Periodic Reporting for period 2 - SPE (Silicon-Carbide-Fiber Pilot-production in Europe)
Période du rapport: 2020-07-01 au 2021-12-31
SPE targets the successful start-up of the Silicon Carbide (SiC) Fiber Pilot Plant production in Bayreuth. It is the only SiC fiber activity in Europe and represents a major milestone after approximately 20 years of research and development. The Fiber Pilot Plant was built by Fraunhofer ISC/HTL using BJS' patented SiC-Fiber-technology.
SiC fibers enable aero-engines to meet the badly needed and challenging regulatory CO2-emission-reduction objectives. They are indispensable for the new generation of aero-engines allowing them to operate at higher temperature where the current metal-based materials would fail. Thus, the aero-engines are more efficient with less noise and - most importantly - generating significant less CO2. In addition, the SiC fiber-based new materials are much lower in weight compared to metallic materials having an additional beneficial impact in turbines on CO2-emissions.
Besides its contributions for significant CO2-emission reductions in aviation, SPE laid the basis for “SiC fibers made in Europe” - rendering Europe independent from oversea sources. This is a key factor for European customers to develop their extremely costly supply chains. SiC fibers are dual-use goods and therefore under export control restrictions. Without BJS’ SPE project, the development of a critical supply chain for a unique advanced material for one of Europe's key industries - aviation - would be dependent on revocable approvals of oversea authorities.
SiC fibers enable aero-engines to meet the badly needed and challenging regulatory CO2-emission-reduction objectives. They are indispensable for the new generation of aero-engines allowing them to operate at higher temperature where the current metal-based materials would fail. Thus, the aero-engines are more efficient with less noise and - most importantly - generating significant less CO2. In addition, the SiC fiber-based new materials are much lower in weight compared to metallic materials having an additional beneficial impact in turbines on CO2-emissions.
Besides its contributions for significant CO2-emission reductions in aviation, SPE laid the basis for “SiC fibers made in Europe” - rendering Europe independent from oversea sources. This is a key factor for European customers to develop their extremely costly supply chains. SiC fibers are dual-use goods and therefore under export control restrictions. Without BJS’ SPE project, the development of a critical supply chain for a unique advanced material for one of Europe's key industries - aviation - would be dependent on revocable approvals of oversea authorities.
The SPE project is a first big step towards the independence of the EU in critical, dual-use and therefore export-controlled advanced ceramic materials indispensable for key EU industries such as aviation, energy production and in future, a hydrogen-based CO2-neutral economy. The SPE project delivered:
1. The successful upscaling of the production process of raw materials based on BJS' patents: Supply chain for sufficient raw material is available to run the industrial SiC fiber pilot line. The acquisition of additional patents regarding raw materials provides even more flexibility for cost-efficient SiC fibers.
2. The successful transfer of BJS' patented production process from lab scale to an industrial pilot scale with novel equipment and configuration allows a cost-efficient SiC fiber production!
3. The successful establishment of a quality management system that measures and controls the process stability and capability as well as the product specification. We will continue to develop it further the more insights we gain. It is the backbone of a strong and capable production for high-quality, top-performing SiC fibers.
4. The first SiC fibers ever produced in the EU were already successfully tested by BJS Composites GmbH, a SME dedicated to the development, production and marketing of ceramic fiber-reinforced Silicon Carbide composites (CMCs) and components therefrom. These first EU SiC fibers were comparable to other competitive ceramic fibers regarding their processability in the production of CMCs.
5. The communication strategy developed in the SPE project is successful and bears fruit: BJS was recently contacted by several EU and oversea's key players in order to establish a SiC fiber supply! First shipments could be arranged. The market entry of BJS takes place in a time of short supply and is therefore highly welcome not only by EU players, but also by non-EU-based customers – as expected in the market study that was updated during the SPE project and in line with third party market research studies.
The SPE project laid successfully the foundation for the further development of next generation SiC fibers, and CMCs therefrom. They will be the basis for further innovation in regards to turbines for aviation and energy production, H2-based energy production- and storage for a carbon-neutral economy.
1. The successful upscaling of the production process of raw materials based on BJS' patents: Supply chain for sufficient raw material is available to run the industrial SiC fiber pilot line. The acquisition of additional patents regarding raw materials provides even more flexibility for cost-efficient SiC fibers.
2. The successful transfer of BJS' patented production process from lab scale to an industrial pilot scale with novel equipment and configuration allows a cost-efficient SiC fiber production!
3. The successful establishment of a quality management system that measures and controls the process stability and capability as well as the product specification. We will continue to develop it further the more insights we gain. It is the backbone of a strong and capable production for high-quality, top-performing SiC fibers.
