Laboratory for Sustainable Synthesis Products

In our laboratory for sustainable synthesis products we develop, test, characterize, and optimize processes, reactors, and materials for the synthesis of Power-to-X products, the production of hydrogen from sustainable synthesis products, and Direct Air Capture (DAC). For our application-oriented research, we develop, build, test, and optimize prototypes, miniplants, and pilot plants.

Let’s work together on your challenge!

Our services in the laboratory for sustainable synthesis products:

Material/Catalyst Screening and Characterization

In our facilities we investigate materials with the aim of improving the economic efficiency of industrial processes. We test your catalyst (commercial product or still under development) according to your requirements. The most frequent investigations are long-term analyses over several thousand hours at one operating point or under dynamic conditions. Using optical temperature measurement, we can carry out rapid and spatially resolved temperature measurements. We derive robust kinetic models for you from kinetic measurements. We test catalysts as shaped bodies or powders for you. We analyze the product distribution in detail and how it influences downstream processes.

Our facilities:

• Surface Analysis using X-Ray Photoelectron Spectroscopy: HT-NAP-XPS
• Kinetic Investigation and Screening Setup
• Test Rig for the Production and Investigation of Olefins
• 4-parallel-Reactor for Continuous Operation
• 8-parallel-Reactor for Continuous Operation
• Chemisorption
• Scale-down Miniplant for Methanol Synthesis
• Adsorption Test Rig with high Pressure Magnetic Suspension Balance

Reactor and Process Demonstration

Our systems and test rigs are suitable platforms for testing, benchmarking, developing, and optimizing your products. Both catalysts and reactors can be tested under realistic or emulated conditions and under real process configurations, e.g. for ammonia or methanol synthesis, for reforming reactions, and for reactive distillations. In combination with our expertise in measurement and modeling, the reactors and processes can be evaluated. The results of the measurement campaigns can be used by our simulation team for process optimization. As our miniplants are developed and programmed in-house, we can react flexibly to customer requirements. We tailor our control strategies to your needs.

Our facilities:

• Scale-down Miniplant for Methanol Synthesis
• Process Miniplant for Methanol Synthesis
• Test Rig for the Production and Investigation of Olefins
• Reformer Test Rig
• Pressure and Vacuum Distillation Column
• Direct Air Capture
• LOHC Miniplant

Production of Sample Quantities

We can produce sample quantities in our facilities and draw conclusions for the optimization of your process. Whether it’s sample quantities for product certification, for niche products with small quantities and high margins, or for demonstrating a proof of concept: thanks to our flexible systems and test rigs, we can make your molecule, e.g. distillation products or isotopes/isomers. We also offer you a comprehensive range of analytical services.

Our facilities:

• Scale down Miniplant for Methanol Synthesis
• Process Miniplant for Methanol Synthesis
• Pressure and Vacuum Distillation Column 

Technical data

• sample size up to 40 mm x 40 mm x 40 mm
• inert sample transfer under inert gas from glovebox to measuring position
• Al Kα monochromatic X-ray source, excitation energy of 1,486.6 eV
• heated sample platform up to 1,000 °C
• Ionoptika GCIB 10S for ion bombardment of the surface (cleaning, depth profiling)

We offer

• measurement of XPS overview spectra and high-resolution spectra
• evaluation and interpretation of measurement data
• XPS investigations in a high vacuum and under a defined gas atmosphere
• N₂, Ar, H₂, H₂O, O₂, CO, CO₂, NH₃ (or gas mixture)
• depth profiling by controlled sputtering using argon ions/clusters

Comprehensive range of services using the HT-NAP-XPS

Technical data

• pressure: vacuum up to 40 bar(a)
• temperature: -40 up to 250 °C (in condenser: -90 to 200 °C)
• inner diameter: 50 mm (DN50)
• up to 50 theoretical separation stages, depending on the selected packing
• educt feed: 100 g/h up to 5 kg/h

We offer

• fully automated distillation column in a large pressure range
• multiple sampling points and temperature measurements across 7.5 meters allow the investigation of gradients along the column
• can be equipped with catalyst packings, allowing reactive distillations to be carried out in the column

Comprehensive range of services using the pressure and vacuum distillation column

Technical data

• oil-cooled reactor designed to behave similarly to a steam-cooled reactor
• inner diameter: 13 mm
• pressure: up to 85 bar
• temperature: up to 300 °C
• production output: up to 150 g/h raw methanol

We offer

• fully automated miniplant for the high-pressure synthesis of PtX fuels with a focus on dynamic operation and high-resolution measurement techniques (fiber optics, FT-IR), e.g. precise kinetic measurement for the synthesis of methanol from CO₂-rich gases
• sample production for the analysis of by-products, e.g. of methanol synthesis

Request Material/Catalyst Screening and Characterization | Reactor and Process Demonstration | Production of Sample Quantities

Technical data

• pressure: up to 50 bar
• temperature: up to 300 °C
• production output: up to 800 g/h raw methanol

We offer

• fully automated, two-stage miniplant for methanol synthesis incl. recycle loop, with a focus on process demonstration and long-term operation for the investigation of catalyst shaped bodies. Integrated online analytics (ND-IR gas analysis, refractometer for raw methanol)
• over 6,000 hours time on stream successfully demonstrated using purified steel mill gases in the Carbon2Chem® research project
• manufacture of product sample quantities for specific questions regarding methanol synthesis
• sample production for the analysis of by-products, e.g. of methanol synthesis

Request Reactor and Process Demonstration | Production of Sample Quantities

Technical data

• pressure: up to 80 bar
• temperature: up to 300 °C
• reactor sizes: inner diameter 4 or 8 mm with a catalyst bed length of 400 mm 

We offer

Fully automated system for the kinetic investigation of catalytic fixed bed reactions: the Kinetic Investigation and Screening Setup system (“KISS”) enables the measurement of axially resolved concentration profiles (multiple reactor outlets in combination with FTIR) with a simultaneous high-resolution monitoring of the axial temperature profile (fiber optic temperature measurement). 

