Environmental and Process Engineering

 

"Closed material cycles help to safeguard natural resources and support local value creation."

Dr. Matthias Jahn, Head of Business Division

For a safe, efficient and climate-friendly conversion of materials and energy, holistic approaches and recycling technologies are needed. 

The business division "Environmental and Process Engineering" focuses on chemical, electrochemical and biological processes for low-emission and sustainable production as well as water, air and soil purification. A particular emphasis is placed on processes with closed material cycles and high energy efficiency as well as the techno-economic analysis of value chains.

Fraunhofer IKTS is one of the world's leading research institutions in the fields of PtX processes, circular carbon technologies and water treatment processes. Based on the use of ceramic materials, membranes, filters, adsorbents and catalysts for environmental and process engineering, processes are developed and integrated into system solutions.    

In laboratory and pilot facilities, new process concepts are tested in fully automated continuous operation, and important measurement data are obtained to validate the flow chart-based models. With numerous laboratories, technology and application centers, the business division has an excellent infrastructure for realizing projects of all sizes and scales.

Innovation projects as driving force for an improved circular economy and process industry

 

Recultivation of landfill areas with fungal sewage sludge mixture

 

Demonstration plant for the separation of ethyl acetate from whey molasses

 

Reaction kinetic investigation of the flexibly operated direct reduction of iron ore

 

Zeolite membranes for the energy-efficient separation of CO2 from biogas

 

Utilization of CO2 and biogas to manufacture high-quality products

 

Energy transition on the high seas

 

Phosphorus recycling from sewage sludge to close regional nutrient cycles

Our competences

Ceramic membranes

  • Porous carriers in tube and disc geometry
  • Membranes from macroporous to nanoporous 
  • Dense, conductive and mixed conductive membranes 

Porous and cellular ceramics

  • Grain ceramics and extrudates with narrow pore size distributions
  • Open-cell foam ceramics with high pore volumes > 90%

Adsorbents and storage materials 

  • Layered and framework silicates based on natural raw materials
  • Synthesis of zeolites and mixed oxides

Catalysts converters and catalyst carriers

  • Catalyst development, production, screening and characterisation
  • In the form of extruded honeycombs, foam ceramics, membranes, bulk materials

Electrodes

  • Testing of electrode materials
  • Development of functional coatings for corrosion protection

Membrane process engineering and particle filtration

  • Membrane and filter testing
  • Development and prototyping of systems
  • Process design and piloting

Process technology for biogenic substrates

  • Process development and design for biomass treatment
  • Processes for the production of solid, liquid and gaseous energy sources

Chemical process engineering

  • Modeling, validation and optimization of mass transport and reaction
  • Development  and optimization of catalytic processes and membrane processes
  • Integrated technology development for the use of domestic carbon sources
  • Automation of process engineering systems

Electrochemical process engineering

  • Process development for pollutant separation and resource recovery
  • Development and production of specific electrolysis cells and test equipment
  • Construction and operation of test plants up to technical pilot scale

  • Preparation of life cycle assessments in accordance with DIN EN ISO 14040 for processes, systems and products
  • GHG balancing and cost calculations for sub-processes or complete product systems
  • Balance sheet preparation for recycling processes
  • Accompanying life cycle assessment of R&D projects and optimization tasks for processes and systems (material and energy flows, cost analysis)
  • Application examples: Material recycling in ceramic production, raw material recovery from sewage sludge, production of natural fiber-based materials, process chains for biogas production and fermentation residue treatment

  • (Mobile) test benches for membranes, filters, adsorbents and catalysts for wastewater treatment/water treatment and exhaust gas aftertreatment/gas treatment
  • ATEX-compliant membrane systems for solvent filtration and vapor permeation
  • Modular test field for the development of industrial water treatment processes
  • Mobile test stand for exposure tests and electrochemical in-situ investigations in deep geothermal energy
  • Radionuclide laboratory
  • Reactor test benches for membrane reactor tests and PtX processes
  • Laboratory, technical center and pilot plants for pyrolysis and gasification
  • Test rigs for biomass treatment, fermentation, digestate treatment and biogas upgrading
  • Test stands for vertical farming as well as nutrient availability and toxicology of fertilizers and substrates
  • Pyrolysis test platform