Leslaw Mleczko

From Automation to Technology Development

Au&I Conference, Gliwice, 27.06.2015Slide 1

Content

1.My Way

2.Under the Bayer Cross

3.High to the Moon

4.Get Together

• Bayer AG • Company Profile 2015Slide 2

Dyplom

Pilot Plant @ IEP, Politechnika Slaska

• Bayer AG • Company Profile 2015Slide 4

Scientific Career

• Bayer AG • Company Profile 2015Slide 5

PhDFaculty forThermal Eng.Silesian TU

Post-DocInst. Tech.ChemistryUniv. ofHannover

SeniorScientist (C2) Tech.ChemistryRUB

HabilitationChemical FacultyRUBv.l.Chem. ReactionEng.

Professorship(C3) for Tech. ChemistryUniv. ofBrunswick -rejected

Professorship(C4-ordinarius) for Chem. Eng. TU Munich -rejected

Professor-ship (apl). RUB

Guest Professor (apl). ECUSTShanghai

1986 1996 2001 2008

•Slide 6

Full year sales: €42.2 billion

119,478 employees

302 subsidiaries

R&D expenditures: €3.6 billion

As of December 31, 2014 / Employees: March 31, 2015

Group Structure

•Slide 7

Business areas Service areas

Holding companyBayer AG

Group Management Board

Currenta

Bayer Business ServicesBayer HealthCare

Bayer MaterialScience

Bayer CropScience Bayer Technology Services

Corporate CenterDr Dekkers, Dietsch, Baumann, König, Malek

Transforming Bayer into a Pure Life Science Company

•Slide 8

… as a Continued Market Leader

under New Ownership

… as anInnovation and

Life Science Company

MaterialScience -> Covestro

• Build further on 150 years of successin Science and Innovation

• Address attractive markets with high growth rates and profitability

• Leverage broad product portfolio withstrong brand reputation

• Focus management on Life Sciences

• All prerequisites given to succeed

• Staffed with required know-how

• Autonomous access to capital

• Competitive edge better leveraged outside the group with tailored processes and portfolio decisions

Bayer Technology Services –Full Year 2014

Page 9

Employees 2,300*

Full Year Sales EUR 480 millionGlobal network 22 offices in 10 countries

* as permanent or fixed-term contracts, in FTE

Managing Director Dr. Dirk Van Meirvenne

Who is Bayer Technology Services (BTS)

Bayer Technology Services initiates, implements and supports technological innovations over the long term.

From product and process development through the planning and construction of plants to the automation and optimization of processes.

Project Management & Engineering –Our Solution Portfolio

Page 11

• Civil/Structure/Architectural

• Equipment & Piping

•PCT

Discipl ine Engineering

• Site Master Planning

• Power/High & Mid Voltage

• Waste Water & Gas

InfrastructureEngineering

• Pharma/ HealthCare

• Polymers

• Chemicals

Process Engineering

• Cost Estimation

• Controls, Permitting

• Procurement

• Construction Mgmt.

Project & Turnaround

• Consulting

• Concepts/Feasibility

• FEL 1 – 3, Detail Eng.

• Construction

Project Phases

• Owner’s Engineer

• Value Engineering

• Bare Bones

• Global Sourcing

Value Pract ices

• Greenfield Invest

• Revamps/Retrofits

• Turnarounds

• Shut-Downs

Project Types

• Authorities

• Contracting

• Materials Mgmt.

• Commissioning

Project Management

PCT = Process Control Technology

Operation Support & Safety –Our Solution Portfolio

Page 12

Consulting and services for efficient and reliable IT-systems: Manufacturing

Execution Systems and CAPE/ CAE-Software.

IT-based plant & process planning and operat ion

Services for maximizing efficiency & flexibility within the supply chain:

logistics studies & concepts, network optimization and track & trace.

Supply Chain & Logist ics Consult ing

Solutions for efficient and reliableproduction processes up to maintenance

management: Online-Analytics,

Advanced Process Control & Operator Training Systems .

Process Analyzer Technology & Advanced Process Control

Centre of expertise for methods and standards in process and plant safety :

safety concepts, explosion protection and hazardous substance analysis.

Process and Plant Safety

Asset strategies & maintenance concepts for safe and reliable assets:

Turnaround, corrosion and inspection management.

Asset Life Cycle Management

Lifecycle of a Training Simulator

Lifecycle of a Trainings Simulator

Simulation study

Training

• Personnel training

• Controller tuning

• DCS checkout

Dynamic Simulation Studies• Process optimization

• Continuous training

• Improvement DCS configuration

• Development of new control strategies

Modeling

• Process Modeling

• Training scenario

• Predictive “What if” studies

• Identify design problems

• Identify equipment design problems

• Test of control loops

• Identify control loop problems

Technology Development –Our Solution Portfolio

Page 14

Conceptual and technological product design and development from a strongly

interdisciplinary perspective.

Product-by-Technology

Screening concepts and systems inLife Science R&D and process control.

Automated, miniaturized assay, fluorescence imaging.

Integrated protein analytics.

Customized Analyt ical Solut ions

Support of R&D processes in life science companies by modeling & simulation.

Computat ional Biology

Optimization & development

of production processes and future innovative manufacturing

concepts.