Press release, March, 2022: Fraunhofer ISE develops mobile test stand for high-resolution Power-to-X kinetic analysis

Request Material/Catalyst Screening and Characterization

Technical data

• on a small scale (focus on screening / characterization of the sorbent)
  • ca. 100 g sorbent
  • automatic measurement of the breakthrough curves for CO₂ adsorption and desorption
  • temperature: up to 400 °C
  • pressure: between 0.1 and 8 bar(a)
  • investigation of gas mixtures possible
• on a large scale (focus on process development):
  • four reactors @ 500 mL for parallel feeding of different gases
  • fully automated process control with programmed sequences
  • flow rate: up to 1,600 L/min (120 kg air/h)
  • preconditioning of supplied air (temperature / humidity / trace gas addition)
  • CO₂ capture capacity of 1,800 g/d total
  •  temperature: up to 500 °C
  • pressure: between 0.01 and 10 bar(a)

We offer

• Two facilities are available at Fraunhofer ISE to investigate Direct Air Capture (DAC), a key technology for climate protection. One facility specializes in the screening and characterization of suitable materials on a laboratory scale. The other can contribute to scaling and thus to process development thanks to its four parallel reactors.
• The focus of our DAC research lies on investigating the most selective sorbents and thus the optimization of the energy input for capture per unit of CO₂. Optimizing this parameter paves the way for the economic efficiency of the considered processes.

Request Reactor and Process Demonstration

Technical data

• pressure: up to 80 bar
• temperature: up to 650 °C
• flow rate: max. 150 g/h (various hydrocarbons)

We offer

Fully automated equipment for the kinetic investigation of catalytic fixed-bed reactions up to 80 bar. This enables the measurement of spatially resolved concentration profiles with simultaneous high-resolution monitoring of the axial temperature profile (16 temperature sensors, 11 axial reactor outlets, GC-FID/TCD). 

Request Material/Catalyst Screening and Characterization | Reactor and Process Demonstration

Technical data

• pressure: up to 300 mbar(g)
• temperature: up to 800 °C
• fuel feed: up to 40 L/min ammonia gas, up to 50 L/min DME

We offer

• fully automated equipment for the reforming of PtX fuels. Equipped with high resolution measurement technology (MS, FTIR).
• successful demonstration of the reforming of ammonia, dimethylether (DME), and other fuels. Heat input through electrically heated catalyst; variable air-fuel stoichiometries and autothermal operation possible
• equipped with an exhaust gas scrubber to mitigate gaseous ammonia emissions

Request Reactor and Process Demonstration

Technical data

• typical catalyst bed: 2 mL
• gas hourly space velocity (GHSV) between 10,000 and 100,000 h^-1
• pressure: up to 90 bar(g)
• temperature: up to 500 °C

We offer

• fully automated test rig for screening and kinetic testing of powder catalysts. Online analysis in the gas phase using GC, and FT-IR possible
• four reactors operated in parallel enable a high sample throughput. Identical catalysts can be fed with different reactants or different catalysts with the same reactant.

Request Material/Catalyst Screening and Characterization

Technical data

• typical catalyst bed: 4 mL
• WHSV (Weight Hourly Space Velocity): 5-20 h^-1
• pressure: up to 80 bar(g)
• temperature: 20-300 °C
• educt feed: 5-25 g/h per reactor r 

We offer

Fully automated test rig for liquid phase reactions, such as e.g. DME synthesis from methanol. Eight reactors operated in parallel enable the rapid screening of many different catalysts and the investigation of their long-term stability. Equipped with high resolution measurement technology (FTIR, MS), with extensive post-mortem analysis of the catalyst also possible (Germanium FTIR-ATR, XPS…)

Request Material/Catalyst Screening and Characterization

Technical data

• pressure: up to 9.5 bar(g)
• temperature: up to 250 °C
• production output: up to 4 kg/h

We offer

• fully automated system for the investigation of the hydrogenation and dehydrogenation of liquid organic hydrogen carriers (LOHC) with new catalysts
• reactor with several temperature measuring points for recording an axial profile
• comprehensive analysis possible (GC-MS, Germanium FTIR-ATR, XPS…)

Request Reactor and Process Demonstration

Technical data

• pressure: up to 85 bar
• temperature: up to 500 °C
• measuring accuracy of the balance: 200 µg

We offer

• fully automated test rig with high-pressure dosing unit and magnetic suspension balance for investigating adsorption behavior of solids
• successful operation for over 2,000 hours time on stream in the PICASO project on the adsorption of ammonia using various chlorides

Request Material/Catalyst Screening and Characterization

Technical data

• temperature: -130 to 1,000 °C
• pressure: atmospheric pressure

We offer

Fully automated system focusing on the analysis of metal surfaces, metal dispersion, and metal crystallite size of catalysts using pulse chemisorption (H₂, CO). Also suitable for ammonia reforming, temperature-programmed reduction (TPR), oxidation (TPO), and desorption (TPD).

Request Material/Catalyst Screening and Characterization