Annual Report 2002 - Fraunhofer UMSICHT - Energie ... UMSICHT Annual Report 2002 Competencies Six areas of expertise are the basis of the process-technological operation in the business

Annual Report 2002

At a Glance: Our Departments

��

��

��

��

��

�� !��

��"��#��"��$��

��%

&��%�'��

&��%� ��(��

��%��

��%��&��

��

�� %�)��%��

�%��

�� $��

�� %��&��

�� '��

��%

��

*�$��

��%

)��!��

+��%��'��

��%

(��

+��'�#��%

��%��

��%,�(��%,�)��%��

2 UMSICHT-Jahresbericht 2001

Structure of staff at Fraunhofer UMSICHT

Development of the operational budget since the establishment of the institute

At a Glance: Facts and Figures

UMSICHT-Jahresbericht 2001 3

Staff

At a Glance: Facts and Figures

Number

145952921

1741232932413

319

Staff at Fraunhofer UMSICHT 2002

Permanent Staff- Scientists and engineers- Technical infrastructure- Central servicesOther Staff- Postgraduates- Undergraduates- Student assistants- Interns, guest scientists- TraineesTotal Staff

Expenditure and Returns

Expenditure 2002

Operational Budget- Staff costs- Other costs

Investments

24.89.5

15.3

2.8

(Mio. €)

Returns Operational Budget 2002

- Industrial Returnssmall and medium-sized enterpriseslarge enterprises

- Public Returns- Others (EU, communities)- Basic fundingTotal Returns

12.810.62.23.41.57.1

24.8

(Mio. €)

2 UMSICHT Annual Report 2002

Preface

The good news first: In 2002, Fraunhofer UMSICHTcould confirm the previous year’s remarkable in-crease of returns. A sprint to the finish line – inwhich all business segments participated to varyingextents – could compensate for the severe problemsof the first six months. Once again, it were theinnovative technical concepts, realized in pilot anddemonstration plants – the institute’s core compe-tencies and hallmarks – that made for economicturn-around and new motivation.

UMSICHT’s expertise can be highlighted by threeexamples:The modular fuel cell power plant(PEM-Oberhausen) was inaugurated on the insti-tute’s premises after a construction time of about

a year. The test plant MARS® provides an innovative concept of thermal wastetreatment: With a thermal capacity of 1 MW, it solves waste problems, and pro-mises economic profits. In the direct proximity of one of our spin-offs, the germancarbon teterow GmbH, which begins the production of pelletized activated carbonthese days, emerged a “jewel case“ of a rotary kiln pilot plant station, in whichUMSICHT employees will develop modified activated carbon.

Today, Fraunhofer UMSICHT is an acknowledged partner of medium-sized com-panies, research establishments, and foreign clients. We complete projects forcustomers in the U.S., Korea, Japan, Singapore, Chile, and in countries of middleand Eastern Europe. At exhibitions and fairs, among others the E-world of energy,Hanover Fair, and IFAT, the institute’s achievements were presented. UMSICHTinitialized the regional initiative “Fraunhofer in NRW“ which united, for the secondtime, representatives of several NRW ministries and the state chancellery with thetwelve North Rhine-Westphalia-based Fraunhofer institutes in the discussion of

UMSICHT Annual Report 2002 3

current research and development topics such as micro production technology,smart living, or sustainable development.

In 2002, the institute’s employees have developed a lot of committment andcreativity in an unfrugal economic environment in order to acquire partners,generate project ideas, and to complete projects. I have to express my veryspecial gratitude to them, our numerous partners, and supporters. We will makeevery effort to strategically rearrange the institute’s research and developmentconcepts in consideration of the UMSICHT-employees’ competencies, successfulareas of operation and modern international trends. Well-founded supportis granted to us by the institute’s board of trustees which was constituted inDecember 2002 with 17 personalities from politics, business, and science.

We are bound and determined to grow with our tasks. Our future challenge iscalled innovation, and it is linked with the sciences by a simple sentence GeorgeBernard Shaw once wrote: “Science is always wrong. It never solves a problemwithout creating ten more.“

With all good wishes

Yours

Rolf KümmelDirector Fraunhofer UMSICHT


In April, Ministerial CounsellorGabriele Pirstadt (picture below)and State Secretary Jörg Bickenbach(picture on the left, 2nd from right)inaugurated the modular test plantfor residue-optimized materialtreatment “MARS®“ in Essen.200 guests took a close look at theinnovative plant concept.

Highlights 2002

Highlights 2002

Keen eyes and creative crayons:In June 2002, the winners of thedrawing contest written out onthe occasion of naming theinstitute’s bus stops “UMSICHT“came to pick up their prizes.

In May, Fraunhofer UMSICHTexhibited at the InternationalFair for Environment andDisposal, IFAT, in Munich


Highlights 2002

Highlights 2002

In October, the North Rhine-Westphalian FraunhoferInstitutes invited the MinistriesMWMEV, MASQT, MSWF,MUNLV, MSWKS as well as theState chancellery to the second“Fall Meeting“ of the regionalinitiative “Fraunhofer in NRW“at Birlinghoven Castle, SanktAugustin

In August, Ernst Schwanhold,Minister for Economic Affairsof the Federal State of NorthRhine-Westphalia, and 200guests got a taste of the ener-gy production of tomorrowduring the inauguration of the“PEM-Oberhausen“ fuel cellplant

“Hands on“: In the context of the10th “Oberhausener UMSICHT-Tage“interested citizens could visit theinstitute’s laboratories and pilot plantsin September


Technology that pays

The industrial nations of today owetheir convenient living conditions tothe, at all times, sufficient productionof economic goods, the secure produc-tion and distribution of energy, as wellas the free exchange of information.Production and consumption areembedded in an economic system,which presupposes economic growthand competition, and an ecologicalsystem whose absorption andprovision capacities are limited.

Which makes apparent: Technologicalprogress is the engine for every mod-ern industrial society. Technologicalinnovations help making efficient andsafe use of resources and resourcesand energy carriers. They allow a satis-factory and inexpensive production ofinnovative goods, create, and securecompetitive jobs.

In this context, Fraunhofer UMSICHTdevelops, tests, evaluates, and opti-mizes technical processes as a catalystfor science and economy. In coopera-tion with industrial and public partners,state of the art findings are beingtransferred into marketable technolo-gies, products, and services.

Fraunhofer UMSICHTThe Fraunhofer Institutefor Environmental, Safety,and Energy TechnologyUMSICHT

Fraunhofer UMSICHT

The business segments environmentaltechnology, safety and process techno-logy, as well as energy technologystand for application-oriented, proce-dural know-how: from first feasibilityand profitability studies, over sophisti-cated simulation programs, to demon-stration plants in production scale.Innovation management, on-the-jobtraining, and project development andfinancing round off the profile. Interna-tionally, the institute is represented inthe U.S., states of central and EasternEurope, and Latin America.

Fraunhofer UMSICHT in Oberhausen islocated in the vicinity of the shoppingand recreation center CentrO. Its morethan 300 employees produced a turn-over of more than 24 Mio € in 2002,about 75 % of which stem frommission-oriented research, and morethan 50 % from the industry.Fraunhofer UMSICHT engages in thestructural change in Oberhausen andthe region with new ideas, technologytransfer, spin-offs, and the formation ofresearch and development networks.


Organizational Chart

Organizational Chart

��

��

��

��

��

��

��

��

��

��

��

��

��!�

��

�"��#

��

��

��

��

��

��

��

��

��

��

��

��

��

�!�� "##�#$%

� ��

��

��

��

��

��

��

� �

��

��

��

��

��

��&��'��

"(#�$�#)*+�,)-.�-)%

$%�&

'(%�'�

��

��)

��/��01�

��"##�2)%

��

��

��

��

��

��'��

��*��

��

��

��

��

��3� ��4�� "+�5.%��

��6��7��"##�28%

��7�!9�7��

�� "##�.$%

:��!��9

��7��;��"##�-8%

�� 9�� 7

��&��7�"##�-+%

�� 9��6��

�� "##�-.%

<��&��

:��6��"##�--%

��7��7� ��7�� *

:��

4�� 7��'��

��:��7��37��"##�.5%

�+��

��'

��*

��/��01�

��"##�$8%

��7��7��7

�=��7

��6��4��>��"##�$+%

�?�� 7

��!��3��"##�+#%

@��7��!��79��

��=��

��7��7��7��

��<��!��7�"##�)8%

��

��7��7��

��4��"#)�),%

��7�� A�:��

��7��A

6��=��7

�� 7��7��

�"##�8#%

��

��

��

� ��

��

��

��

��

!"#

��$�

%�$&

'&(�

#&)�

�*��

��

��

��

��

��

��

��

��

##�

!"#�

�$�%

�$&'

"�+&

�"&)

��*�

��

��

��!��*��

��'�

��*

��!7��!��17��"##�),%

:��7��?��!��=��

/��!��"##�-)%

&�4��9

0��7�� 3��"#)�2#%

B��:��!9�7��

��/�� "#)�8+%

��?�� 9

��"##�)5%

!��9��

�� "##�)#%

;�'��

��C�� "##�$5%

��7��?�� 9��

�� 7

��0��0��"##�,8%

6��

��!7��0�4��"##�,$%

��7��?�� 9

��"#)�,+%

��7��?��7��7*

��4��?�� 9

C��/�4��7�"##�52%

��7��*��:��

C��!��"#)�-+%

��7��?�� 9

C1� ��6��7�� "##�,-%

?��7��

�� 7

?��7��"+�52%

!��79��9��

��<��!��7�"##�)8%

9��

��3� ��4�� "+�5.%

B��!��79��D��

��7��7��

��<��!��7�"##�)8%

!��7'��=��7

?��7��"+�52%

��*�'�

��*

��7��"##�-,%

,�-��

�'�

��*�'��

�!��

��6��7��"##�28%

?�� :��7��

��7��"##�##%

:��7�9A�6�� 9A��97��

��?��

��"#)�+2%

��<7��77� 6��"#)�).%

��7�B�� *

!��

:��7��"##�82%


Competencies

Six areas of expertise are the basis ofthe process-technological operation inthe business segments. They findapplication in the project and theme-oriented areas of expertise.

