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WELCOME TO THE FRAUNHOFER INSTITUTE FOR CHEMICAL TECHNOLOGY ICT

International Greening Education Event – Day 2

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© Fraunhofer ICT

International Greening Education EventAgenda of the morning

09:00 – 09:10 Welcome speechProf. Dr. Frank Henning Fraunhofer ICT, Germany

09:10 – 09:50 Research & Development for SustainabilityDr. Stefan Tröster Fraunhofer ICT, Germany

09:50 – 09:10 Coffee break

10:10 – 11:00 Sustainability Center “A Practical Approach to Build Human Capital for Sustainable Economy”Arshad Rab European Organisation for Sustainable Development

11:00 – 12:30 Visit of the R&D Facilities

12:30 – 13:30 Lunch

13:30 Transfer to the City Hall Karlsruhe

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Fraunhofer is the largest organization for applied research in Europe

� Founded in 1949, the research organization undertakes applied research that drives economic development and serves the wider benefit of society.

� 67 institutes and independent research units

� The majority of the more than 23,000 staff are qualified scientists and engineers.

� An annual research budget of €2 billion

� More than 70 percent of this contract research revenue is derived from contracts with industry and from publicly-financed research projects.

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Joseph von Fraunhofer

The Fraunhofer-Gesellschaft

Discovery of the “Fraunhofer lines” in the solar spectrum

New methods for processing lenses

Director and partner in a glassworks

Research and development on behalf of industry and state

MP3 music format, white LEDs, high-resolution thermal camera

Research volume: approx. €2 billion annually

Researcher

Inventor

Entrepreneur

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The Fraunhofer-Gesellschaft

Research and development

� Application-oriented research of direct benefit to business and society

� Application-oriented basic research

Business community

� Institutes work as profit centers

� One-third of the budget consists of revenues from industrial projects

� Spin-offs by Fraunhofer researchers are encouraged

Contracting partners/clients

� Industrial and service companies

� Public sector

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� 67 institutes and independent research units

� More than 23,000 staff

The Fraunhofer-GesellschaftMain locations of the Fraunhofer institutes and research institutions in Germany

Main sites

Other sites

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Pooling of competences by networking Fraunhofer Alliances (ICT participation)

� Adaptronics

� AdvanCer

� Ambient Assisted Living

� AutoMOBILE Production

� Battery Technology

� Building Innovation

� Big Data

� Cloud Computing

� Digital Cinema

� Embedded Systems

� Energy

� Food Chain Management

� Generative Manufacturing

� Lightweight Structures

� Nanotechnology

� Photocatalysis

� Polymer Surfaces

� Cleaning Technology

� Simulation

� Space

� Water Systems (SysWasser)

� Traffic and Transportation

� Vision

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Regional Fraunhofer Innovation Clusters (ICT participation)

Adaptive Production for Resource Efficiency in Energy and MobilityAdaptronic SystemsAutomotive Quality Saar AQSBioenergyCloud Computing for LogisticsDigital Commercial Vehicle TechnologyDigital ProductionElectronics for Sustainable Energy UseSmart, Energy Efficient Regional Value Adding Chains in IndustryFuture Urban SecurityGreen PhotonicsLeistungselektronik für Regenerative EnergieversorgungLife Cycle Engineering for Turbomachines (LCE)Mechatronic EngineeringMultifunctional Materials and Technologies (MultiMaT)Nano for ProductionNext Generation IDPersonal HealthRegional Eco Mobility 2030 (REM 2030)Plastics and Plastics Technologies for the Solar IndustryTechnologies for Hybrid Lightweight Construction (KITe hyLITE)Virtual Development, Engineering and Training (VIDET) 17

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Fraunhofer worldwide

Dubai

Bangalore

Jakarta

Beijing Seoul

Tokyo

Cairo

Ampang

Santiago de Chile

Singapore

Brussels

Porto

Vienna

Bolzano GrazBudapest

Wrocław

Gothenburg

Thessaloniki

Sydney

Salvador

Sendai

Paris

São PauloCampinas

Jerusalem

� Subsidiary� Center� Project Center� ICON / Strategic Cooperation� Representative / Marketing Office� Senior Advisor

