To quote the famous Terminator (Arnold Schwarzenegger) punchline: I’ll be back !

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Competing with Composites…. Metals to the Fore!

Hello everyone,

This post comes at a time when many would be planning their summer getaway and/or traveling. Judging by the soaring mercury that cut short spring in several parts of North America and Europe, thereby ushering in an early summer, weeks in advance; resorts & beaches would be all set to beckon many holidayers with open arms.

After the holiday-mood opener, readers may castigate me for the damp squib that follows. The most recent announcement by the Bank For International Settlements (BIS) has warned that low interest rates across the globe are a threat to world financial stability [BBC Business News]. It warned that low cost of borrowing had resulted in a credit and property price boom that was fueling inflation, more so in emerging economies. In a CNN News publication, BIS spoke of the need for global economic growth to slow in order to curb inflationary pressure around the world and urging nations to act urgently to close budget deficits.

The global economy requires to dorn a new avatar… it would be awhile even for Merlin’s magic wand to restore the 2007 economic glory. Is not hope a soothing balm that is savored by one and all, for obvious reasons?

BUZZWORDS: RENEWABLE, LIGHTWEIGHT…& STEEL?

Renewable energy continues to be the buzzword of many nations bolstered by GWEC‘s prediction that renewable technologies could supply the world with more energy than it would ever need and, that too, at a highly competitive cost. A column in The Montreal Gazette cited stats from the U.S. Energy Information Authority [EIA] on the cost in $/MWH of different energy sources: conventional coal power ($100.40), natural gas ($83.10), nuclear ($119.00), onshore wind power ($149.30), offshore wind power ($191.30). EIA further states that the ability to produce electricity on demand is 85 % for coal, 87% for natural gas, 90% for nuclear and 34-39 % for wind power. The focus on wind power however remains and, from a composites viewpoint, it implies thousand of tons of glass fiber, carbon fiber and thermosetting resins!

As per Trade Arabia News, the International Energy Agency (IEA) believes that global demand for natural gas is poised to rise by 13.6% between 2010 and 2016, with the bulk of growth coming from rising power generation. Little wonder that the U.S. is pushing for shale rock drilling to tap the vast gas reserves, while Qatar remains the undisputed leader in LNG.

A recent Bloomberg Businessweek column on demand for armored cars made for interesting reading. It mentioned that the demand for armor-plated cars is a rage in Venezuela – dubbed as the new murder capital of South America and displacing Columbia in the process. Apparently, the global demand for armored vehicles & ballistic protection is on the rise for different reasons… the bottomline is however protection to human lives and the answer is, inevitably composites [be it aramid, glass, polyethylene fiber based].

                    COMPOSITES, ALUMINUM : SKY-HIGH COMPETITION

Just as we were continuing to rave about the extensive use of composites in the next generation Airbus and Boeing airplanes, comes the news of  leading aluminum producer Alcoa announcing the development of a new aluminum alloy and claiming possibilities of planes being 10% lighter than composite – intensive airplanes [Autopia].

When it comes to lightweight materials, we are probably on the cusp of witnessing games of one upmanship in the future. It definitely goes to show that composites cannot rest on its laurels for prolonged periods. Are carbon fiber and resin producers taking note?

More competition from competing materials… this time from steel. If you think that steel is eternally heavy, think again! A Detroit engineer claims to have recently developed a heat treatment that makes steel 7% stronger than any steel on record – and, that too, in less than 10 seconds. The new steel has tested stronger and more shock – absorbing than most common titanium alloys [R&D]. The new steel may hold the key to make cars and military vehicles stronger, lighter and more fuel-efficient!!

Phew ! – are we about to witness a Materials Revolution in the coming years? It may not be an outlandish thought, prima facie.

OUT GOES ONE, IN COMES ANOTHER

Brace for more startling news on the composites front. Styrene has been listed as a “reasonably anticipated” carcinogen in the latest (June 2011) “Report on Carcinogens” following observations in the National Toxicology Program . We are all aware of LSE resins that have been in use for decades by the composites industry. The increasing popularity of bio-based resins should serve as a fillip to the composites industry …especially due to the fact that the bio- based resins are finding increasing commercial applications in automotive, building/construction and other sectors.

The composites industry has always been ahead of competition through its relentless pursuit of technological innovation backed by a strong track record. When one door closes, another opens – a familiar cliche worth remembering at this juncture.

HOT OFF THE PRESS!

Last week, China announced the successful test run of its new high-speed bullet train topping 350kms/hour as part of its nationwide high-speed network. It outpaced Japan’s newest bullet train March debut of 300kms/hour. This bodes well for both composites and aluminum that would be extensively used in these high-speed trains.