Main Areas of Expertise

• Process and application development

• Studies, expertises, and surveys fordecision-making processes (processengineering, market)

• Planning, construction, and oper-ation of pilot and demonstrationplants (PD plants)

• System analysis, system technology

• Software for process engineering

• Project development and financing

Waste Technology andWaste Management

Thermal waste treatment; wastereprocessing; waste confectioning;utilization of residues; looping;optimization of thermal processes;simulation of waste treatmentprocesses; material flow managementContact: Dr. rer. nat. Kai KeldenichPhone: +49 (0) 2 08/85 98 -11 [email protected]

Plastics Technology

Plastics Technology; automo-bile recycling concepts; productdevelopment; material and recycling-oriented design; injection molding;extrusion; plastic testing technology;Finite Elements Method analyses (FEM);market and technology studies;material development/compounding;fiber-reinforced and bio-degradablematerials; new areas of applicationContact: Dr.-Ing. Edmund DolfenPhone: +49 (0) 2 08/85 98 -12 [email protected]

Bioengineering

Synthesis of valuable materi-als; reprocessing of biotechnologicalproducts; modeling; biological sewagetreatment, waste air and solid wastetreatment; production of biogasContact: Dr.-Ing. Stephan KabasciPhone: +49 (0) 2 08/85 98 -11 [email protected]

Departments and Competencies

Departments

Department ofEnvironmental Technology

Head: Prof. Dr. rer. nat. Rolf KümmelPhone: +49 (0) 2 08/85 98 -11 [email protected]

New Processes

Analysis of conventional pro-duction processes; development oflow-emission syntheses; crystallizationby means of supercritical fluids; micro-reaction technologyContact: Dr. rer. nat. Joachim DanzigPhone: +49 (0) 2 08/85 98 -11 [email protected]

Particle Technology

Particle technology; crystalli-zation processes; comminution; micro-encapsulation; spray drying; separation;sample processingContact: Dipl.-Ing. Jürgen BertlingPhone: +49 (0) 2 08/85 98 -11 [email protected]

Adsorption/Gas Cleaning

Flue gas cleaning; gaswashing and adsorption; catalyticconversion of gaseous airbornecontaminants; production andcharacterization of adsorbents;adsorber modelingContact: Dipl.-Ing. Jens SohnemannPhone: +49 (0) 2 08/85 98 -12 [email protected]


Fire Safety Engineering,Fire and Explosion Protec-tion for Technical Plants

Fire safety concepts for buildings,smoke extraction; material behavior;fire and explosion precaution policiesfor technical plants; consulting for firebrigadesContact: Dr.-Ing. Ulrich SeifertPhone: +49 (0) 2 08/85 98 -11 [email protected]

Technical InformationManagement

Information management for systemsecurity and process technology;advice concerning the state of techno-logy; support in legal permissionprocedures; graphically supported anddialog-based guidelines; full-text infor-mation systems; e-commerce solutionsContact: Dipl.-Phys. Thorsten WackPhone: +49 (0) 2 08/4 68 48 -3 [email protected]

Pipeline Technology

Pipeline test area (tempera-ture up to 200 °C, pressure up to 80bar); water and cavitation hammer;layout of pipeline systemsContact: Dr.-Ing. Andreas DudlikPhone: +49 (0) 2 08/85 98 -11 [email protected]

Department ofSafety andProcess Technology

Head: Dr.-Ing. Stefan SchlüterPhone: +49 (0) 2 08/85 98 -11 [email protected]

Safety Analysis and Design

Safety of plants and plantcomponents; transport and storagesafety; safety analyses in compliancewith German regulations; thermalanalysesContact: Dr.-Ing. Ulrich SeifertPhone: +49 (0) 2 08/85 98 -11 [email protected]

Dynamic Processes

Pattern recognition; processcontrol system protection andmitigation planning; model-basedmeasuring methods; simulation ofplants and scheduling of productionprocesses; substance data provision;layout/evaluation of ethoxylationprocesses; application of commercialsimulation softwareContact: Dr.-Ing. Görge DeerbergPhone: +49 (0) 2 08/4 68 48 -3 [email protected]

Software Development

GUI (graphical user interface)for Windows-NT and X-Windows sys-tems; database technologies; client-server solutions; generic systems;software designContact: Dipl.-Phys. Thorsten WackPhone: +49 (0) 2 08/4 68 48 -3 [email protected]

Water Treatment/Membrane Technology

Development of new areas ofmembrane technology; linking ofprocess water streams; reprocessingof pickling acids with membrane-combined processes; filtration ofsewage system discharge for there-utilization of waterContact: Dipl.-Ing. Josef RobertPhone: +49 (0) 2 08/85 98 -11 [email protected]

Special Polymers

Temperature sensitive/hydro-philic gels, superabsorbers, thermo-chromate; syntheses; product charac-terization; analytics; applicationtechnologyContact: Dipl.-Ing. Holger WackPhone: +49 (0) 2 08/85 98 -11 [email protected]

Chemistry, Biology,Analytics

Thermal analysis; reaction cal-orimetry; rheological exami-nations; particle size distribu-tion; testing of contaminantsand summary parameters; characteri-zation of products and residues; testingand online-analyses for processingsystems; biological testing processes;analysis of organic materials; isolationof combined and pure-culture micro-organisms; determination of combustionproductsContact: Dr. rer. nat. Thomas MarziPhone: +49 (0) 2 08/85 98 -12 [email protected]: Dr. rer. nat. Ute Merrettig-BrunsPhone: +49 (0) 2 08/85 98 -12 [email protected]



Department ofEnergy Technology

Head: Dr.-Ing. Wilhelm AlthausPhone: +49 (0) 2 08/85 98 -11 [email protected]

Use of Lean Gas

Coal mine gas (CMM); landfillgas; biogas; hazardous gases; thermalutilization concepts; burner technology,emission controlContact: Dipl.-Ing. Clemens BackhausPhone: +49 (0) 2 08/85 98 -11 [email protected]

District Heating/CHP (Combined Heat andPower Generation)

Generation; distribution; networkconcepts; GIS; leakage localization;energy supply concepts; solar/geothermal energies; local heating;refrigerants (ice-slurry); expert reports;energy trading; efficiency; energypoliciesContact: Dr.-Ing. Christian DötschPhone: +49 (0) 2 08/85 98 -11 [email protected]

Cold Supply

Cold supply technologies;thermal cold production; steam jetrefrigeration plants; cold storage anddistribution; air conditioning technology;combined heat, cold and powergeneration (CHPC); solar thermalrefrigeration; energy supply conceptsContact: Dipl.-Ing. Peter NoeresPhone: +49 (0) 2 08/85 98 -11 [email protected]


Energy Management

Energy management; energytrading; power plant planning; opti-mized co-generation; IT solutions forenergy networks (consulting,realization)Contact: Dipl.-Ing. Michael LuchtPhone: +49 (0) 2 08/85 98 -11 [email protected]

Energy from Biomass

Re-utilization concepts; powergeneration; combustion; gasification;gas generation using fluidized bedcombustion (FBC); hot gas and taranalytical testingContact: Dr.-Ing. Markus IsingPhone: +49 (0) 2 08/85 98 -11 [email protected]

Fuel Cell Systems

Fuel cell systems: PEFC,MCFC, SOFC; regenerative gases, gasseparation technology, system model-ing and analysis, flue bed combustion,computational fluid dynamics (CFD)Contact: Dr.-Ing. Ralf HillerPhone: +49 (0) 2 08/85 98 -12 [email protected]

Plant Systems Engineering

Process control and visuali-zation; planning, construction andoperation of pilot and demonstrationplants; heating, refrigerating, and airconditioning technologiesContact: Dipl.-Ing. Adam HadullaPhone: +49 (0) 2 08/85 98 -11 [email protected]

Department of Knowledgeand Technology Transfer

Head: Dr.-Ing. Bernhard DietzPhone: +49 (0) 2 08/85 98 -11 [email protected]

International ProjectDevelopment

Head office of the German-Polishresearch association INCREASE;cooperation in the North Rhine-Westphalian action program for thepromotion of external trade withcentral and Eastern European countriesCEEC; scientific alliances and businesscooperation; consulting services tocentral and Eastern Europeancountries; European Union projectsContact: Dr.-Ing. Barbara ZeidlerPhone: +49 (0) 2 08/85 98 -11 [email protected]

Training Center

Knowledge, know-how, andexpertise transfer; distance studiesprogram Environmental Sciences(infernum); network programs withschools, universities, and privateenterprises; vocational trainingprograms; customized courses forindustry; multi-media learning;seminars, workshops; coursesContact: Dipl.-Ing. Anja GerstenmeierPhone: +49 (0) 2 08/85 98 -11 [email protected]


Project founding/Spin-offs

Combined and single project founding;implementation of pilot and demon-stration projects; financial support;consulting services to spin-offenterprises; finding business partnersContact: Dipl.-Ing. Christian WolfPhone: +49 (0) 2 08/85 98 -11 [email protected]

Administration

Human resources; projectmonitoring; research contracts;budgeting; purchasing; accountancy;business trips; infrastructure; controlingContact: Dipl.-BW Andreas WeberPhone: +49 (0) 2 08/85 98 -12 [email protected]

Marketing,Communication,Business Development

Innovation management;market surveys and techno-logy studies; project develop-ment; marketing concepts; sales;business field policies; strategicplanning; intellectual property rights;public relations; composition andlayout of print media; media work;information medium internetContact: Dr.-Ing. Hartmut PflaumPhone: +49 (0) 2 08/85 98 -11 [email protected]: Dipl.-Chem. Iris KumpmannPhone: +49 (0) 2 08/85 98 -12 [email protected]

IT-Management

Support of the IT infrastruc-ture; user help desk; high-efficientservers and services; software design;installation and support of LAN andWAN; development of web-applica-tions; training of IT specialists;consulting in IT-specific projectsContact: Dipl.-Ing. Andreas SchröderPhone: +49 (0) 2 08/85 98 -11 [email protected]

Central Technical Services

Project management; basicand detail engineering; sampling,analytical testing and pilot programs;technical services; central implemen-tation of measurement and controland PLS (process control systems);internal technical services; mechanicsand electric workshops; constructionof demonstration and pilot plantsContact: Dipl.-Ing. Richard SprickPhone: +49 (0) 2 08/85 98 -11 [email protected]

Library

Information systems; onlineliterature research; document supply;Fraunhofer Publica updating; UMSICHTnewslettersContact: Dipl.-Bibl. Kerstin HölscherPhone: +49 (0) 2 08/85 98 -12 [email protected]


Occupational Safety andEnvironmental Protection

Coordination and advice in topicsrelated to occupational safety:vocational training and on-the-jobcourses; registration and notificationprocedures; monitoring of legislativeregulations; safety-relevant instructionof the staffContact: Dr.-Ing. Ulrich SeifertPhone: +49 (0) 2 08/85 98 -11 [email protected]

Fraunhofer Center forEnergy and Environment

Development of Fraunhofertechnologies for the U.S. market:process water treatment and sewage;power generation from biomass;integrated energy supply conceptsContact: Dr.-Ing. Achim LoewenPhone: +1 4 12/3 62 -89 [email protected]


Laboratories andWorkshops

Laboratories and Workshops

Analytical Laboratory

The analytics laboratory handles envi-ronmental tasks, performing analyseson solid materials, gaseous andaqueous samples as well as onmaterials from process engineeringplants. Our spectrum ranges from theanalysis of soil, dust, and waste overthe analysis of sewage sludge andwaste water to landfill and purificationgases. Where no standard analyticalprocedures exist, the lab team developsnew methods and applications tailoredto specific needs such as pilot tests.The staff also provides consulting tocustomers in the planning and evalu-ation of examinations.Our objective is the development ofcomprehensive solutions to techno-logical problems using analyticalmeasuring methods.