Chemical & Polymer Processes

Development, scale-up, transfer, optimization and implementation of Biotechnological Processes.

Biotechnological Processes

Centre of expertise for technology evaluation, strategic consulting and

acquisition of public research subsidies.

Technology Consult ing & Public Funding

Microreaction engineering(micro reactors, micro mixers)

Micro Technology (MT)

microfluidics

microelectronics

microsensors

micro-optics

Novel Manufacturing Technologies:Microreaction Engineering

Novel Manufacturing Technologies:Modular Production Plants

• Bayer AG • Company Profile 2015Slide 16

Project consens

Synthesis of Electronic Materials

Productby Process

Fullarenes

SolarSi

Semiconducting polymers

CarbonNanotubes

QuantumDots

Ta & Nbpowder

Soft Ferrites

Graphenes

Ta2O5

Ta + MgO

ICBA200nm93910 : 1

Space Shuttle Accidents

Challenger1986

Columbia2003

After the Columbia accident the further flights were suspended. The whole space shuttle concept was questioned.

Space Elevator

NASA estimates the tensile force to be 100 GPa, steel ~ 3 GPa

Elevator (System 40 Bill. $), Load 13 t (Shuttle 12-25 t), Cost of transportation 100 $/kg (Shuttle 10,000 $/kg, Rocket 17,000 $/kg)

Carbon Nanotubes – Novel Material

Carbon Nanotubes (CNT, Kohlenstoffnano-röhrchen) -graphitic, one-dimensional structures with a diameter between 0.4 and 200 nm

Unique properties :

E-modulus/stiffness five times higher than steel (up to 1000 GPa)

Tensile strength approx.. 60 times higher than steel (up to 250 Gpa)

Electric current density 1000 times higher than copper (1010 A·cm-2)

Heat conductivity nearly twice as high as

diamond (6000 W ·m-1·K-1)

Resistant to heat in oxidizing atmosphere (up to 650°C)

Low weight, density 1/6 that of steel (1300 kg·m-3)

Specific surface area and definite structure(200-400 m2·g-1)

The demands for the materials for construction of a space lift can be fulfilled only by CNT´s

Catalyst Development

0

10

20

30

40

50

60

70

80

90

100

rela

tive

Yie

ld %

200nm100000 : 1

1. commercial Fe/Ni-catalysts2. Claimed catalysts

BTS catalysts

More than 250 catalysts prepared and tested

High activity of the catalyst is important for:- economics of the process- quality of the product

Very active, proprietary catalyst was developed: Co&Mn

WO002006050903A3

Optimization of Catalyst Preparation

Metal Support

Dispersion measured by TEM-EELS:Catalyst reduced with H 2

Initial method of catalyst preparation

20 nm

MetalSupport

Metal Support O2

Optimized catalyst preparation

20 nm

Continuous synthesis of the catalyst using micro-mixers

WO 2007093337, 2007

Scale-Up

• Bayer AG • Company Profile 2015Slide 23

Model Based Reactor Scale-Up

Kinetics und hydrodynamics

DP,average

ρaveragePopulation balances

Hydro-carbons

DP, CatρCat

mKat

mCNT

,

Reactor

H2

u

umf

u-umf

Bunnles

GasGasFeststoff

Emulsion

Reaction

massf-

transport

Blasen-

durchmesser

Comprehensive reactor model – similarity to the gas-phase polymerization

Model-based Scale-Up

0

1

2

3

4

5

6

0 1 1 2 2 3 3 4

Ractor height [m]

Con

cent

ratio

n [m

ol/m

³]

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Con

vers

ion

[%]Conversion

cblase

cemulsion

2000mm-reactor

� Fast bubble growth and ratio of mass transfer to re action kinetics influence the conversion on a large scale

� Catalyst deactivation limits CNT-agglomerate growth

0

0,2

0,4

0,6

0,8

1

1,2

0 100 200 300 400 500 600 700 800 900

dp [µm]

F(d

p)

[µm

-1]

Basisfall

2 Gasverteiler

3 Gasverteiler

Baytubes/Polymer Composites

Total dispersion of primary agglomerates has been a chieved for a large number of polymers. However the processing technolo gy differs

200n

200000 : 1 200 nm 200 nm200 nm

Ø= 0,2 - 2 mmØ= 10 - 50 nmL= 1 - 40 µm

?

Damascus Steel Blade

New developmentshavesometimeslong roots

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Bayer Fundation & Awards

Bayer Science & Education Foundationlaunches new round of ScholarshipsCanada NewsWire (press release) MISSISSAUGA, ON, June 24, 2015 /CNW/ - The Bayer Science & Education Foundation (the Foundation) is nowaccepting applications for this year's ...

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Cooperations

Preferred Universities(Traditionn, recruiting)

TU DortmundRWTH AachenTU DelftMITUniv of HoustonECUST Shanghai

Joint Research Centers

TUD&BTS InviteNovel Manufacturing

RWTH&BTSComputational Biomedicine

RWTH&BTSCatalysis

Projects

Bilateral, e.g. PolWawnBaldyga

Consortia:

EU projects

BMBF

Academic vs. Industrial Career

• Bayer AG • Company Profile 2015Slide 30

Academia Industry

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Thx