Stellenbosch

Boston

Plymouth

East LansingSan José

NewarkMaryland

Cambridge

LondonVancouver

Storrs

Glasgow

SouthamptonDublin

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FRAUNHOFER INSTITUTE FOR CHEMICAL TECHNOLOGY ICTRESEARCH & DEVELOPMENT FOR SUSTAINABILITY

© Fraunhofer ICT © Fraunhofer ICT

© Fraunhofer ICT

Fraunhofer Institute for Chemical Technology ICT

� Established 1959

� Location Pfinztal-Berghausen

� Staff (full-time equivalent) 549 (approx. 402)Scientists, PhD candidates 144Graduates, laboratory technicians 105Workshop and laboratory assistants 95Administration 52Trainees 16Scientific assistants, work experience placements approx. 137

� Budget 2013 (ICT Pfinztal only) 38.3 million €

� Total site area 200,000 m2

Laboratories, offices, pilot plants, workshops approx. 13,000 m2

Test sites, infrastructure approx. 12,000 m2

February 2014

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Fraunhofer Institute for Chemical Technology ICTProfessorships

Prof. Dr. Peter ElsnerProfessorship for Polymer Technology, KIT

Prof. Dr. Frank HenningProfessorship for Lightweigt Construction of Vehicles, KITExtraordinary Professor for Research, Faculty Mechanical Engineering, Western University, Ontario, Canada

Prof. Dr. Ulrich TeipelProfessorship for mechanical process engineering and particle technology, Technische Hochschule Nürnberg

Prof. Dr. Klaus DrechslerProfessorship for Carbon Composites, TUM

Prof. Dr. Michael MaskosProfessorship Physical Chemistry, University Mainz

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Department of Applied Electrochemistry

� Primary and secondary batteriesMaterial and system development, battery testing and service, new battery materials (e.g. for lithium-oxygen and lithium-sulfur batteries)

� Redox-flow batteriesInvestigation and development of alternative electrolytes, electrodes and membranes, design of process technology

� Fuel cellsMaterial development for direct alcohol, anion exchange membrane and HTPEM fuel cells, fuel cell system development, APU/range extender and military applications

� Sensor technology and analysis systemsElectrochemical sensors, trace detection, patternrecognition, online analysis of volatile substances

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Department of Polymer Engineering

� Compounding and extrusionMaterials and cutting-edge processing technology

� NanocompositesFunctional composites and their characterization

� Foam technologiesProcesses and materials for particle and extrusion foams

� Thermoplastic processingInjection and compression molding, thermoplastic composites

� Thermoset processingProcess and material development, tailored SMC

� High-performance compositesRTM processing chain, injection, preforming, prepregs

� Microwaves and plasmasMicrowave technology, surface modifications

� Plastics testingMechanical and rheological analysis, microscopy, DoE

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Department of Environmental Engineering

� Reaction and separation technologyPlatform chemicals and monomers from renewable raw materials, mechanical and thermal separation processes

� Polymers and additives Synthesis, chemical synthesis of materials, purification, impregnation, coating

� Recycling and resource efficiency management Mechanical processes, recycling of secondary raw materials and material composites, life-cycle analyses

� Environmental simulation and productqualificationClimate, vibration and shock tests, corrosive gas test, test of chemical stability, solar simulation, thawing

� Analytical characterizationChemical analytics, breakdown and analysis of biomass, plastic characterization, emission measurements

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Project Group for New Drive Systems NAS

� Hybrid drive trains and e-mobility� Improving efficiency of electrified

powertrains� Thermal management systems for EVs

� Conventional powertrains� Improving efficiency of conventional

powertrains� Ics and partly electrified powertrain

topologies

� Stationary drive trains and heat utilisation� Decentralised energy supply systems based

on CHP� Electrical and thermal storage systems

� Lightweight powertrain design� Weight reduction of stationary and moving

powertrain components

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Project Group for Electrochemical Storage Devices in Garching

� Materials for energy storage devicesNew electrode materials (alloy anodes, composite electrodes)

� Small-series productionProduction of cells

� Module and battery developmentThermal, electrical design

� Testing of battery systemsTest stands for operational stability and abuse tests on batteries >20 kWh