Special emphasis is placed on theanalysis of combustion and decompo-sition processes and the identificationof siloxanes in sewage and landfillgases. Further area of expertise is thedetection of isomers of DDT, PCP, andHCH in highly contaminated woodmaterials.

Among others, the range of theanalyzed standard parametersincludes:

Inorganic substances

• anions and cations- quantitative and qualitative

analyses of heavy metals andanions

• summary parameters- total nitrogen (Kjeldahl)- organic and inorganic carbon

contents (TOC, TIC )- water hardness- acid and base capacity- tensides (MBAS, BIAS)

Organic substances

• hydrocarbons- aliphatic hydrocarbons- benzene, toluene, xylenes (BTX)- polycyclic aromatic hydrocarbons- various solvents

• halogen compounds- pentachlorophenol (PCP)- γ-hexachlorocyclohexane (HCH) and

other isomers- highly volatile chlorinated hydro-

carbons• GC-MS-screenings

Physical-chemical analyticalmeasurements

• analyses of chemical reactionsin reaction calorimetries

• thermal analyses• rheological analyses• laser-optical determination of particle

sizes in solid materials• analyses of combustion and

degradation reactions (also equip-ment according to DIN 53436)

• BET-surface analyses• pore volume investigations




Biotechnological Laboratory

The biotechnological laboratory spe-cializes in solutions for the clarifi-cation of contaminated media (soil,water, air), performing analyses onpotentials of inherent biodegradabilityand biological production, and devel-oping novel microbiological processesin laboratory and technical scales.

New biotechnological methods andsystems are developed, designed, andtested step by step in order to ensuretechnical feasibility at a high efficiencyand operational safety. In many cases,the traditional methods existing haveto be completed by specific processestailored to the customers’ needs. Inclose cooperation with the analyticsdepartment and experts from the engi-neering staff, the biotechnologicallaboratory advances the developmentof novel and efficient solutions.

Equipment (selection)

• Fourier-transform-infrared spectro-meter (FT-IR)

• elementary analyzer• differential scanning calorimeter

(DSC)• gas chromatographs including mass

spectrometer (GC-MS)• high-performance liquid chromato-

graph also with mass spectrome-tric detection (HPLC-MS/MS)

• atomic emission spectrometer withinductively coupled plasma asinitiating unit (ICP-AES)

• reaction calorimeter (RC1) including2-liter-reactor, temperature range0 °C to 200 °C, 0 to 50 bar excesspressure

• thermal analysis system for combi-ned thermal gravimetry (TG) anddifferential thermal analysis (DTAresp. DSC), temperature range from-150 to 1 500 °C

• rheometer, regulated by shearingstress with air bearing technology

• equipment for laser optical particlesize analysis (3-laser-technique, sizerange 0,1 bis 700 µm)

• ion chromatograph (IC)• graphite tube atomic absorption

spectrometer (AAS)• BET-surface analysis equipment• solid and liquid matter TOC• mercury porosimeter


Services

• analyses of compost materials incompliance with BGK methods(Fraunhofer UMSICHT is an accre-dited testing laboratory of the„Bundesgütegemeinschaft Komposte. V.“ (Federal association of compostquality standards))

• microbiological examinations incompliance with DIN, ISO and OECDmethods

• analyses of the biologicaldegradability of chemical substances(aerobic und anaerobic)

• investigations on bio-degradablematerials in compliance with DIN V54900

• isolation of mixed and pure bacterialcultures with specific degradationpotentials

• development of microbiologicalprocesses

• scaling-up of biotechnologicalprocesses (performance, support)

• sensitivity analyses of biotechnolo-gical processes

• consulting and analyses inhazardous incidents or optimizationdemand in biotechnological plants(e.g. sewage treatment orcomposting)

• R&D projects: e.g. aerobic andanaerobic treatment (fermentation orcomposting of organic residues)

• license for handling pathogenicagents in compliance with § 19Abs.1 Nr. 2 BSeuchG of the GermanFederal Law on Epidemic Control



Equipment

Additionally to the standard equipmentfor microbiological research up to se-curity level 2, the following instrumentsare available:

• bioreactors (2-20 l) with modernmeasuring and control equipment

• BOD apparatus (Sapromat), inhibitortest for bioluminescent bacteria(sampling equipment for airborneorganisms)

• anaerobic work bench involving ananaerobic breeding reactor


Workshops

The institute’s workshops comprise

• electric and electronics workshops,and

• mechanic workshops.

The service range of the electric andelectronics workshops covers themaintenance and operation of the in-house power supply system, of thetechnical plants and the laboratories,as well as the planning and construc-tion of new plants in the low voltageand in the high voltage range up to1 000 V, consistent with VDE guide-lines. Small units ranging from measur-ing and control equipment, compre-hensive control modules to completemeasuring and control systems aredeveloped and constructed.

Our service range also includes, in ad-dition to the design and drawing up ofwiring diagrams, also the installationand implementation of structural units.Our solutions designed for internal usesupport the engineering and research-ing staff in the performance of measur-ing, control, and monitoring works, andin the delivery of innovative technology.



The manufacturing facilities offer bothservices in cutting production (drilling,abrading and polishing, lathe work,milling) as well as non-cutting process-ing (welding) of plastic materials andmetals.

The workshops, thus, offer the possi-bility both to set up complete plantsand to manufacture specific scientificinstruments or custom-made analyticalequipment. As a result, custom-madeparts and solutions are ready for usewithout delay. Furthermore, small-scale serial production of work-piecesor small tools is also available.


Marketing, Communication,Business Development

The marketing of products andservices, analyzing, and handling ofbusiness sectors, developing newmarket strategies, and finallyrepresenting the institute in publicare the tasks of the department of“Marketing, Communication andBusiness Development“. Beingdirectly responsible to the directorate,we support the scientific staff in thepositioning of new products and fieldsand in tailoring them to the customer’srequirements. Market surveys andtechnology studies help to assessopportunities and risks of newdevelopments at an early stage.

Developing and preparing the insti-tute’s public relation materials andweb appearance is among ourstrengths. Our web news regularlyand readily keep editors and journa-lists updated about the latest researchresults at Fraunhofer UMSICHT.

Marketing, Communication,Business Development

Marketing, Communication,Business DevelopmentIT Management

To protect new developments fromplagiarism, our department is alsoresponsible for the registration ofinventions, assistance in intellectualproperty rights, and in license agree-ments.

Innovation management and marketingare more than void phrases for us:our services encompass guided brain-storming, market surveys, businesssector analyses and strategies, marketintroduction of products, marketingconcepts and industrial property rightspolicies as well as public relationconcepts, particularly offered to smalland medium-sized enterprises.We want projects with FraunhoferUMSICHT to be attractive, successful,and reliable projects – for our custo-mers and together with our customers!

IT-Management

An efficient and reliable informationand communication technology serviceis an indispensable prerequisite for anyefficient project work. The IT manage-ment provides internal and externalservices, focusing on the followingareas of expertise:

• planning, continuous operation andsupport of the DP infrastructure

• provision and update of softwarepackages

• assistance in IT-specific problems• provision of IT systems to support

the work flow

A powerful server network equippedwith a gigabit backbone is available forthe efficient use of resources such ascomputer servers or data bases. Thesystem comprises highly available fileservers with capacities in the terra-byterange including adequate band security,as well as intranet services, which areof increasing importance.

The IT management also offers servicesto external customers, in particular tosmall and medium-sized enterprises,including:

• DP-auditing• planning, installation, and operation

of local networks• applications development concepts of

central data management and storage• development of system solutions

The department currently employs sixtrainees who are becoming IT-specia-lists in the field of system integrationand applications development.

IT-Management


Library

LibraryOccupational Safety and EnvironmentalProtection

Library

The in-house technical library currentlycomprises approx. 6,900 monographs,91 scientific journals, 44 permanentlyupdated loose-leaf editions, 31 infor-mation brochures (among them publi-cations by ministries, associations,boards and organizations), and bulle-tins issued by government boards invarious research disciplines.

In addition to literature researchthrough the Fraunhofer wide librarydata network STAR, professionalliterature and patent research throughonline data bases is available.

Fraunhofer UMSICHT offers access tothe major electronic data base provi-ders (STN International, FIZ Technik,DataStar) as well as inquiries via in-house data bases such as the Chemi-cal Engineering and BiotechnologyAbstracts data base, supported byDECHEMA. Further online informationsources are KOWI and ECHO databases, reporting continuously oncurrent and future activities in theEuropean Union member countries.

Occupational Safety andEnvironmental Protection

Additionally, research on enterprisesis made available to staff through theHoppenstedt data base from everywork station.

Necessary interlending of requiredmaterials is carried out by the librarystaff.

The library documents and collectspublications made by FraunhoferUMSICHT scientific staff to be includedinto the FhG Publica, a world-wideaccessible Fraunhofer data base.

The responsibilities of the library in-clude the editing of the UMSICHTpublications, ranging from advisorysupport to the authors to the deliveryof the printed copies to the TechnischeInformationsbibliothek (TIB, TechnicalInformation Library) in Hanover.

Occupational Safety and Environ-mental Protection

The work group “Occupational Safetyand Environmental Protection“ (AU)acts as coordinating and organizingboard for issues related to occupatio-nal safety and environmental protec-tion, through consulting of executivesand staff, and through continuouspromotion and upgrading of the AU-related organization.

The scope of duties includes the orga-nization and coordination of occupa-tional injury prevention and healthprotection, emergency and risk mana-gement, emergency precaution, andoccupational injury notification.Qualification courses and on-the-jobtraining in the field of occupationalsafety are offered to AU-administratorsand decision-makers.

Core projects in 2002 were:

• fire prevention organization• safety coordination for building

projects• occupational safety in outposts


Fraunhofer Center Pittsburgh

Fraunhofer USA

Fraunhofer Center for Energy andEnvironment, Pittsburgh

Fraunhofer UMSICHT operates theFraunhofer Center for Energy andEnvironment (CEE) in Pittsburgh,Pennsylvania, USA. The Center,which cooperates with the Universityof Pittsburgh, serves a variety ofpurposes. One of them is to offer theservices and technologies of UMSICHTto the U.S. market. Project work iscarried out both in Germany and inAmerica. In addition, a close tie to

technological developments in theU.S. is ensured, which is supported bycooperation with leading institutionsin the Pittsburgh region. This leads toincreased reputation and competenceand, thus, enhances competitivenessin Germany. Furthermore, Germancompanies are supported in theirefforts to develop and offer productsfor the American market. Finally, theCenter also serves as a tool forhuman resources development andrecruitment.

