Use of Carbon Fiber Components in the Automotive Industry 2012

Use of Carbon Fiber
Components in the
Automotive Industry 2012
Goals, Challenges, and
Case Study

Slide 1 © Contrium Research GmbH 2012. All rights reserved.

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Reduction of CO2 emissions has become a strategic
target of the automotive industry
DRIVERS AND EFFECTS OF CO2 STRATEGIES

CO2-emissions
[g/km]
Legal
requirements
regarding fleet
XXX
consumtion

YYY
Increased
sales taxes
ZZZ
and prices
for gas/fuel

Life cycle Fleet consumption
considerations Selected models2

2004 2005 2006 2007 2008 2009 2010


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BMW has started its “Project i”, targeting significant weight
and subsequent CO2 reductions by using CFC1
BMW’S “PROJECT I” AND KEY SUCCESS FACTORS IN LIGHTWEIGHT CONSTRUCTION WITH CFC

Vision: Large scale production of
electric mobility using CFC lightweight
 200x: Project kick-off (project lead
directly reporting to XXX)
 Mid 200x: Decision on CFC as Ability to produce
preferred material for XXX and XXX on a large scale
parts, as well as XXX as preferred
supplier Capable
XXX Key
 Mid 200x: Clearance of major suppliers
success
investments (among these XXXmEUR factors CFC light-
for a JV with XXX and new assembly
weight construction
lines in XXX)
 Early 200x: Creation of a new brand Competitive
for those cars being developed in manufacturing XXX
course of Project i: „BMW i“ costs
 200x: Forecast launch of „BMW XXX“
(sales price estd. 40.000 EUR) and
„BMW XXX“

1 CFC = Carbon Fiber Composites; CF = Carbon Fiber
Source: BMW website, press releases


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Within their “Project i”, BMW makes use of their substantial
in-house carbon fiber competency
BMW “PROJECT I”, INITIAL STEPS

 In XXX, BMW started to set up own
technology for components
 Development of basic concepts,
production processes and quality
standards with up to XXX
employees
 Small-scale production of Find out more…
components with XXX-material
from XXX in their Landshut plant
(e.g. BMW M6 using CC XXX and
CC XXX)

Source: BMW press releases


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BMW invests heavily to ensure the security and stability of
its carbon fiber supply chain
BMW “PROJECT I” – MATERIAL SUPPLY CHAIN

Carbon
Precursor Fabrics XXX XXX Assembly
fiber

Joint Joint
BMW-owned component New BMW
Joint Venture Venture XXX Venture XXX
manufacturing in production
XXX and XXX and BMW and BMW
XXX and XXX in XXX
(USA) (GER)

XXX mEUR XXX mEUR XXX mEUR
XXX mEUR
(51:49) (51:49) (Budget until 2013)

Special know-how:
Special know-how:
XXX
XXX

Total Invest XXX mEUR
1 XXX
Source: XXX/BMW Press Releases


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However, other major players have started to follow
JOINT CF PROJECTS IN THE AUTOMOTIVE INDUSTRY (EXAMPLES)

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 Joint Venture (started  JV for XXX/component  Letter of intent signed to
XXX) production (XXX) establish a development
 Products: XXX materials  XXX has broad partnership (XXX)
and components experience with the raw  Objective: Production of
 XXX: XXX and material, mature XXX materials and
development of XXX production processes and development of a highly
processes know-how automated process chain
 XXX: XXX design and XXX  Optimized and for large-scale production
 Objective: competitive, guaranteed material  XXX has a CFC
XXX time supply by XXX competence center at
 Usage of CF components  XXX has, as a classical Tier XXX
in Mercedes XXX in XXX 1, XXX  XXX has years of
 Prototype production in experience in XXX
XXX(acquisition of XXX) production with XXX(XXX)

Source: XXX


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BWM learnings: some factors are critical for success
CRITICAL SUCCESS FACTORS FOR USING CFC

XXX and stable quality standards are crucial.

Manufacturing costs have to be reduced to target costs.

XXX production is more crucial than just XXX production.

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Serial mass production of CFC requires far more capabilities than production of
small volumes.

Current supplier situation does not fulfill the requirements of XXX. BMW XXX as a
consequence.

Close cooperation between XXX and XXX is essential. XXX alliance recommended.

Source: BMW press releases


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Two major issues have to be addressed in CFC
ISSUES OF CFC

1 Manufacturing costs to be reduced 2 Appropriate supply chain required

Production costs structural components Carbon fiber Com-
[EUR/kg](estimates) XXX XXX
fabrics ponents

XXX

So far, no comprehensive Ability to Producer
XXX concepts set-up a expertise
Capable suppliers limited XXX existing
XXX XXX
but available

XXX XXX XXX Target costs

< XXX < XXX ~XXX >XXX
pieces pieces pieces pieces
Other critical issues:
XXX

Source: Primary interviews


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CFC manufacturing costs must be reduced at least by
XX%
REDUCTION OF CF COMPONENT COSTS [EUR/KG] (ESTIMATES ONLY!)