� Post-mortem, agingFailure analysis of battery systems, analytics for aging investigations

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Fraunhofer Project Center @ Western in London, Ontario, Canada

� Sheet molding compound SMC� Direct SMC technology� Conventional SMC� Formulation and process development

� Long-fiber-reinforced thermoplastics� Engineering thermoplastics� Local reinforcement

� High-pressure RTM� New processing technology� Mold design for compression molding� Alternative resins

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TheoPrax Center and TheoPrax Foundation

� Teaching-learning methodologyDeveloped at the Fraunhofer ICT in 1996 for schools and higher education institutions; emphasis on natural sciences and technology, 12 centers throughout Germany

� Combination of theory and practiceProject work in a real-life context, approx. 700 successful projects carried out with pupils and students

� Teacher trainingApprox. 60 teacher training courses in 5 German states; integration of topics from external partners (research, enterprises) into the curriculum

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EXAMPLES OF OUR RESEARCH ANDDEVELOPMENT FOR SUSTAINABILITYFRAUNHOFER-INSTITUTE FOR CHEMICAL TECHNOLOGY ICT

© Fraunhofer ICT

Weight increase of typical medium-class vehicle since 1970

Implementation of EU regulation

Alternative drive train concepts:

fuel cells,

hybrid and

E-propulsion

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1980 1985 1990 1995 2000 2005 2010

1200

1000

Weight [kg]

+ 400 kg +50 %

+ 100 to 300 kg

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AutomotiveLightweight design in transportation sector

Reduction of consumption and emissions through lighter structures

Improvement of passive and active safety and product attractiveness through functional design

For commercial vehicles: increased payload

Lightweight design requires quality-controlled, high-volume manufacturing processes for composites

© Fraunhofer ICT

Lightweight Design, Materials and ProcessesApplications of Resin Transfer Molding in the automotive industry

Side frame

Roof

Body in white

Bumper

Audi R8 Spyder

BMW M6

BMW Project ISource: BMW AG

Source: AUDI AG

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Source: BMW AGSource: maschinenmarkt.vogel.de

Source: maschinenmarkt.vogel.de

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ElectromobilityBattery Development and crash-safe battery protection for electric cars

Lohner-Porsche (1898) Frecc0 (2011)

Source: Hybrid-vehicle.org Source: Fraunhofer

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Primary and secondary batteriesMaterial development and testing

� Electrochemical systems� Li-ion, Li-S, Na-ion, Si- and Sn-anodes,

super-capacitors

� Electrolytes and separators� Organic electrolytes, ionic liquids, polymer gel

electrolytes and ceramic separators (e.g. forlithium-ion and lithium- or sodium-metalbatteries)

� Material testing� Testing and benchmarking of electrode materials,

electrolytes and separators� Construction of laboratory test cells� Safety and abuse tests according to international

standards

© Fraunhofer ICT

Primary and secondary batteriesProject RedoxWind

� Development of large-scale redox-flow storage devices in the kW to MW range� Design of storage devices for houses;

prototype development from the stack to the complete system

� Assistance in the approval process for the construction of storage solutions

� Design and development of storage solutions in the MW range

� Project “RedoxWind” to connect a 2 MW / 20 MWh redox-flow battery to a wind power unit

© Fraunhofer ICT

Primary and secondary batteriesApplication in an industrial park

� (Semi) self-sustaining provision of power, heat and cold in an industrial park

� Study at the industrial park Karlsruhe-Grünwinkel

� Simulative illustration of the energy flow for different scenarios

� Cooperation with Hochschule Karlsruhe and Wirtschaftsförderung Karlsruhe

� Load-peak management

� Waste-heat utilization

� On-site energy production

� Energy storage

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Thermal storage devicesIntelligent systems for individual applications

� Storage materials� Material characterization� Kinetic evaluation� Modification / functionalization

� System design� Thermodynamic analysis� Power dynamics� Simulation / modeling� Corrosion� Safety analysis

� System development� Construction� Compatibility� Manufacture� Demonstrators� Economic evaluation

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BiorefineryFraunhofer Center for chemical and biotechnological Processes (Fraunhofer-CBP) in Leuna