One area the Center works in is thetreatment of process and wastewaters.For instance, in a cooperation projectwith the University of Pittsburgh micro-filtration membranes are employed totreat Combined Sewer Overflows(CSO). CSO occur during heavy rainevents when rain infiltrates sewerlines in excess of system capacity andoverflows to surface waters causingsevere water pollution. In two mem-brane modules, a variety of membraneswere tested under varying operating

Meadville, the town for which CEE isdeveloping an energy supply concept


Cross flowmembrame modulefor wastewatertreatment

Fraunhofer USA

Farm inPennsylvania

Switchgrass, an energy cropto use as renewable fuel forenergy generation

conditions. Different bacteria wereused as indicator organisms to de-termine pathogen retention efficien-cies. Removal of these organisms tonon-detectable levels was achieved.The results suggest that there is com-mercial potential. As a next step, fieldtrials and additional tests to obtainmore data on specific membraneswill be carried out before commercialdesign can be commenced.

In the field of energy technology, CEEis investigating the economic feasi-bility of decentralized energy supplysystems. Mainly focusing on Pennsyl-vania, where “green power markets”are emerging, background informationon price structures, measures tostimulate green energy like tax incen-tives etc. was collected. In order tocarry out economic calculations forspecific sites, a computer model wasdeveloped that correlates this infor-mation with data on different compo-nents of decentralized energy generationplants. The program delivers financialassessment indicators such as netpresent values and payback periods.It also allows to carry out sensitivityanalyses on the influence of criticalparameters like APRs (annual percen-tage rates) or electricity reimburse-ments.

The Center is evaluating how renew-able energy sources can contribute toan economically feasible and environ-mentally beneficial decentralizedenergy supply. Pennsylvania is a ruralstate characterized by agricultural andwood processing industries.

Therefore, particularly the applicationof technologies for digestion andgasification of biomass such as liquidmanure or waste wood is beinginvestigated. In order to find potentialsites for biomass based generationplants, CEE is currently carrying outfeasibility studies for different locationsin Pennsylvania. In Meadville, a townin Northwestern Pennsylvania, CEEinvestigates which options for energygeneration are best suited to cover thedemand for electricity, heat, and coldof different industries and other con-sumers based on local resources.

Dr. Achim LoewenFraunhofer Center for Energyand Environment5940 Baum Square, Suite 7Pittsburgh, PA 15206Phone: 0 01(4 12) 3 62 -89 82Fax: 0 01(4 12) 3 62 -85 35



Modern environmental technologydevelops means, methods, andtechniques designed to improve theeco-efficiency and to reduce ecologicaldamages. Thus contributing to thereduced emission of ecologicallyhazardous substances and their mini-mized introduction into environmentalcompartments, it provides a directeconomical benefit through cost-effective use of natural resources.

The department of environmetaltechnology offers a repertoire of com-petencies and qualifications, able toperform the tasks of conventionalas well as preventive environmentalprotection. Since the institute’s

foundation, an explicit accentuationtowards integrated environmentaltechnology, intelligent material flowmanagement, and identification ofadded value potential has occured.

Separation processes, functionalmicro-particles, adsorption processes,bio-technological transformations,functional polymers, and thermalprocesses are impressive examples ofhow intelligent solutions lead to thereduction of ecological damages andcreate material value. Mathematicalmodeling and process simulation areappropriate tools to simplify the transferinto pilot or demonstration plants.

Decontamination for art treasures

Supercritical carbon dioxide gently ridswooden pieces of art off contaminantssuch as lindane, DDT, and pentachloro-phenol. Instead of having vanishedinto the “poison cabinet“, this figurefrom the 16th century againdecorates the epitaph of the villagechurch at Döben, Grimma district,Saxony, right after the treatment.

Department of Environmental Technology

Environmental Technology

© Roland Punge


Environmental Technology

The Fate of Hazardous Materials in WastewaterPurification Plants and Membrane Technology forthe Conditioning of Pickling Acids

German wastewater purification plants excel by a far reachingelimination of COD, BOD5, nitrogen and phosphorus. There are,however, constraints to comply with limit values for halo-organiccompounds (such as AOX), metals and their compounds and fortoxic effects on fish. Wastewater also contains a number ofinteresting, synthetically produced and ecologically relevant tracematerials, the elimination of which is currently hardly consideredin municipal wastewater purification. Fraunhofer UMSICHT isinvolved in a project conducted in collaboration with the DPUDeutsche Projekt Union GmbH on behalf of the University ofDortmund, and funded by the North Rhine-Westphalian Ministryof Environmental Affairs, performing studies in-situ at two muni-cipal sewage plants on the behavior of the above substances,which are included in the list of priority materials, part of the EUWater Framework Directive (appendix X of the guideline 2000/60/EG).

Quite versatile – mobilemembrane plants recover theacids flexibly exactly wherethey accrue

On the basis of literature research and first measurements,the list of the materials to be examined in the inflow andoutflow of the wastewater treatment plant was specifiedand supplemented.

In a follow-up project, methods of a more efficient andnearly complete elimination of these hazardous materialsby the balancing of selected substances through theoperation steps in the sewage plant will be presented.

A further project is conducted aiming at an increasedadded value in the metal-surface-treating industry throughthe development of membrane procedures preferablybased on nanofiltration and reverse osmosis. To date,waste acids, a by-product in this application, are sub-jected to a low-grade utilization, re-concentrated ther-mally or discharged directly or indirectly after neutrali-zation. The skilful choice of suitable chemically stablemembrane materials allows to remove impurities fromthe process solution down to the size of metal ions. Theions are subsequently refed to material recovery so thatthe life cycle of the solution is markedly increased.

ContactDr.-Ing. Edda Möhle (+49 (0)2 08/85 98 -12 31)Dipl.-Ing. Josef Robert (+49 (0)2 08/85 98 -11 50)Dr. rer. nat. Joachim Danzig (+49 (0)2 08/85 98 -11 45)

Water – Wastewater Treatment and Looping


Environmental TechnologyPackaging Film from Renewable Raw Materials

The Development of a Novel, Biodegradable PackagingFilm Using Renewable Raw Materials

The lack of discharge systems for conventional packaging ma-terials and their disposal on landfills cause considerable ecologicalproblems. The use of packaging materials from renewable, bio-degradable polymers may help save resources with the bio-dustbinin Germany and other industrial countries, and consequently,costs may be cut down considerably.

In the research project, a new material formula was developedusing polylactic acid and aliphatic-aromatic co-polyester, for astiff, contact-clear film, which displays similar properties com-pared to the LDPE film.

Can bear a lot and vanishesquickly – granules and filmbag made from biodegrad-able material.When composted degrada-tion reaches 70% alreadyafter 43 days.

Processing of thebiodegradable materialon a blow film plant

The haptic properties of the film are pleasant andlack the latex-similar qualities of pure or polyester-films filled with thermoplastic starch. These propertieswere attained through a development of a newsystem of compatibiliers. The binding of the inor-ganic fillers in polymer could be improved andthe compatibility between polylactic acid and co-polyester could be increased.

Manufacturers of LDPE film are highly interested inthis material, since it can be processed on conven-tional blow molding lines, avoiding expensive ad-justments to screws, nozzles or take-offs. At thepresent moment, the films are manufactured andtested by numerous companies. Film blowing testshave revealed that the film is stretchable to 8 µmand has similar shrinking properties as LDPE.Several projects with different partners are current-ly conducted being in the implementation phase orin the practical testing phase of the film products.

ContactDr.-Ing. Edmund Dolfen (+49 (0) 21 54/92 51 -12)Anneliese Kesselring (+49 (0) 21 54/92 51 -24)


Environmental Technology Technology of Activated Carbon

Task Force Teterow – Research Laboratory for ActivatedCarbon Technology

Close collaboration in research, production and application fieldsis required for the development of activated carbon to be em-ployed in promising new industrial branches such as materialsrecovery, automotive engineering, and life sciences. A showcasejoint research and development project is the cooperation bet-ween german carbon teterow GmbH and Fraunhofer UMSICHT.For the optimized performance of projects, a task force wasestablished at Teterow, Mecklenburg-Western-Pomerania.

In July 2002, five employees started research work in theBiomedical Laboratory Teterow (Biomedizinisches TechnikumTeterow BMTT). Facilities comprising 60 m2 of office area and308 m2 of laboratory area were provided with support fromthe municipal council of Teterow. As early as two months later,in September, the bench-scaled production unit designed byFraunhofer UMSICHT was commissioned, the ceremony wasattended by State Premier Harald Ringstorff. The plant isoperated continuously and is designed to produce 5 kg/h high-quality formed activated carbon.

This process excels by high flexibility in production flow. It allowsfor as many degrees of freedom as possible, resulting in flexibleprocess investigations, both optimum research conditions and thestand-alone or combined operation of instruments.Consequently, tailor-made activated carbon can be produced.

Additionally to the development of product recipesand products in gram to kilogram scale in a discon-tinuous operation mode, the continuous productionof samples in larger quantities of 120 kilogram perday is possible. Standard methods and specifictechniques to investigate chemical, physical andadsorptive parameters are provided in the labora-tories in Teterow and Oberhausen, and permit theidentification of material data necessary for designingthe process equipment. The expertise in down-stream processing of activated carbon products iscurrently being extended. The acquired technologi-cal competencies allow Fraunhofer UMSICHT tooffer all-in-one services in the field of activatedcarbon production.

ContactDipl.-Ing. Jens Sohnemann(+49 (0)2 08/85 98 -12 83)Dipl.-Ing. Toralf Goetze(+49 (0) 39 96/1 59 -3 80)Dipl.-Ing. Christian Horn(+49 (0)2 08/85 98 -11 61)

Biomedical Laboratory Teterow(Biomedizinisches TechnikumTeterow BMTT)

Material feeder of thecarbonizer


Environmental TechnologyHybrid Hollow Micro Spheres

Pure inorganic or polymeric hollow spheres oftenonly partially meet technical requirements regard-ing strength, toughness, chemical stability, etc.Hollow spheres of composite materials, structurallyinspired by biological mineralization processes,seem to be more promising in this respect. In bio-logical structures, high strength and low weight arerealized by using organic-inorganic hybrid materials.In the case of bones, a matrix of collagen is rein-forced by small inorganic crystals, yielding superiorstrength compared to the pure organic material.

In the current project, polymeric microcapsules arecombined with ceramic materials to synthesizehybrid hollow spheres. In a first step, one reactantsolution is encapsulated in microcapsules, to be fedsubsequently into a second reactant solution. Thereactants get into contact with each other throughdiffusion of the reactants through the permeablewall, and the inorganic material is formed bychemical reaction. Interpenetrating networks of theinorganic crystals in the organic matrix are formedconsequently. The microstructure of these hybridhollow spheres can be controlled by changing thepermeability which influences the mass transportthrough the capsule wall.