4. The first SiC fibers ever produced in the EU were already successfully tested by BJS Composites GmbH, a SME dedicated to the development, production and marketing of ceramic fiber-reinforced Silicon Carbide composites (CMCs) and components therefrom. These first EU SiC fibers were comparable to other competitive ceramic fibers regarding their processability in the production of CMCs.
5. The communication strategy developed in the SPE project is successful and bears fruit: BJS was recently contacted by several EU and oversea's key players in order to establish a SiC fiber supply! First shipments could be arranged. The market entry of BJS takes place in a time of short supply and is therefore highly welcome not only by EU players, but also by non-EU-based customers – as expected in the market study that was updated during the SPE project and in line with third party market research studies.
The SPE project laid successfully the foundation for the further development of next generation SiC fibers, and CMCs therefrom. They will be the basis for further innovation in regards to turbines for aviation and energy production, H2-based energy production- and storage for a carbon-neutral economy.
With the end of the project, we successfully established an industrial fiber pilot production in Europe that will meet the requirements of industrial customers very short-term, and our aviation customers’ requirements by the end of 2022! With this, our customers can start the approval process for their aero-turbines made with BJS SiC fibers to meet the highly challenging and very much needed regulatory CO2-emission reduction targets in aviation. Aviation is one of the key economic sectors within Europe, so SPE contributes to the long-term survival and success of the European aviation industry.
This pilot production will serve as blue-print for our planned commercial SiC Fiber Production Plant that we plan to establish in the mid-2020ies based on the demand scenarios of our customers in aviation, and industrial applications. The innovative, patented BJS high-tech SiC fiber technology requires less production steps, delivers higher yields at less energy input than our oversea’s competitors’ processes. The lower cost will allow entering more fields of application and thus increasing the positive environmental impact to other industries and applications - generating a competitive manufacturing opportunity for many applications!
This will create significant additional high-skilled employment throughout the 5-step value chain:
1. Chemical industry for raw materials (EU-based)
2. BJS Commercial SiC fiber production plant (EU-based)
3. Textile processing, e.g. weaving (EU-based and oversea's)
4. CMC-component production build up for aero-engines, and other industrial applications (EU-based and oversea's)
5. Turbine Manufacturing/Maintenance as well as the development of other industrial applications – e.g. hydrogen turbines, energy production and storage, space and friction applications (EU-based and oversea's).
Last, not least, our SiC-fiber ensures the EU’s independence from oversea’s authorities for a critical dual use good and technology that has unique high-temperature-, thermoshock-resistant, light-weight properties while keeping its high mechanical strength – attractive for many challenging operating conditions.
In summary, SPE enables the aviation industry to meet CO2-reduction regulations, it will enable the build-up of new innovative industries further supporting significant CO2-reductions and long-term, a carbon-neutral economy. Thereto, we identified several promising application areas which will only be tapped on once product is more abundantly available and lower in cost. Future development programmes will focus on this! SPE laid the foundation for significant high-skilled employment generation in up- and downstream industries as well as prosperity for employees and the EU. Moreover, it will strengthen the EU’s position internationally and create independence in a critical dual-use good market & multi-step value chain.
This pilot production will serve as blue-print for our planned commercial SiC Fiber Production Plant that we plan to establish in the mid-2020ies based on the demand scenarios of our customers in aviation, and industrial applications. The innovative, patented BJS high-tech SiC fiber technology requires less production steps, delivers higher yields at less energy input than our oversea’s competitors’ processes. The lower cost will allow entering more fields of application and thus increasing the positive environmental impact to other industries and applications - generating a competitive manufacturing opportunity for many applications!
This will create significant additional high-skilled employment throughout the 5-step value chain:
1. Chemical industry for raw materials (EU-based)
2. BJS Commercial SiC fiber production plant (EU-based)
3. Textile processing, e.g. weaving (EU-based and oversea's)
4. CMC-component production build up for aero-engines, and other industrial applications (EU-based and oversea's)
5. Turbine Manufacturing/Maintenance as well as the development of other industrial applications – e.g. hydrogen turbines, energy production and storage, space and friction applications (EU-based and oversea's).
Last, not least, our SiC-fiber ensures the EU’s independence from oversea’s authorities for a critical dual use good and technology that has unique high-temperature-, thermoshock-resistant, light-weight properties while keeping its high mechanical strength – attractive for many challenging operating conditions.
In summary, SPE enables the aviation industry to meet CO2-reduction regulations, it will enable the build-up of new innovative industries further supporting significant CO2-reductions and long-term, a carbon-neutral economy. Thereto, we identified several promising application areas which will only be tapped on once product is more abundantly available and lower in cost. Future development programmes will focus on this! SPE laid the foundation for significant high-skilled employment generation in up- and downstream industries as well as prosperity for employees and the EU. Moreover, it will strengthen the EU’s position internationally and create independence in a critical dual-use good market & multi-step value chain.