TUCcurrent research
The Free State of Saxony is providing more than 60 million euros for the systems and building infrastructure of the “Carbon LabFactory” as a branch of Chemnitz University of Technology in Boxberg/Oberlausitz – planning work has started
Claudia Vogt and Dr. Mario Naumann from the “Carbon Fiber and Processing Technologies” research area is examining a rotary carbon fiber-reinforced lightweight pressure vessel that is in the manufacturing process in the fiber composite laboratory of the SLK Professorship in Chemnitz. Photo: Robert Wolf
Today’s world faces the urgent challenge of combating climate change and reducing environmental pollution. Against this background, lightweight construction plays an important role, because by reducing the mass of aircraft, cars, trucks, trains and other mobile applications, not only can the environmental impact be reduced, but energy efficiency can also be increased and resources conserved. Carbon fibers play a key role in producing extremely light yet robust components that are used in many industries.
In order to help carbon fibers make the breakthrough for a sustainable future that is still pending in many industries, the Chair of Lightweight Structural Engineering and Plastics Processing (SLK) at Chemnitz University of Technology, together with the Saxon State Ministry for Regional Development, has initiated the “Carbon LabFactory Saxony” as an interdisciplinary state project – a Europe-wide one Unique scientific location for sustainable carbon fiber research on a pilot line scale. To set up and expand the “Carbon LabFactory” as a branch of Chemnitz University of Technology, Chemnitz University of Technology received a funding decision of 5.87 million euros from the Federal Office of Economics and Export Control in December to set up a research team. The financing is provided as part of the “InnoCarbEnergy” project, funded by the Federal Ministry of Economics and Climate Protection as part of the funding guidelines to strengthen the transformation dynamics and new beginnings in the mining areas and at the coal-fired power plant locations (STARK). “The Carbon LabFactory Saxony is an important step in dealing with structural change and the effects of the lignite phase-out,” emphasizes Prof. Dr. Lothar Kroll, head of the SLK professorship. “It will both advance research and make a decisive contribution to the climate-friendly future of the Lausitz and the entire country can achieve.”
In addition to the federal government’s consumable funds, investment funds of around 60 million euros are planned for systems and building infrastructure by 2026 to establish the “Carbon LabFactory”. On March 13, 2024, the starting signal for investments in systems and equipment was given with the handover of the grant notice. A budget of more than 32 million euros, provided by the Saxon Ministry of Science, Culture and Tourism in cooperation with the Saxon Ministry for Regional Development, is now paving the way for the development of a comprehensive research infrastructure for the Carbon LabFactory Saxony. “We need new ideas and technologies in order to survive in the future. That’s how it always was and that’s how it is now. You could always rely on the Saxons’ innovative and inventive spirit. The Carbon LabFactory Lausitz in Boxberg will make Saxony one of the leading locations for carbon fiber research and thus help create future-oriented jobs in the region. The investments by the federal government and the Free State in the Carbon LabFactory Saxony are an important step towards this,” said the Saxon State Minister for Regional Development, Thomas Schmidt, who is responsible for structural change. “I would like to thank the Free State of Saxony for their support and the very good cooperation. Together with the Carbon LabFactory we are shaping the future of lightweight construction and thus significantly supporting technological progress in global climate protection,” added Kroll.
The financing not only opens up special opportunities for basic research on carbon fibers on an industrial scale, but also for the development of a holistic value chain from the fiber to technical textiles to high-performance components. In addition, the Saxon Real Estate and Construction Management (SIB) will receive further allocations of around 30 million euros for the planning and construction of the research center for “green” carbon fibers. After the “Qualified Declaration of Requirements” has already been worked out in close collaboration with the SIB headquarters in Dresden, concrete planning is now being started with the locally responsible SIB branch in Bautzen. The tender process for planner commitment is currently underway.
The Carbon LabFactory Saxony, which will begin research work at the power plant site in Boxberg/O. at the end of 2026 with a team of around 25 scientists and technicians. L will not only serve as a scientific center, but also as a stimulus for the regional economy. In close cooperation with companies from Lusatia, innovative lightweight construction solutions are to be developed in order to create future-oriented jobs and secure prosperity in the region.
Once completed, the heart of the Carbon LabFactory Saxony, the so-called Black Line pilot plant, will allow scientists to carry out basic research into the production of carbon fibers to the extent of around 25 tons per year. In addition, material combinations, two-dimensional technical textiles, thermoplastic tapes and profiles will be researched on a pilot line scale. Another manufacturing complex that automatically links various plastics processing processes will also serve research into fiber-plastic composite components. This entire industry-related production chain also represents a unique selling point compared to the globally established pilot plants in the USA and Australia.
The Carbon LabFactory Saxony also aims to play a pioneering role in the research and development of sustainable carbon fibers that are based on renewable raw materials and renewable energies. The focus is not only on the production of fibers, semi-finished products and components, but also on “tailoring” the properties that meet the requirements of different industries. These efforts are aimed not only at reducing environmental impact, but also at reducing material and process costs to make sustainable solutions economically attractive. The collaboration with the Fraunhofer Institute for Applied Polymer Research in Brandenburg will expand the value chain from the molecule to the component.
The Carbon LabFactory Sachsen will be built in the Kringelsdorf industrial area in the municipality of Boxberg/Oberlausitz, which is heavily affected by the coal phase-out. The transfer of the municipal property to the Free State of Saxony has already been initiated. The massive expansion of renewable energies, including associated storage solutions and investments in the production of hydrogen by LEAG at the power plant site in Boxberg, represents an important location factor for the energy-intensive processes of the Carbon LabFactory Saxony. Concepts for the use of renewable energies within the Carbon LabFactory Saxony, which contributes significantly to achieving the goal of “green” carbon fibers.
“I would especially like to thank the entire SLK team, the colleagues from the university administration, everyone involved from the Saxon ministries and the SIB, the representatives of the Boxberg/Oberlausitz municipality and the many other actors who have helped us along the path to successful implementation so far “The Carbon LabFactory Saxony was highly motivated and actively supported with their expertise,” says Dr. Mario Naumann, Scientific Director of the Carbon LabFactory Saxony. The goal is clear: “The Carbon LabFactory Sachsen should become a beacon for sustainable carbon fiber production in Europe.”
Further information granted by Dr. Mario Naumann, Scientific Director of the Carbon LabFactory Saxony, telephone +49 (0)371 531-38758, email [email protected].
(Authors: Dr. Mario Naumann, Sylvia Decker)
Mario Steinebach
28.03.2024