© Fraunhofer ICT

Lab IILab Full-scaleScale-up and process developmentPilot-scale

BiorefineryFrom the laboratory to the industry

© Fraunhofer ICT

� To reduce the environmental impact of the aircrafts:

� 50% reduction of CO2 emissions

� 80% reduction of NOx emissions

� 50% reduction of external noise

� A green product life cycle: design, manufacturing, maintenance and disposal / recycling

� Eco-Design & End-of-Life - green design and production, withdrawal, and recycling of aircraft, by optimal use of raw materials and energy

� Identification of application fields and markets for secondary raw materials

� Economically and ecologically efficient processing of composites

Clean SkyReduction the environmental impact of aircrafts

© Fraunhofer ICT

� Manufacture of railway sleepers from post-consumer plastics

� Development of a thermoplastic polymer matrix and of the technology for the continuous extrusion of the sleeper

� Scale-up of production - production of several 2.6 m sleepers

� Successful performance of sleeper tests

� Life Cycle Assessment study

Recycling: RailWasteRailway sleepers from post-consumer plastics

© Fraunhofer ICT

� Use of polymer waste for the replacement of bitumen in asphalt in order to enhance its properties

� Separation and preparation of the mixed waste material to be used as additive

� Characterization of mixed plastic waste with several analysis methods

� Successful application at the ICT-Campus

Recycling: AsphaltPolymer wastes for the replacement of bitumen in asphalt

© Fraunhofer ICT

� Recycling of rotor blade, through an efficient recycling processing maintaining maximum fiber length and their mechanical properties

� Identification, characterization and reclaim of carbon- and glass-fibers layers and fillers (PVC foam, balsa wood)

Recycling: Rotor blade (Wind Power Turbine)Efficient recycling processing maintaining maximum fibers length

© Fraunhofer ICT

� Production of insulation material from Posidonia (Sea weed), which is collected as a waste material in the Mediterranean Sea.

� Separation and preparation of natural fibers for thermal insulation and other applications

� Development of binding material and process

� Characterization of the material with several analysis methods

� Life Cycle Assessment study

Building Industry: Posidonia-InsulationSustainable insulation material

© Fraunhofer ICT

Metal solutionsBioleachingElectrophoresisFilter adsorption

Hybrid componentsDesign for recyclingFiber / metals recoveryFlame retard. removal

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MSW incinerator slagsMinerals reuseMetals recovery

Waste woodWood recoveryCascade patternMetal recovery

High-transmission glassLow iron content glassSorting process in meltPigment masking

Flue gas filtrationSensors and filtersMetals recoveryMinerals recovery

MOLECULAR SORTING – Demonstrators

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FRAUNHOFER INSTITUTE FOR CHEMICAL TECHNOLOGY ICTRESEARCH & DEVELOPMENT FOR SUSTAINABILITYTECHNICAL CENTERS, LABS, SERVICE AND SUPPORT

© Fraunhofer ICT

Reaction and separation technology

� High-pressure synthesis, extraction andpulping processes

� Platform chemicals from sustainable rawmaterials

� Separation process for material recovery(DSP)

© Fraunhofer ICT

Reaction and separation technology

� Separation process for material recovery(DSP)� distillative: rectification, distillation,

film evaporation� extractive: solid/liquid, liquid/liquid,

continuously or in batches, with supercriticalfluids

� membrane processes: microfiltration toreverse osmosis, dead-end and cross-flow

© Fraunhofer ICT

Processing of thermoplastic materials

� Injection and compression molding� Inline compounding of long-fiber-reinforced thermoplastics

(LFT) in compression and injection molding� Thermoplastic tape placement� Functionalization of components by addition of continuous

fiber structures in compression and injection molding processes

� Chemical and physical thermoplastic foam injection molding � Processing of electrically conductive polymers� Processing of biocomposites� Advanced processing technologies for injection molding

© Fraunhofer ICT

� SMC and D-SMC� Material development� Low density SMC� Glas, natural and carbon fibers� Recycling� Validation of Class-A� Endless fiber reinforcement� Local reinforcement by inlays� New matrix systems and applications� Short process chain� Flexibility� Inline Prepreging