I am reminded of the James Bond movie with a slight twist to the title “Live and let Live” (not Die). Who says that competing materials cannot complement each other successfully?  After all, it is the innovative ingenuity of the designers that come into play when using such combinations of diverse materials of construction. When it comes to lightweight, the stakes are definitely higher.

For carbon fiber producers and processors, there was some news to cheer about. MotoGP bikes could soon be made with a carbon fiber chassis (much to the chagrin of Japanese bike makers) wherein the engine is considered as a stressed member with a carbon swingarm attached to it, as reported by Bikesport News.

Whether it is bikes, cars or bullet trains… speed thrills. The icing on the cake is the exciting synergistic combination of lightweight materials that makes such high speeds attainable, yet safe.

PRECIOUS LIQUIDS: OIL AND COFFEE

While oil prices and stockmarkets have sent us in a tizzy in recent weeks, how many know that 46% of a barrel of oil is refined into gasoline, another 40% into jet and fuel oil while a paltry 2% becomes petrochemicals (polyethylene, benzene etc) with the rest going to other uses.

After a century of coffee economy, Brazil (as an elite member of BRICS) is benefiting from the right policies, regaining international credibility and more recognition. It survived the financial crisis better than most. It will soon host the both the Olympic Games and the Soccer World Cup within two years of each other.

Now that’s ambition & recognition and great news for composites usage in the stadia and infrastructure for the mega events.

Till the next post,

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Innovations in Composites : Perennial requisite to reign Supreme !

Hello all,

Here we go again……

Globalization, the internationalization of supply chains and the integration of global financial markets that has been occurring over the past two decades is expected to continue in the next growth cycle, knitting the world’s economies closer. The trend is towards alignment of growth among the world’s different economies. As trade, investment and financial flows become increasingly more entwined and integrated, individual economies cannot avoid the ups and downs of global growth. The OECD sees risk of “stagflation” for global recovery in its latest economic outlook.

World growth is forecast to be 4.2 % this year, down from 4.9% last year, before rising to 4.6% in 2012.

GERMANY CLOSES ONE ENERGY DOOR, AND OPENS ANOTHER

Germany’s decision to close all nuclear plants by 2022 and focus on renewable energy instead was not surprising. The nation’s energy legislation is expected to benefit offshore wind farms with a targeted 20-25GW generation by 2030. The Environment Ministry’s plan to keep a 2 euro cent/KWH bonus for utilities with offshore wind parks up and running by 2015 amply demonstrates the ambitious objectives. Around the same time last week, came GE‘s announcement of its maiden commercial-scale power plant (integrating solar & wind power) heading to Europe through its newly released combined-cycle gas turbine.

The eurozone  is definitely walking the talk with its daring path – breaking initiatives that has success written all over!

COMPOSITES AND DESIGN

The Pultrusion Industry Council of the American Composites Manufacturer’s Association [ACMA] recently completed the Load & Resistant Factor Design [LRFD] pre-standard for pultruded shapes. A special committee is drafting a Code of Standard Practice that will complement the LRFD when it becomes a full ASCE [American Society of Civil Engineers] standard this year. Through its Fiberglass Grating Manufacturers Council [FGMC], ACMA is a step closer to finalizing a draft standard to make it easier for structural engineers to design and specify pultruded fiberglass and molded grating.

 ACMA continues to render yeomen service to the composites industry through strategic initiatives involving considerable foresight, that ultimately is of immense benefit globally.

Light weight-high strength has always been the tagline for propagating composites for the past four decades. Add a dash of ecological impact and hallelujah…behold Lufthansa‘s new Quantum Light Weight Trolley to be introduced gradually till mid-2014 on all its long-haul intercontinental flights. The composite service trolley is a third lighter than its predecessor and will save 9,000 Tonnes of kerosene and 28,350 Tonnes of carbon dioxide annually.

BEATING ELEMENTS OF NATURE 

Another interesting  recent application was that of UPS testing a composite-body diesel van that is anticipated to be 40% more fuel efficient than a traditional aluminum vehicle [Environmental Leader]. Currently being subjected to exhaustive tests in five different locations (based on tough weather conditions and rugged terrain) in the U.S., the resulting van is about 1,000lbs or 10% lighter than a comparable member of the UPS fleet with no cost premium. In view of the pigmented finish, the composite van does not require painting and requires less energy to produce.

Simple, less exotic applications like those exemplified above, are just the tip of the iceberg when it comes to harnessing the enormous potential of composites in a multitude of market sectors.

Composites, in general have inherent corrosion resistance and rival carbon steel on this score. It was interesting to read a column in Bloomberg Businessweek, captioned “The high cost of waging war on rust” that  dwelt on the Pentagon enlisting defense contractors in the battle against corrosion in ships, tanks, planes that is expected to cost an estimated $115 billion over the next five years! Creation of a Corrosion Policy envisages new technology (read Composites) and stepped-up maintenance that could cut the annual cost of corrosion by at least 30% in about 20 years.