Stage 1 Stage 2
(immediate actions) (economies of scope)

 Decreased raw material costs XXX
 Improved XXX, integrated facilities with XXX
XXX  Economies of scale
 Decreased energy costs
 Enhanced XXX properties, improvement in
consistency
Open question:
 XXX cost gap
too large?

XXX XXX
XXX
~XX
Current costs at Mid-volume Target costs Classic steel
XXX



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Several hundred million Euro of investments may be saved
by optimizing the supply chain
REQUIRED INVESTMENTS IN PRODUCTION EQUIPMENT BMW VS. BEST CASE (ESTIIMATES ONLY!)

Carbon
Precursor Fabrics XXX XXX Assembly
fiber

Joint Venture Joint Venture BMW-owned component New BMW
Joint Venture
XXX and BMW XXX and BMW manufacturing in XXX production
XXX
(USA) (GER) and XXX in XXX
BMW

XXX mEUR XXX mEUR XXX mEUR ∑ XXX
XXX mEUR1
(51:49) (51:49) (Budget until XXX) mEUR

 Strategic partnerships, e.g. Selection of
partners key  Utilization of XXX infrastructure
 Consideration of well-established success factor  Optimized procurement of machinery and tools
foreign companies
Best case

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(Alliances with machine manufacturers)
 Alliances with newcomers (assumed solid
 Outsourcing of XXXmanufacturing
financial basis and low energy costs)
(Partnerships with XXX producers in XXX)

∑ XXX
XXX EUR XXX EUR XXX EUR XXX mEUR
mEUR

Source: SGL/BMW press releases , primary interviews


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From a lifecycle perspective, carbon fiber production and
recycling are critical in terms of CO2 emissions
CF LIFECYCLE PERSPECTIVE: CO2 EMISSIONS

 Issues in XXX XXX regarding precursor
Carbon fiber  Inefficient chemistry in CF production
production1  Large amounts of XXX as a byproduct of CF production
 XXX requires significant amounts of energy input

Carbon fiber • CO2 emissions tolerable
processing2
• Comparably low CO2 emissions in usage phase due to high XXX in
combination with low weight
Usage • Significant advantages to other materials, e.g. metals, glass fiber

• Difficulties in XXX of CC
• CC is outperformed by XXX
Recycling

1 Represents value chain steps “precursor” and “carbon fiber”
2 Represents value chain steps “fabrics”, “preforming”, “molding/finish” and “assembly”


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The exact trade-off between CC production and use in the
automotive sector is being discussed controversially
BREAK EVEN CO2 EMISSIONS OF CC CARS

CO2 trade-off in the automotive sector Different CO2 break even scenarios [driven 1,000 km]
(CC employment vs. traditional manufacturing)

„Using CC in automobiles pays off
after … kilometers have been driven!“

XXX
Higher CO2 Less CO2
emissions emissions
than steel due to CC

Pessimistic Moderate Optimistic
CC production CC usage



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There are different approaches to assess eco-efficiency
OVERVIEW OF DIFFERENT APPROACHES (EXEMPLARY)

KPI Applicable regulations/
Description
(common) standards1
Carbon accounting is the accounting
process undertaken to measure the
amount of carbon dioxide
CO2-balance/ Carbon
Tons CO2 (or equivalents) equivalents that will not be released XXX
accounting
into the atmosphere as a result of
flexible mechanism projects under
the Kyoto Protocol
Fleet consumption describes the
average fleet consumption of a car
Fleet consumption g(CO2)/km XXX
fleet (all Find outa company,
vehicles of more…
producer or of a vehicle class)
LSA is a technique to assess
environmental impacts associated
with all the stages of a product's life
Ecobalance/ Life cycle from-cradle-to-grave (i.e., from raw
Diverse XXX
assessment (LSA) material extraction through materials
processing, manufacture, distribution,
use, repair and maintenance, and
disposal or recycling)

1 Exemplary
2 World Business Council for Sustainable Development and World Resources Institute
3 XXX


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The Greenhouse Gas Protocol (GHG) guidelines provide a
general framework for assessing CO2 emissions
POSSIBILITIES IN CO2 ACCOUNTING – GHG (EXAMPLES)

Organizational possibilities Operational possibilities Possibilities in calculation

Different approaches can be Emissions can be classified in Emissions can be calculated
used to consolidate GHG different categories and using different approaches
emissions calculated/reported  Direct measurement of GHG
 XXX approach: a company accordingly emissions
accounts for GHG emissions  Scope 1: XXX  Application of documented
from operations according to  Scope 2: Electricity indirect emission factors
its share of equity in the GHG emissions of purchased
operation  Calculation from fuel use
electricity data
 XXX approach: A company  Scope 3: XXX
accounts for 100 percent of Calculation methods often
the GHG emissions from differs according to scope
operations over which it has  XXX: Calculation from internal
control (financial or data
operational)
 XXX Calculation primarily from
activity data and published or
third-party emission factors

Source: The Greenhouse Gas Protocol


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