In the first phase of the project, different salt solu-tions were encapsulated as reactants to examinethe wall permeability. Additionally, inorganic layersof titanium oxide, using a synthesis at low tempera-tures, on capsules of polyamide and amino resinhave been precipitated in order to obtain pureinorganic hollow spheres through dissolution orburning out of the organic core.

ContactDipl.-Ing. Jürgen Bertling(+49 (0)2 08/85 98 -11 68)Dipl.-Ing. Martin Sgraja(+49 (0)2 08/85 98 -11 57)

Tailor-made withoutneedle or thread – hybridamino resin hollowspheres are microscopicbeauties

Hybrid Hollow Micro Spheres

The properties of polymers may be altered widely by using addi-tives and fillers. In this respect, hollow spheres, consisting of apolymeric or inorganic wall enclosing a gas as a core material, arepromising materials for the creation of “intelligent products”.Hollow spheres are used to reduce the weight of structural partswithout decreasing their mechanical properties. Additionally, theycan be used to increase the impact strength, to change the thermaland electrical properties as well as to manufacture foams.

Material mix and precipitationreaction are a highlight inthe synthesis of hybrid microspheres – worthwile havinga detailed look at


Environmental Technology Supercritical Fluids

Enzymatic Reactions in Supercritical Fluids

Enzymes are natural catalysts accelerating chemical reactionsin biological systems. Used in technical processes they permitthe targeted production of various substances.

Separated from their natural environment, enzymes are ableto keep their catalytic activity in different solvents and reactionconditions. Innovative processes are enzyme-catalyzed reactionsin supercritical fluids. The preferential use of e. g. compressedcarbon dioxide (CO2) as a solvent is due to an enhanced solubilityfor hydrophobic compounds compared to water and from thelow mass transfer resistance in the reaction medium.

Used in enzyme-catalyzed reactions, CO2 can be recycled.Products are separated by variation of pressure. This processis examined for the production of aroma compounds for thefood or the cosmetics industries and other fine chemicals.

A lab-scale high pressure plant was constructed for the ex-perimental investigation of the described process. A highpressure pilot plant will be used for the production of largescale test batches.

Under pressure – enzymes in aninnovative process.Precise assembly – preparing the highpressure plant for experimental use

The use of immobilized enzymes allows for the easy re-tention of the enzyme preparation in the reactor. Addi-tionally, immobilized enzymes show a higher stabilitycompared to free enzymes.

As a scientific foundation a mathematical description ofthe process is developed. Experimental studies and modelcalculations will be performed to identify suitable processparameters as pressure, temperature and concentrationof substrates. The theoretical model elaborated is valida-ted using the experimental results.

ContactDipl.-Ing. Ulrike Ehrenstein (+49 (0)2 08/85 98 -11 56)Dr.-Ing. Stephan Kabasci (+49 (0)2 08/85 98 -11 64)


Environmental TechnologyDecentralized Incineration Plants

MARS® (Modular Incineration Plant with Reduced Flue GasCleaning Residues)

Fraunhofer UMSICHT operates a decentralized incinerationplant (MARS®) in co-operation with specialized small andmedium sized plant engineering and construction companiesand the Chair for Environmental Process Engineering and PlantDesign (LUAT) of the University of Essen. The test plant isdesigned to encourage the positioning in the market of smallincineration plants allowing for an on-site energy recovery ofdifferent fuels. The plant can be operated with different fuelssince the single modules of the plant may be readily combined(e.g. the arrangement of the aggregates of the flue gascleaning).

These properties are significant in case the opera-tor intends to recover derived fuels (RDF) with highcalorific values. These fuels can be produced bymechanical-biological waste treatment plants.The energy recovery ensures the steam, heat andpower supply of industrial areas.

Technical parameters of the test plant are:• Water cooled forward-moving grate and direct

current combustion• Throughput of approximately 450 kg/h• Calorific value of the fuel ranging from 8 000 to

16 000 kJ/kg; thermal capacity of approximately1 MW

• Quasi-dry flue gas cleaning with:- Quench- Cyclone and fabric filter- Catalyst (applicable at low temperatures) with

additional ozone generator and mercury sorption

Market introduction of the MARS® plants is plannedfor 2003. Currently, the plant is tested under oper-ational conditions. The planned standard plants willdisplay the following characteristics:• Modular constructed plant with 5, 10 and 15 MWth

• Single modules will fit into normal sea containers• Water cooled grate (adjustable to the calorific

value of the fuel)• Energy recovery (power, heat or steam generation)• Simple plant assembly by combining the modules• High technical standard (compliance to EU require-

ments).

ContactDr. rer. nat. Kai Keldenich(+49 (0)2 08/85 98 -11 67)



The safe and optimal operation of in-dustrial plants and processes, and thereliable control of technical processesare fundamental for modern enterprises.By these means, the economic opera-tion as well as the compliance withsafety requirements for staff, the neigh-boring area and the environment areensured.

The department of safety and processtechnology specializes in processengineering design, in the optimizationof operation processes, and in safetyassessment of industrial equipment andprocesses. The prime objective is tosupport our customers in the develop-ment and operation of economical

Department ofSafety and Process Technology

Safety and Process Technology

Fire and water – the panoply of safetytechnology is enormous. Ranging fromsecure “playing with fire“ over the im-provement of fire prevention, all the wayto the research of currents in pipelines,a crucial prerequisite for the secure andeconomic process flow in process plants

processes which at the same time meetthe currently valid environmental andsafety requirements.

Services in the areas of plant safety, fireand explosion prevention, process ana-lytics and dynamic modelling, informa-tion and pipeline technologies are offered.The development of environmentallyfriendly software systems to be appliedin safety and process engineering for theprocess simulation serve as technicaland legal information systems represen-ting an intelligent tool combining thevarying fields of expertise.


Electrolysis as an Alternative Processfor Pool Water Disinfection

Operators of public swimming-poolshave to comply with specific require-ments that are embodied in the FederalEpidemic Law. Currently, chlorinatingthe water is the only legally alloweddisinfection method for the productionof hygienic pool water. The disinfectionchemicals used so far are based ongaseous chlorine or inorganic chlorinecompounds, which make extensiveindustrial safety and safety precautionsnecessary.

An innovative process for pool waterdisinfection is based on the electrolysisof aqueous sodium chloride solution.To this end, brine is added to the swim-ming pool water. The salt concentra-tion amounts to approx. 0.4 %. Theelectrolysis cells are integrated into thepure water pipe of the pool. Thus, theproduction of the chloric disinfectanttakes place directly in the pool water.The use and storage of chloric hazar-dous materials is no longer necessary.

Electrolysis is another method to pro-duce elemental hydrogen. However,this formally conflicts with existing rulesand regulations, according to whichhydrogen must not escape from theelectrolysis chlorine gas productionplant into the environment. At normalconditions, hydrogen is a transparent,odorless, nontoxic gas, and is easilyinflammable. It is particularly here,where a high degree of danger by theexplosiveness of hydrogen/air mixturesis observed. The lower explosion limit(LEL) is reached at approximately40,000 ppm.

The process was analyzed theoreticallyand measurements were performed toestimate the hazard risks. The massbalance of the process as well as themeasurements revealed that undernormal operation conditions, the hy-drogen concentration in the air is abouttwo orders of magnitude below theLEL. Consequently, the formation ofexplosive atmosphere can be excluded.A safety analysis demonstrated thatthe protection targets defined in legalrules are met. Further recommenda-tions regarding the reliable monitoringof the process were developed.

Electrolysis for water disinfection atthe public pool at Lünen

Safety and Process Technology Pool Water – Clean and Safe

The study conducted by FraunhoferUMSICHT has met with considerablyimproved acceptance of the processdescribed from authorities, federationsand operators. For the development ofthe process, a partnering medium-sizedenterprise was awarded the GermanHazardous Material Protection Prize.

ContactDr.-Ing. Ulrich Seifert(+49 (0)2 08/85 98 -11 27)Dr.-Ing. Jürgen Grän-Heedfeld(+49 (0)2 08/4 68 48 -3 58)


Modeling and Simulationof Process Engineering Systems


Simulation by Cell-Networks: Complex but Clear

Simulation systems support operators of process engineering plants duringthe entire life cycle of their plants: from the first planning to the productionthrough the entire process chain from the incoming orders to thedistribution of products. Appropriate models and software must comply withhighest requirements regarding integrative capacities, for the optimaldescription of the processes in the industrial context, including today’s mostcomplex technological aspcets.

In the age of the Supply Chain Management (SCM) and Computational FluidDynamics (CFD), relevant influences on the most diverse levels of productionare taken into account and looked into in a holistic way - ranging from su-perordinate logistic aspects to reaction technology of multi-phase processes.

A modeling strategy is needed that meets these various requirements. Simulationby cell-networks offers this in an outstanding way. Offering rough localdiscretization including simplified physical effects of several phases, cell-networksare capable to supply approximated information on the flow and excel by bothcomplexity and modeling depth. Besides, their clear and simple mathematicalstructure permits the integration into different software systems.

Using the cell net approach, Fraunhofer UMSICHT develops models for the simu-lation of micro-reactors, stirred tank reactors in reaction calorimeters, lab scaleplants and pilot plants. Additionally, models for continuous dryers for food indus-tries, as well as plants equipped with complex multi-phase stirred tank reactors aresimulated successfully. In addition to the application of the models, suitable simu-lation programs can be developed on demand, possibly coupled with logisticssimulators.

ContactDr.-Ing. Görge Deerberg (+49 (0)2 08/4 68 48 -3 59)Dr.-Ing. Stefan Schlüter (+49 (0)2 08/85 98 -11 26)

Caught in the net –modeling of a stirred tankreactor (disk stirrer radially)using simulated cell-net-work

(Source: Handbuch derRührtechnik, EKATO-Rühr- und MischtechnikGmbH, Schopfheim (leftpicture); MVK Medien-verlag Köhler, Tübingen(right picture)


Knowledge Transfer for Industrial Safetyand Plant Safety


Information Systems for Operational Safety andOrganization

Anyone who plans and operates process engineering plants, hasto consider numerous legal regulations of occupational safetyand environmental protection. Permanent availability as well asfast and problem-specific access to the required up-to-dateinformation are decisive for competition. Without expert know-ledge and suitable procedures neither the legally demandedmeasures can be determined nor converted into practice andbe interspersed demonstrably on all staff levels.