Are  thermosetting resin and glass producers  listening? All roads leading to the Pentagon to pitch the case for more extensive use of composites by the Defense Department?

UNDERRATED BUT USEFUL OBJECTS: PIPES AND SEATS

While steel and concrete were the leading materials for large-diameter pipes (pipes with a diameter 15 inches or more) in the U.S. in 2010, the long-term outlook for plastics (including glass fiber composites, HDPE, PVC) is favorable, according to Plastics News. The U.S. demand is projected to grow 6.2% per year through 2015. Sewers – including both storm  & sanitary sewers, will remain the leading outlet accounting for about 50% of the total demand.

With composites having a proven solid track record for sewer pipes, it should be a cakewalk. But one should never underestimate HDPE pipes…more so, in the wake of last week’s announcement of a Singapore company having successfully demonstrated its high stress, crack-resistant HDPE pipes. Et tu thermoplastics? For sure.

Thinner seats are bound to become increasingly important as automakers try to shave weight and size from cars to meet improved fuel economy. A processor in the U.S. has developed a compression molded  plastic composite structural back that can be more easily shaped to match the body’s contours compared with foam and wire used in a typical seat structure [Plastics News]. Though 1 inch thinner and 2 lbs lighter than standard seats, the seat is safe enough that it can stand up to Federal crash requirements.The material of the  plastic composite seat can also have a visible surface rather than covering it with laminate or textiles.

Big may be beautiful; but thinner, sleeker, lighter, ergonomic designs are what the future beckons for automotive seats.

CHEMICALS MAKE THE WORLD GO ‘ROUND!

Pricing volatility of benzene feedstock continues in North America coupled with shortages of butadiene feedstock. With styrene monomer being derived from benzene, it is no wonder that thermosetting resin producers announced yet another price increase recently.

Whether skyward or northward is more appropriate to describe price increases, depends on the state of the mind !

For those with a scientific (read chemistry) bent of mind; last week’s news via BBC mentioned the addition of two new elements to the periodic table…curiously having temporary titles of ununquadium and ununhexium.

Another piece of latest news is that average prices of iron ore are expected to drop off in the coming years…around 30% in 2011 and 9% in 2012, according to Forbes. One main reason being attributed to this is the continuous build up of iron ore inventories in China – the world’s largest producer & importer of iron ore.

Which makes us wonder…is the Chinese economy a blessing or a curse? Take your pick.

UH OH…

I end this post with, not unexpectedly, startling news. Late last week, Fitch Ratings stated that the U.S. risked losing its prized AAA sovereign rating in August, if it suffered even a “technical” default on its debt. Moody‘s credit rating agency also echoed similar views on possible cutting of the top-notch credit rating if there was not enough progress by mid-July on a deal to reduce the deficit and raise the $14.3 trillion debt ceiling.

Sad and unthinkable as it may be, the harsh truth hits all Americans real hard. Is there a possibility of global markets being roiled in August?

Fingers crossed, a prayer on everyone’s lips…and????

Till the next post,

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com

Composites, Economy & Lifestyle – Market Dynamics at Play

Hello everyone,

I commenced writing this post on May 21 branded as Judgement Day that predicted the end of the world. The reason being I was curious to see whether it would happen; in which case, this post would have remained unread. A CNBC News columnist stated that writers came down heavily on the prediction “with the fervour of Disney lawyers quashing a Mickey Mouse painting at a daycare center”.  A fair sprinkling of people world over, however seem to attach greater importance to Apocalypse 2012… more precisely December 21, as it is tied to a real astronomical event – the earth and sun will be roughly lined up with the center of the Milky Way galaxy.

I am sure there are numerous agnostics who would scoff at such prophecies. Why stir the pot?

AEROSPACE AND INFRASTRUCTURE

Composites professionals in the aerospace sector would have been overjoyed to read a Bloomberg News report that Airbus aims to begin assembling the first A350 by end 2011 in France. Imagine flying in an airplane that has 50% composites by weight and also offers 20% operational savings over traditional aluminum models. Wing components, fuselage, access panels,ducting and overhead lockers are some of the  parts that form the slew of composite products which would be featured in the aircraft. No doubt, Boeing‘s technology for the Dreamliner was revolutionary and paved the way for extensive use of composites in aircraft structures.

For frequent flyers and  airlines alike, the stage is set for more comfortable and luxurious flying, if one were to go by the total makeover of cabin ambience imminent in the new generation airplanes.

