Carbon fiber from cheap Moses Lake, WA hydropower is key

http://seattletimes.com/html/businesstechnology/2022215066_bmwcompositexml.html?cmpid=2628
Moses Lake plant key to hopes for BMW electric car
By Kyung M. Song  November 7, 2013  ht2ph

BMW is a week away from delivering its new all-electric vehicle, built with
the help of petroleum-based carbon threads spun in a plant in Eastern
Washington. 

WASHINGTON — Americans are hardly flocking to battery-powered electric cars.
The allure of zero-emission driving and a $7,500 federal tax credit hasn’t
quite overcome higher sticker prices and anxieties about recharging times
and limits on traveling ranges.

BMW is hoping to buck that — with help from its carbon-fiber plant in Moses
Lake.

The German automaker is just a week away from delivering the keys to its
first i3, the world’s newest all-electric vehicle. The i3’s passenger
compartment is made of carbon fibers produced at BMW’s joint venture plant
in Eastern Washington.

The i3 is the first mass-produced model built with lightweight,
carbon-reinforced plastic. And on Thursday, BMW put on an exhibit at a
Washington, D.C., gallery to trumpet the i3’s green creds.

Promoting cleaner forms of transportation is a key part of President Obama’s
climate action plan. As part of that, the federal government has raised
mandatory fuel-economy standards for passenger cars to a fleet average of
54.5 miles per gallon by 2025, up from 31.1 mpg this year.

Plugging in an electrical car costs much less than filling up at a gas
station. Yet U.S. sales of Nissan Leaf and all other electric- vehicle
models total about 45,000 a year. Ford sells more F-series trucks in a
month.

BMW conceived the i3 from the start as an electrical vehicle for optimal
design and technologies. Lured in part by lobbying by former Gov. Chris
Gregoire and $2 million in state tax credits, BMW and SGL Group, a major
German carbon-products company, jointly opened the SGL Automotive Carbon
Fibers plant in Moses Lake in 2011.

Today, the 80 employees at the plant’s two production lines — the second of
which began operating in August — can produce a total of 3,000 metric tons
of carbon annually, said Kenn Sparks, a spokesman for BMW North America. A
second plant is under construction on the 60-acre campus and is scheduled to
open next year.

Producing carbon fiber consumes lot of energy, and BMW and SGL were also
drawn to Moses Lake by cheap hydropower from dams on the Columbia River.

Spools of carbon fiber from Moses Lake are shipped to BMW plants in
Wackersdorf and Landshut, Germany, to be woven into fabric. The carbon fiber
is molded into parts at the BMW plant in Leipzig, Germany, where the i3 is
manufactured. Moses Lake also provides carbon fiber for the upcoming i8, a
plug-in hybrid sports car that runs on both gasoline and battery power.

Carbon frames are half as light as steel and a third lighter than aluminum.
The pounds are critical because the battery and electric drivetrain can
weigh more than the combustion engine, fuel tanks and exhaust system they
replace, said Manuel Sattig, project manager for the BMW i sub brand.

Sattig said BMW is considering incorporating carbon fiber into its other
models. If so, he said, the Moses Lake plant will have adequate capacity to
meet the demand.

BMW would not disclose its production rate for the i3, which has a base
price of $42,275. It had 10,000 preorders in Europe and will deliver the
first i3 on Nov. 16, probably to a German customer. First deliveries in the
United States are scheduled for April.

Sen. Maria Cantwell, who has pushed for federal investments in biofuels and
composite materials technology, made brief remarks at the event. She said
BMW’s presence in Moses Lake attests to potential to generate more green
jobs.

“We want to put a big banner in Washington state,” she said. 
[© 2013 The Seattle Times]




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