Modern information and communication technologies makeconcepts and systems practicable for the automatic generationof higher-ranking knowledge. They help to master operationaltasks safely and within a short time in order to protect humansand the environment. Analysis and restructuring of the relevantinformation lead to results in the developed system approachesrelative to problem-specific data concerning duties to obtaina licence requirement, condition, equipment, marking, list,operational procedures etc. Intuitive access mechanisms andinteractive manuals enhance knowledge transfer and ensurea reliable result by high user-friendliness. The knowledge-basedsystems are independent and usable as an internet/intranetsolution.

Beyond the editing of information for the pure determinationprocess, the intelligent cross-linking of more available in-houseand third-party information via intranet and internet wins in-creasingly in meaning. Based on operational data from riskassessment, documentation of plants, operating instructionsetc. linked with externally available sources of information andthe competencies in the enterprise – e.g. the fulfilment of theoperational organization obligations can be proven.

Examples are the program LAGERguide, an interactive manualfor the storage of hazardous substances and wastes, as well asthe information network DUBAnet® concerning the integratedmanagement of occupational safety and environmental protec-tion.

Enterprises using such system approaches save time and labor-consuming searches as well as long information paths.Uncertainties regarding the valid legal position of the enterpriseare omitted and liability claims can be excluded in case of damage.

ContactDipl.-Phys. Thorsten Wack (+49 (0)2 08/4 68 48 -3 50)

Measured variables on theoperational organization forthe fulfilment of relevantenvironmental and safetyrequirements

Graphically supportedcontrol of the determinationprocess in the programLAGERguide



Fire Protection Guidelines – Conciseand Comprehensible

There are about 200,000 fires in Germanhouseholds each year, which equals550 fires a day. These fires cause a deathtoll of 600 victims per year, leaving55,000 persons injured. Despite thesefigures, fire protection at home is oftenneglected, and due to a lack of riskawareness, typical hazards are oftennot identified or are simply ignored.

Most people will luckily never experiencea real fire scenario at their homes. Their»knowledge« about fires and adequatereactions in a fire situation will usuallybe taken from movies and similar sources.For reasons of entertainment, however,movie fires in many cases are presentedin a fashion which is far from real, andadequate behavior in a fire situation israrely as spectacular as the action ofmovie stars. In order both to preventthe outbreak of fires and to preventpeople from becoming fire victims, arealistic and concise information of thepublic on fire protection is mandatory.

On behalf of the Landesinstitut fuerBauwesen NRW (State Building Insti-tute), Fraunhofer UMSICHT has de-veloped Guidelines for Fire Protectionat Home. The guidelines presentedaim at providing basic informationto interested persons and may helpidentify potential fire hazards, rea-listically assess the related risks andprevent unnecessary risks.

The principles of fire development andspreading are described and illustrated.Using checklists, the reader may betteridentify potential hazards in differentrooms of his home. Additional infor-mation is presented on safe rescue pathsand the use of technical devices suchas smoke alarms.

Finally, the reader is given advice onhow to deal with a real fire situation,including measures of fire extingui-shing, on how to alarm the fire brigadeand some basic rules on whether to”stay or escape?”.

The Guidelines have been designed topresent basic information about firesand fire prevention in a technically

“She lit a match, it was so nice! It crackled so, itburned so clear, – exactly like the picture here.“(Extract from Heinrich Hoffmann ‘s “The DreadfulStory of Pauline and the Matches“)

Not only at Struwwelpeter ’s times illustrationshelped to memorize the advice given.

Guidelines for Fire Protection at Home

correct, easy and comprehensiblemanner. Valuable advice and additionalinformation has been supplied by theexpert members of the advisory board,to which we are indebted.

The “Guidelines for Fire Protection atHome” will be published in 2003 by theLandesinstitut fuer Bauwesen.

ContactDr.-Ing. U. Seifert(+49 (0)2 08/85 98 -11 27)Dipl.-Ing. J. Stein(+49 (0)2 08/85 98 -11 28)Dipl.-Ing. S. Springer(+49 (0)2 08/85 98 -11 35)



Plant Documentation – The Operator’s View on LegalSecurity

With the information system RMO (regularization managementoperator of modules) of the Trisium AG, which is based on theplant documentation system Comos PT of the company Innotec,the plant operator can use an ergonomic tool for the plantlifecycle management. In this system the from the operator’s viewessential fields of plant documentation and process docu-mentation merge. With conventional tools they must be regar-ded separately and serviced. Outstanding characteristics are:

• Storage of plant, material and process data in a central database to avoid data redundancies

• Separated examination of plants and processes followed by aflexible linkage, by which in particular plants in batch processedoperation fitting (multi-product plants) can be documentedefficiently

• Support of systematics for investigation of danger in anyrequired detail depth, demanded by the Hazardous IncidentOrdinance

• Flexible analysis mechanisms including visual feedbacks on R+Iflow sheets

Fraunhofer UMSICHT develops further RMO detail componentswith the Chair for plant design and safety technology of theTechnical University Cottbus (BTU). It concerns:

• Reciprocal effect stencils for the collection of the material/material and material/process material behavior and

• Interfaces to simulation programs for the observation ofleaking out and propagation behavior.

Material/materialreciprocal effect matrixin dependence of thetemperature

Data Processing Support of Plant Documentation

Reciprocal effect stencils are realized in existing softwareproducts as two-dimensional relations structures, this iswhy an analysis of material combinations is not possibleas a function of process conditions. The RMO system,however, offers the possibility of illustrating the dimensio-nality of the reciprocal effects in the complexity wantedby the user e.g. material/material reciprocal effects independence of arbitrarily defined temperature ranges orpressure ratios. This quantitatively and qualitatively freedesignation of reciprocal effects permits an individualdescription of the environment conditions and its con-nections. The entire analysis is carried out on the basis ofa plant-related tree structure.

The user surface offers comfortable drag&drop supportand makes possible a spontaneous overview of potentialweak and danger spots in a plant. Furthermore it can beinserted smoothly into the structure of the market-esta-blished system Comos PT/RMO.

ContactDipl.-Phys. Thorsten Wack (+49 (0)2 08/4 68 48 -3 50)

Setting and selectionof the conditionparameters


Analysis and Design of Pipeline Networks andPipeline Components

Work under pressure:Pilot plant pipeline system atFraunhofer UMSICHT (detail)


ABS and KAVITAS for Safety Pipelines

Transient flow in pipeline systems(pressure surges) may lead to danger-ous operating conditions that put a riskon human life and environment.Depending on the industrial branches,different operation conditions as con-tact condensation of steam and water(power stations), sudden changes ofliquid velocity (water, chemical industry)or plug flow (oil and gas) can lead toso-called water, cavitational and con-densation hammer. This is why calcu-lations of pressure surges in pipelinesystems should be integrated into thedesign of process plants. The advan-tages are: improved design for safetyaspects, capacity and availability of thecomplete system.In many cases, cost-effective measurescan be taken in the early design stage

to obtain an optimum plant construc-tion. The use of bladder accumulators,surge tanks, or the new Fraunhoferdevelopments ABS-Armatur® or KAVITAS

for preventing or attenuating pressuresurges, can considerably increase safetyconditions in already existing plants.

Furthermore, fluid and structure dyna-mic processes which are significant forthe construction of pipelines in processplants can be predicted by using suit-able simulation codes.

The entire service range of FraunhoferUMSICHT comprises planning, calcu-lation (static, dynamic), design andoptimization of pipelines, valve tests,leakage detection and on-site measure-ment of pressure and force (pressure

surge detection), and prevention ofpressure surges using ABS-Armatur®(prevention of pressure surges) andKAVITAS (prevention of cavitationalhammer). Expertise studies for thesafety and availability of pipe-linescomplement the offer.

Using a large test rig PPP (Pmax = 140bar, Tmax = 180 °C), software calculationcan be evaluated and validated. Thanksto the close collaboration with otherresearch institutes and industrial part-ners, research and testing work can beperformed using the most modernmeasurement and analysis equipment.

ContactDr.-Ing. Andreas Dudlik(+49 (0)2 08/85 98 -11 25)



Fraunhofer UMSICHT supports busi-nesses in successfully positioningthemselves on the converted energymarket. Efficient system solutions arethe center of application-orientedactivities in an innovative combinedheat-power-cold generation (CHCP).Here, Fraunhofer UMSICHT concen-trates on smart energy technology:efficient, local, customer-oriented,and flexible.New technologies (e.g. fuel cells, micro-turbines, gas processing), renewableenergies (e.g. biomass fuel, solar andgeothermal recovery), as well as non-standard fuels (e.g. refuse derived fuels(RDF), special gases) are being appliedin modular local power generationplants: And in the future, our know-how in the area of combined heat-power-cold supply will be expanded bytechnologies for the prevention andreduction of emissions harmful to theclimate.

Based on its market and costs know-how, Fraunhofer UMSICHT offers ener-gy analyses and concepts, IT consulting,and design engineering.Customized studies and policy studiesround off our profile. Already today, wedevelop emission trading projects, andfurthermore, Fraunhofer UMSICHT isable to provide energy consumptionmeasuring, and CAD, GIS, and CFDapplications according to our customers’needs. We are involved in creatinginformation portals and develop toolsfor the support of the operationalbusiness of energy supply companies:an integrated energy managementsoftware is being launched onto themarket at present, and new productsfor the risk protection and portfoliooptimization, as well as the strategicgeneration planning are in the state ofcreation.

Department ofEnergy Technology

Energy Technology

Descending for innovative energy technology –the sea bottom is where you can find them:gas hydrates enclose gases at high pressuresand low temperatures in a crystal cagestructure, and store twice as much carbonas all other fossil fuels togeher


Smart Energy Engineering – Decentralized and VirtualEnergy Technology

Smart Technology, Intelligent Communication and Control

Smart energy technologies are characterized by high efficiency(e.g. CHP) and various applicability. Their modular structureallows for multiple linkage via both physical nets (power, heating,cold supply etc.) and IT networks and for the cooperation ofmanufacturer and customer groups to elaborate a timetable andrisk management.

Active demand side management, peak shifting, peak shavingand virtual power stations are varieties of modern energy manage-ment. Fraunhofer UMSICHT develops new applications andsystem solutions and is particularly dedicated to the develop-ment, demonstration and market introduction of decentralizedheat-cold power-cogeneration (CHP) such as fuel cells, microturbines, micro thermo chiller and small-scale steam power andORC processes. The service range also comprises the supply andprocessing of special fuels (e.g. special gases, refuse derivedfuel).

Fuel Cells and Micro Turbines in System Solutions

Commissioning the demonstration plant of the PEM-Oberhausenproject in August 2002, constructed in a cooperation projectwith industrial partners, Fraunhofer UMSICHT has gone over topowering the institute’s entire facilities by using power-heat-coldcogeneration, based on natural gas and renewable mine gas.The power supply system comprising PEM fuel cell, micro turbineand a gas engine cogeneration unit, provides the power andheat supply. A power quality unit is capable to meet highestquality requirements in power supply and permits conceptualinvestigations. The control and IT system comprises convenientvisualization, remote control and the testing of most diversifiedmodes of operation (e.g. heat/power-oriented, timetable) throughto isolated operation.

