Fraunhofer Institute for Solar Energy Systems ISEThe chemical industry’s transition toward green molecules requires technologically robust and economically viable solutions. Using simulation-based process modeling and transparent in-house cost analyses, we provide a solid foundation for decision-making for industry, project developers, and startups.
We Offer Integrated System Analyses and Optimizations
for sustainable, competitive process and chemical technologies, including Bio-to-X, Power-to-X, and hybrid solutions.
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Process Simulation for Innovative Industrial Processes
From Concept Development to Techno-Economic Evaluation
Our Services Include:
- Development of innovative process options and flow diagrams, quantification of efficiencies, material flows, and optimization potential, technology selection, and process routes for decarbonized process engineering concepts for synthetic fuels and H₂ derivatives
- Detailed process simulation using Aspen Plus® and in-house models to develop process concepts and reaction engineering in synthesis and reforming processes
- Techno-economic assessments across the entire production and supply chain, including the evaluation of relevant KPIs (e.g., carbon, hydrogen, and energy efficiency) as well as the calculation of CAPEX, OPEX, and production costs, and benchmarking of alternative technologies
- Optimization of synthesis and reforming processes, taking into account, for example, material and energy integration potentials, CO2 capture, storage, and utilization, heat recovery via high-temperature heat pumps, and the design of key process components
- Independent and scientifically-based technological evaluations of novel concepts, taking into account findings from in-house research facilities, market analyses, and references from existing projects. Additionally, shortlisting of equipment suppliers, OEMs, and EPCs based on selected indicators
Your Benefits:
- Development of advanced and cost-effective process concepts, taking into account technological and environmental constraints
- Scientifically based, independent benchmarking and evaluation of complex technology options
- Quantification of efficiency and cost drivers along the entire process chain
- Transparent decision-making frameworks for investments, technology selection, and project development, as well as strategic approach regarding scaling and market entry
Development of Innovative Process Options
Example of the conversion of biogenic gas sources in Chile into bio-based methanol. Two plants with different CH₄/CO₂ ratios: Cases 1–3 landfill gas (La Hormiga), Case 4 biogas (Agrícola plant).
We develop innovative process options for potential real-world biogenic CO₂ applications aimed at producing bio-based green molecules such as methanol, dimethyl ether (DME), and sustainable aviation fuels (SAF) via the methanol-to-jet pathway.
Research Pojects:
SHIFT – Sector Coupled Systems for Heat, Industry, Fuels and Transport in Chile
Feasibility Studies:
- Feasibility study on the production of green fuels based on renewable energy and CO2 from a substitute fuel plant
- Feasibility study for the implementation of the first pilot-scale power-to-jet-fuel plant in Italy on behalf of an industrial company
- Feasibility study for a biogenic CCU project focusing on methanol in North Rhine-Westphalia on behalf of an industrial company
Detailed Process Simulation for Illustrating Process Concepts
Example of the optimization of synthesis and reforming processes through material and energy integration, CO₂ capture, heat recovery, and the design of key process components.
We perform process simulations using Aspen Plus®, combine these with techno-economic assessments, and optimize process routes while taking into account feedstock conditions, material and energy integration, and in-house cost models. In this way, we support the development of hybrid “Power & Bio-Carbon” concepts that efficiently utilize existing sources and minimize production costs.
Our work includes case studies of real-world applications in which readily available and cost-effective biogenic sources with promising CO₂/CH₄ ratios, as well as the corresponding production costs for green molecules, are analyzed.
Research Projects:
SHIFT – Sector Coupled Systems for Heat, Industry, Fuels and Transport in Chile
Techno-Economic Assessments across the Entire Process Chain
Example of the holistic optimization of the NH3 reforming process, including material and energy integration, heat recovery, CO₂ capture from process and exhaust gas streams, as well as a techno-economic assessment and cost estimation.
Our work provides the cornerstone of energy- and cost-efficient chemical processes. It includes Aspen Plus® process simulations for the design of large-scale ammonia and methanol reformers, optimization and heat recovery, material and energy integration of pre- and main reformers, and CO₂ capture from process and flue gas streams. In addition, we perform reliable cost estimates for entire process chain.
Research Projects:
NAMOSYN – Sustainable Mobility with Synthetic Fuels
LNG2Hydrogen– TransHyDE Project: Making LNG Terminals Suitable for Hydrogen-based Energy Carriers