� Fiber reinforced polyurethanes� Process development for long fiber spraying� Alternative filler � Paintable surfaces� Emission testing and fire protection testing� PUR RTM� Sandwich technologies

Thermoset processing

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� HP-CRTM and HP-IRTM�Fast infiltrating strategy�New matrix systems�Preforming technologies�Binder technologies�automated handling of textiles and preforms� Industrialization of process chains

� Thermoplastic RTM�Process development for cast PA 6� impact-resistant high-performance composites �Controlled polymerization through

introduction of alternative energies

High Performance Composites

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Recycling laboratoryMechanical treatment of waste material

� Mills

grinding; cutting; crushing; hammer and ball (impact)

� Classification and sorting separators

wet and dry screening; gravity sorting; fluid; sieve machines: metals; nonferrous metals separation

� Preparation for analysis

sample divider; sieve analysis; mixer; vacuum drying cabinet; fiber length and particle size measurement

© Fraunhofer ICT

Recycling and resource efficiency management

� Identification of application fields and markets for secondary raw materials� Raw material recycling of polymer materials

(e.g. MKS, PC, PE, PET, PP, PS, PUR, PU, PVB, PVC)

� Material recycling for the development of high-value products and processes (e.g. railway sleepers, insulating material, asphalt)

� Economically and ecologically efficient processing of composites� Insulation systems for construction and

façades� Plastics: Multilayer, trays� GFRP/CFRP: Recycling of wind plants and

aircraft� Electronic waste

© Fraunhofer ICT

Recycling and resource efficiency management

� Development of combined treatment and separation processes� physical� chemical-reactive� mechanical

� Material characterization� mechanical properties� analysis of fiber length; particle and sieve analysis� biodegradability

� Evaluation

� life cycle analysis (LCA) � strategies for resource efficiency� eco-design (design for recycling)

© Fraunhofer ICT

Environmental simulation and product qualification

� Measurement of environmental conditions

� Development of tailored tests

� Conduction of testing programs� Temperature / climate / thawing� Corrosion / salt mist / corrosive gases� UV and solar radiation� Vibration / mechanical impact

� Product qualification� IP protection category� Material testing / chemical stability

� Evaluation of the effects on materials and products

� Investigation of service life and operational stability

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Analytical characterization

� Complete methodology development fororganic and inorganic products and reactions

� Analysis of natural substances� sugars, lignins, lignin breakdown products using

GC-MS, HPLC-MS, HPLC-DAD, EA� oils, fats, fatty acids using fat parameters

� Inorganic analytics� measurement of the mineral content

using MW fractionation and ICP-OES� incineration

� Biomass fractionation� of different woods and straw according

to NREL TP 510 -42619 to -42630

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Analytical characterization

� Product qualification� using HPLC-MS, GC-MS, TDS-GC-MS, ash

content, pH value, UV-VIS, parameters

� Emissions and smells� accredited for the automotive sector

(VDA278, VDA276 and DIN 16000)� testing possible in 1 m³ chambers as well

as 20 l chambers� thermal desorption testing using

TDS-GC-MS

� Plastics characterization� TG-MS, pyrolysis GC-MS and

GPC-RI-visco-LSD

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Material and process analysis

� Measurement of materials during processing using rapid spectroscopic methods (UV/VIS, NIR, RAMAN, MIR, GC) suitable for industrial application

� Process monitoring and process analysis to optimize production cycles and product yields

© Fraunhofer ICT

Plastics testing

� Mechanical and thermo-mechanical testing

� Microscopy for the structural investigation ofpolymers

� Rheology of polymer melts

� Complementary testing methods� (Di)electrical properties, aging / weathering,

haze measurement and colorimetry, Karl-Fischer titration

� Density measurement� Taber test� Interfacial energy� Thermogravimetrical analysis� Measurement of fiber content� Moisture measurement� Measurement of the residual monomer

content ofPA6 / PA12

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Contact

Dr. Stefan Tröster

Stefan.troester@ict.fraunhofer.de

Office +49-721-4640-392

Mobile +49-172-632 54 79

www.ict.fraunhofer.de