Fraunhofer UMSICHT develops solutions for the fuel preparationusing regenerative special gases in fuel cells. Based on efficientgas analysis technology for the submicron range, portable gaspurification modules and MCFC test status preliminary investi-gations, tailored to specific customer needs, can be performed.

In the field of micro turbines, R&D work focuses on the stableoperation with lean gases, promising applications using hightemperature level of low emissions exhaust gases, and the de-velopment of virtual power stations powered by micro turbines.

ContactDr.-Ing. Ralf Hiller (+49 (0)2 08/85 98 -12 73)

Production modules in the demonstrationproject PEM-OberhausenFuel cell: 212 kWelPQ-Unit: 100 kVAGas production: 75 Nm3/hMicro turbine: 100 kWelEngine CHP: 469 kWel

www.pem-oberhausen.de


Solar Driven Refrigeration

Thermally driven refrigeration systemssupply cold energy using heat as motiveenergy. This heat can be obtained fromsolar energy, combined heat and powersystems or waste heat sources.

Fraunhofer UMSICHT optimizes thedesign and the operation of refrigera-tion systems focusing on innovativeprocesses which are run through vacu-um tube or parabolic through collec-tors, and promotes the developmentand standardization of new thermallydriven processes as the steam jet ejec-tor chiller.

Since August 2002, a solar driven H2O-LiBr-absorption chiller has been run atthe premises of Fraunhofer UMSICHT,providing the cold energy for air condi-tioning and process application.Extending the cold supply systems byan ice-slurry refrigeration and steam jetejection chiller is being planned.

Utilities of Refrigeration

In addition to an economical heatproduction and an efficient refrigera-tion, thermally driven cold supplysystems require optimized utilities forrefrigeration (in particular re-cooling,process water), an optimized controlconcept and operation (for examplepower management, free cooling).Fraunhofer UMSICHT offers suitableengineering and consulting servicesfounded on analyses, in addition tonew processes.

Phase Change Materials andAdvanced Fluids

Storage and distribution innovationsare required particularly for energy-intensive cooling. Fraunhofer UMSICHTexamines the use of advanced fluid andphase change materials for storage andtransport of cooling energy. Furtherstudies are conducted on the use ofparaffin for latent cooling storage from6 to 12 °C and the production and useof ice slurries for the cooling distributionfrom -10 to 0 °C. An ongoing study isdedicated to the conceptual analysis ofnew logistic distribution systems forcooling on the basis of mobile coolingstorage. Currently, the laboratory ofFraunhofer UMSICHT is being equippedwith an ice slurry cooling system for theair supply.

ContactDipl.-Ing. Peter Noeres(+49 (0)2 08/85 98 -11 87)Dr.-Ing. Christian Dötsch(+49 (0)2 08/85 98 -11 95)

Steam jet cold andparabolic throughcollectors for innovativecold production(Source: DLR Köln-Wahn)

Innovative Methods of Cold Supply

Guiding Beams – not only well-known and popular from StarTrekand similar movie pictures:in refrigeration technology, laserbeams ensure the correct mixing inthe Ice Slurry plant. Only this waythe coolant CryoSol® can efficientlystore the cold and reduce load peaks

Energy Technology


Energy Technology

Finalization of the Process Development and Novel Applications

Supported and sponsored by the German Federal Ministry of Consumer Protec-tion, Food, and Agriculture in cooperation with industrial partners, a technologyfor biomass conversion based on fluidized bed gasification has been developed fora study initiated in 1994. The integration of proven process components for theconceptual design, as well as the development of the appropriate gas conditioningsystem and accurate optimization work were the road to success. Several continu-ous test runs at a pilot plant on the institute’s premises have approved the perfor-mance and efficiency expected of the process.

The required gas quality may be achieved without wet scrubbing through catalyticreforming of inherent tars, which also increases the heating value. The combina-tion of the CFB-gasifier’s appropriate operation, the catalytic reformer and a fabricbag filter guarantee a constant level of residual inherent tars in the gas below thecritical value of 50 mg/m3 (s.T.p.). A 4,000 hour-test run with the catalytic reformeris currently prepared to be carried out at a commercial gasification plant.

Pre-commercialdemonstration plantwith 5.0 MW fuel input,corresponding to1.45 MWel

The gasification technology is predominantly designed for un-contaminated biomass feedstocks such as wood chips, tree bark,lumber shavings etc. The fluidized bed technology yields a veryconstant gas generation. The target power range for commercialapplication is 10-15 MW fuel capacity which equals 14,000-21,000 t/a bio mass consumption. This yields a 3-5 MW poweroutput. Economic assessments reveal attractive potential biofuel prices for this technology if the green power revenues maybe completed by significant heat sales. Further testing anddemonstration work is going to start in 2003 when launchingthe construction of a pre-commercial plant.

Applications Development

Fraunhofer UMSICHT will focus future activities on novelapplications for fluidized bed gasification such as sewagesludge or RDF gasification and combination of gasifiers withkilns. Micro turbines might be another suitable application.

ContactDr.-Ing. Markus Ising (+49 (0)2 08/85 98 -11 89)

Green Power and Heat Through Wood Gasification


EnergyDataManagement andEnergy Information Portals

Energy Technology

Modern Processing of Energy Data

EnergyDataManagement aims at decision support in acomplex techno-economical field. Modeling in optimization,prognosis and simulation is based on data acquisition,analysis and aggregation. These tasks are integrated inthe software system “EnergyManager”, which has beensuccessfully implemented at the DREWAG StadtwerkeDresden in 2001. “EnergyManager” provides resourceplanning tools in scheduling, contract management andtrading. Currently, this tool is extended by a method forthe automatic optimization of energy portfolios.

In the field of district heating, an algorithm for the aggre-gation of network structures has been developed, whichallows for the optimal control of dynamic processes likeheat storage in the network.

GIS and Energy Information Portals

Fraunhofer UMSICHT actively designs energy informationportals for partners from the energy industry (e.g. energie.de,nahwaerme-forum.de) and elaborates geographical infor-mation systems (GIS) using data systems presenting space-oriented energy information.

ContactDipl.-Ing. Michael Lucht (+49 (0)2 08/85 98 -11 83)Dipl.-Ing. Clemens Backhaus (+49 (0)2 08/85 98 -11 88)

Portfolio-Optimization –optimal application ofenergy supply contractsand futures

Evaluating energy data andrepresent them for ”pointsof interest” in maps


Environmental Protection and Emissions TradingEnergy Technology

Energy Management, Concept Evaluations, Gas Separation

Active climate protection requires the reduction or removal ofenvironmentally hazardous emissions. Carbon dioxide separationand attachment contribute to the emissions reduction equally aseconomical energy use, efficient application of existing utilitysystems, decentralized couple supply, regenerative energies aswell as efficiency optimization using innovative energy engineer-ing technologies. Fraunhofer UMSICHT develops and examinesprocesses, operation and control measures for the decrease andprevention of greenhouse gas emissions. Studies are performedon the applicability of substitute fuels, including the evaluation ofnew processes and sub-processes as well as the development ofgas separation process technologies.

Increasing Use of Coal Mine Gas (CMM) in the Ruhr Area

Coal mine gas derived from hard coal pits contains methanewhich has a high relative global warming potential (GWP) of21. Fraunhofer UMSICHT has initiated the use of coal mine gasfrom abandoned mines, which was expanding significantly after

Emission Trading, joint im-plementation und cleandevelopment mechanism –emissions reduction by usingflexible mechanisms of thekyoto-protocol (source: DBU)

Support in allocation/stock-taking, screening of technicalprocesses for emissions reductionand support in emissions trading(source: DBU)

the Act on EEG came into force (EEG = ErneuerbareEnergie Gesetz = Renewable Energy Law, whichguarantees prices for power production).In late 2002, there was an installed power supply ofaround 58 MW in the Ruhr area. Greenhouse gasemissions equaling around 1.7 million tons of CO2 p.a.could thus be prevented. Future revenues from emissionstrading will enable even small projects to yield majorbenefits. Inquiries from throughout the world, in parti-cular from Eastern European countries, demonstratethe international interest in this technology. FraunhoferUMSICHT supports the ”Landesinitiative Zukunftsener-gien NRW” (Governmental institution for developingfuture energy projects) and the “InteressenverbandGrubengas e.V.” (Association of Coal Mine Gas).

Emissions Trading

Fraunhofer UMSICHT is a founding member of theBundesverband Emissionshandel (German EmissionsTrading Association) and offers consulting services forthe start-up, development, approval, and trading ofemissions reduction projects. This includes theeconomical and ecological assessment of the projects aswell as the preparation of baseline studies andapplications for project certification on customers’order.

ContactDr.-Ing. Christian Dötsch (+49 (0)2 08/85 98 -11 95)Dipl.-Ing. Clemens Backhaus (+49 (0)2 08/85 98 -11 88)


With Energy to the Customer Energy Technology

Optimized energy coststhrough efficient appli-cation of conventionaland regenerative boilers

Energy Consulting, Energy Analysis and Innovative EnergySupply Concepts

Innovative power supply concepts bring added value to thecustomer. Environmental protection, cost reduction, optimizedoperation and capital investment grants are the predominantobjectives of consulting services offered by Fraunhofer UMSICHT.Project evaluations are performed to ensure security for projectinitiators and funding parties, concentrating on feasibility studies,expert auditing reviews, and risk assessments on energy, econo-mical and process technology aspects.

Early integration into current planning and assessment of con-ventional and innovative solutions open large optimization po-tential. Power-heat-cold co-generation (CHP), heat pumps, ther-mal cooling, geothermal potentials, line-bound heating and coldsupply as well as waste heat recovery are among the core com-petencies of Fraunhofer UMSICHT.

Another benefit is the co-operative work among UMSICHTdepartments which facilitates the elaboration of all-in-oneconcepts, covering the fields of energy, water, wastewater, andwaste technologies through safety at work and fire protection.

For special-contract customers and large-scale, decentralized pro-duction plants such as wood power stations, tailor-made conceptson demand have yielded optimized results both in economicaland technological respects. Fraunhofer UMSICHT will continuously

adjust its services to the requirements of specificenergy customers (e.g. recreational centers, sportsstadium operators, hospitals, zoological parks,planners of restructuring projects).

More than Consulting: Innovative TechnologicalServices

Thorough and well researched information on time,place and causes of energy demand, compiled inenergy analyses is needed for transparency and foroptimized operation. The range of FraunhoferUMSICHT comprises leakage search duringoperation, pipeline simulation, a pressure surgesimulation, and GIS mapping for water and long-distance heating pipelines.