At the recently concluded ACMA‘s Construction, Corrosion & Infrastructure Conference [CCI], one of the hot topics was infrastructure rehabilitation through use of composites. Interesting facts emerged such as composites requiring less than 90 days to rehabilitate a one-mile long bridge and that too at 15-20 % less cost. Further 90 % of concrete repair use carbon fiber composite [CFRP] with aramid and glass fiber being lesser options.  Glass fiber composites’ [GFRP] susceptibility to creep failure is a major drawback. North America’s preference to use fabrics instead of laminates for rehabilitation stems from the logical advantage of the former being more flexible and therefore easier to manoeuver round columns and beams.

RENEWABLE SOLUTIONS

When it comes to renewable energy, the discussions are endless as also the multifarious options in reducing dependence on fossil fuels and reduction of carbon footprint. Earlier this month, the U.N. Intergovernmental Panel on Climate Change which met in Abu Dhabi made an ambitious forecast that 77% of the global energy sources in 2050 would be from renewables [wind power, solar power, biomass, geothermal, ocean energy & others], resulting in a reduction in greenhouse gas emissions and aided by cheaper technology for renewable energies.

Compare that with 13% in 2008 !  If that’s not progress with relentless pursuit, what is ?

A central Indiana city bus system is turning to wind power in hopes of cutting its electrical costs and reducing its environmental footprint, by installing three turbines each capable of generating up to 100KW of rated power and saving the bus system up to $40K in electricity costs and generating up to $250K in revenue from selling tax credits. Audi, in fact plans to use wind power as a source of clean energy for its upcoming electric and natural gas vehicles.

In situations that require seeking solutions against all odds or with definite intentions, the mind brooks no limits.

PIPES, PRICES and MORE

Polypropylene prices are at an all-time high in North America and are susceptible to supply disruptions for the next few years. For the third time this year, there has been a price increase totaling 37 cents/lb since January 1, arising mainly from shortage of propylene feedstock. This could negatively impact the D-LFT/LFRT and short fiber reinforced thermoplastics market with softening of demand, especially when the automotive sector is showing signs of revival.

The market for coated pipes is set to keep growing as applications in energy and water supply continue to increase. The highest demand for coatings is from Asia (23 %) followed by Europe at 19% and NAFTA/CIS States at 17%. Concrete at 42 % and external anti-corrosion at 38% are the highest value sectors. There is  need for a newly developing market for pipelines [Pipe &Profile] in carbon capture and storage. The International Energy Agency predicts the need for 43,000 kms by 2030 for 1.44GT of carbon dioxide capture per annum.

One can already see a beeline of thermoplastic and composite pipe producers hopeful of tapping this emerging application.

The Eurozone’s economic growth accelerated in Q1 with the economy of 17 countries that use the euro growing at 0.8%. Germany alone reported 1.5 % growth, with the U.K. reporting 0.5%. While the dollar had one of its strongest weeks last week, pushing the euro to its lowest since last March, the strength is seen by many as short-lived. A correlation is also being built between the yuan and euro which, at times, have moved in tandem in recent years per a CNBC article. Many economists are factoring a 5% appreciation of the yuan this year (or over the next few years) which could cause the dollar to slide anywhere between 20-30% on indices based on baskets of currencies.

A stronger yuan could land a knock-out punch on trade competitors and partners in Asia and large emerging markets. Game on?

”PAIN AT THE PUMP”

For Americans, the “pain at the pump ” continues with oil prices well above the $ 100 mark and gas prices soaring to almost $4/gallon. It is however good news for composites in a convoluted way.  An April poll shows general consensus that the U.S. Government should require car companies to boost fuel economy. Increases that could double the current 30mpg are being considered by the Environmental Protection & the National Highway Traffic Safety Administration, amongst other bodies.

Composite raw material producers (glass fiber, carbon fiber,  thermoplastic & thermosetting resins) and processors could possibly be laughing all the way to the bank in the coming 18 months on more extensive use in automotive applications? A distinct possibility, it appears!

AND NOW…BEER!

Beer has always been considered a man’s drink. In a recent Gallup poll via CNBC on U.S. drinking habits, only 27% of women named beer as their preferred drink. Wine was the top choice at 48%. As for men, beer was the top drink (54%). Considering the fact that only 6% women listed beer as their top drink in 2009 , the recent stats is a sea change! Danish-base brewer Carlsberg is looking to speed up the trend by offering a gender-neutral beer with a balanced taste…..a real alternate to white wine and champagne. The beer is set to be released in Denmark later this year and the rest of Europe and part of Asia in 2012.

Americans would have to wait for this beer – it is not scheduled to come to the U.S. anytime soon!  A revolution in liquor taste & guzzling – why not?

Till the next post,

Cheers,

S. Sundaram
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website : www.essjaycomposites.com