Starting from the results of energy analyses, follow-up planning is performed project-specifically.Specially trained engineers at UMSICHT elaboratethe detail planning and control the testing and supplyof innovative systems.

In 2002, Fraunhofer UMSICHT cooperated in theconstruction of four additional biogas plants andcould thus significantly participate in encouragingbiogas utilization in power supply.

ContactDr.-Ing. Christian Dötsch (+49 (0)2 08/85 98 -11 95)Dipl.-Ing. Adam Hadulla (+49 (0)2 08/85 98 -11 94)



The department of knowledge andtechnology transfer is dedicated tobringing the broad range of inno-vations elaborated at the Instituteto the market.

The distribution to the market is per-formed through the transfer of know-how (vocational training), throughtechnology transfer across the nationalborders (international project develop-ment) and through application of ourknow-how and experience in spin-offenterprises. On request, direct consult-ing services are offered to customersin the areas of R&D projecting and theimplementation of innovative techniques.

Department of Knowledge and Technology Transfer

Knowledge and Technology Transfer

On the path totransnational andinterdisciplinaryknowledge transfer



Globalization and the growing international competition representthe challenge of today’s economic and cultural activities. Scientificestablishments as well are subject to the competition resultingfrom the positioning and asserting in an international environment.Establishing the department of “International Project Development“at Fraunhofer UMSICHT in 1997 has been one measure to respondto this development.

The department focuses on internal and external services in thefields of scientific and economical co-operation responding to therequirements of the scheduled enlargement of the EuropeanUnion. The German-Polish Research Network INCREASE andthe North Rhine-Westphalian Initiative for Foreign Economy arenetworking platforms to ministries, scientific and economic or-ganizations providing assistance to internal and external cus-tomers.

Over the past few years, activities at Fraunhofer UMSICHT havebeen focusing on regions in Central and Eastern Europe, whereasnow these activities are being expanded to other countries.

3rd INCREASE-seminarin Warsaw, June 2001(left to right: Prof. Górak,Prof. Buzek, Doc. Buzek,MR Schlicht)

INCREASE

“Addressing current environmental problems and con-tributing to the improvement of German-Polish relationsthrough co-operation in collaboration projects”. This isthe guideline of INCREASE (International Cooperation onResearch in Environmental Protection, Process Safety andEnergy Technology), established at Warsaw in 1997.Today, over 30 scientific institutions of both countries areincorporated in the INCREASE network.

A variety of projects in co-operation or on behalf ofthe industrial partners from both countries have beencarried out by the INCREASE members. The topics aremainly related to the environmental protection andenergy technologies sector. Two head offices – under thedirection of the chairmen of the Steering Committee,Prof. Dr.-Ing. Andrzej Górak (University of Dortmund),and Prof. Dr.-Ing. Stanislaw Ledakowicz (TU Lódz) –are coordinating the INCREASE activities.

Fraunhofer UMSICHT is involved in a variety of German-Polish collaboration projects and is the German HeadOffice of INCREASE. The Polish Head Office is based atthe Polish Academy of Sciences in Gliwice.

International Project Development


International Project Development Knowledge and Technology Transfer

North Rhine-Westphalian Action Program for CEEC countries

The North Rhine-Westphalian Action Program for CEEC countriesis a bilateral initiative between political institutions and industrialenterprises in North Rhine-Westphalia (NRW). Work is realized inpublic-private-partnership (ppp) structure, so far unique, whichserves as the networking platform for enterprises in the environ-mental, transport and energy technologies sectors based through-out NRW which collaborate closely with the Ministry of EconomicAffairs, Energy and Transport (MWMEV) of the State of NRW.

The objective of the initiative is facilitating the initiation of projectsin the CEEC countries Hungary, Czech Republic, Romania, andPoland, to support the IN.NRW AG partners, as part of the pppstructure. The shareholders are supported in a project group,consisting of four enterprises, and co-ordination agencies hostedin the target countries. The main working areas are environmen-tal and energy related sectors, transport and funding issues aswell as issues related to political implementation.

The political basis of the CEEC initiative is the”Agreement on Mutual Economic Co-Operation”that is being issued jointly from the State of NRWand the target countries or regions. Since thelaunching of the initiative in January 2001, a coupleof agreements have been signed. According to therequirements outlined therein, early project infor-mation is being researched and made available tothe IN.NRW AG members. Additional practicalsupport to the enterprises is supplied through theprovision of qualified local project partners. Theshareholders may profit from many competitiveadvantages.

In spite of the relatively short time which has elapsedsince this CEEC initiative was created, work has al-ready shown substantial success. One of the IN.NRWAG members, a well-known engineering agency,succeeded in placing a large order in one of thetarget countries. Other shareholders expect firstoffers as a result of an application submitted jointlywith local business partners – first successes thatare well suitable to demonstrate that the programhas been well introduced. As a result, 14 newenterprises could be won to buy shares in theIN.NRW AG to profit from the many advantagesoffered.

ContactDr.-Ing. Barbara Zeidler(+49 (0)2 08/85 98 -11 43)Dipl.-Biol. Volker Knappertsbusch(+49 (0)2 08/85 98 -12 32)

Representatives of the Moravia Silesia region, (Czech Republic)visiting the UMSICHT institute:Dipl.-Ing. Wantula, Vice Regional President (3rd from the left),Doc.RNDr. Ing. Mrázek (5th from the left), Chairman of theInternational Committee of the Region Parliament; Mayor ofOpava, and Dipl.-Ing. Tosenovský, President of the Region ofMoravia-Silesia, Mr Helmut Czichy, Head of the EnvironmentalProtection Board of the City of Oberhausen (at the right)


TheoPrax® presents a practice- andsystem-oriented education modeltargeted at the early linking of theoryand practice in learning. The programdates back to 1998 when it was intro-duced by the Fraunhofer ICT (Institutefor Chemical Technology) at Pfinztal.Since then it has been very successfullyapplied in the state of Baden-Württem-berg. During a nation-wide extension, aTheoPrax® communication center wasestablished at Fraunhofer UMSICHT,with the objective to introduce theTheoPrax® network in the greaterRhine-Ruhr region.

How does TheoPrax® work?

Fraunhofer UMSICHT acts as a regionalcommunication platform in the net-working between industrial enterprisesand schools/universities. Interdisciplinaryworking groups are formed amongstudents to work on process engineer-ing related problems set by the indus-trial partners. The workshops are co-

ordinated by UMSICHT and tutored bythe Institute’s experienced engineeringand research staff.

What are the Benefits of TheoPrax®?

TheoPrax® provides an early basic un-derstanding of real world work andhelps students develop key practicalskills such as creativity, conflict manage-ment, communicative and team skillsand other soft skills. When enteringtheir professional career, students arebetter prepared and know what isreally required in practice. TheoPrax®

projects thus give employers an idealopportunity to present their profile andto select and recruit qualified futurestaff.

In March 2002, the first official TheoPrax®

project was organized jointly by Fraun-hofer UMSICHT, the Chair of Environ-mental Technology at the University ofDortmund, the Elsa-Brändström-High-school in Oberhausen, and the BabcockBorsig Energy GmbH. The project wasperformed in a two week in-houseworkshop at UMSICHT: seven studentsenrolled at Dortmund university andthree junior students of the Elsa-Bränd-ström-high school collaboratively workedout a Germany-wide overview of biogasprocessing plants and biogas technolo-gies currently available.

ContactDipl.-Ing. Anja Gerstenmeier(+49 (0)2 08/85 98 -11 11)

Senior and juniorstudents are taughtto comprehend realworld work

TheoPrax®

Knowledge and Technology Transfer Learning on the Job – the TheoPrax® Model



In collaboration with the FernUniversität Hagen (Open University),a German distance learning institution, Fraunhofer UMSICHT hasintroduced the interdisciplinary distance learning programEnvironmental Sciences (infernum) in November 2000.This four-semester course aims at providing updated, practical andcomprehensive environmental know-how to students both in theirown and related disciplines and is equally designed for engineers aswell as for scientists, economists and graduates from humanities andlaw. The students are trained in interdisciplinary skills, which are in-dispensable for solving complex environmental problems.

From the winter term of 2002/2003, the ”Master of EnvironmentalSciences” degree is being offered to students. Infernum is to date theonly Master study in the field of environmental studies available inGermany.

infernum has encountered wide-spread interest and acceptance bothnationally and internationally, for instance from Austria, Switzerland,the U.S., China, and South Africa. Students enrolled display a varietyof qualifications from different disciplines, ranging from engineering,sciences business studies and economy, medicine, theology to educa-tional sciences.

DisziplinübergreifendeZusammenarbeit istVoraussetzung fürnachhaltigen Umwelt-schutz

In-house seminars that are regularly conducted at Ober-hausen offer the opportunity to meet fellow studentsand teaching staff, and to deepen the knowledge gainedthrough interdisciplinary workshops and lectures. In2002, a total of six meetings were held and have beenmet with great success among all participants.

Regularly, the Hochschulgesellschaft Oberhausen e. V.awards scholarships for the infernum course. The scholar-ship holders stand out by high scientific qualification anda special personal or professional commitment to mattersof environmental protection and sustainable development.

The innovative training model infernum has becomean important building block in the scientific life ofthe Rhine-Ruhr area, acting as a transregional pole ofattraction for the site of Oberhausen.

ContactDipl.-Ing. Anja Gerstenmeier (+49 (0)2 08/85 98 -11 11)

infernum

Distance Learning Program Environmental Sciences

Interdisciplinary cooperationis a prerequisite forsustainable environmentalprotection


Project Funding


Projects and ventures tobecome building blocks andnot stumbling blocks –Fraunhofer UMSICHT offersconsulting services intransnational project fundingsolutions

Project Funding/Spin-offs

Project Funding

In addition to the classic services offeredin research and development, the pro-curement and access to funding resour-ces is a rather newly emerging field ofactivity.

However, the term project funding hereis not to be regarded in the narrowmeaning of the word, describing thedirect participation of a sponsor in aproject to ensure the credit granted viathe cash flow. As a matter of fact, therange of capital procurement, that maybe required to perform research anddevelopment services encompasses awide variety of activities, such asventure capital, public funding or loansgranted by banks that have to beprovided in order to make project workstart.

Besides the “economical” rates of re-turn, future project work will be influ-enced increasingly by ecological criteria(as formulated in the Kyoto Protocol).This is reflected already now in thespecialization of some banks or in theincrease of relevant funds.

Successfully realizing both technologi-cally and economically challenging pro-jects in collaboration with FraunhoferUMSICHT thus means to face the risingdemands. To this end, we offer solutionstailored to the needs of our R&D custo-mers, meeting requirements such asenergy efficiency, production-integratedenvironmental protection and the safemanagement and implementation ofindustrial processes.

Additionally to public and private spon-soring, numerous contacts to banks,”Business Angels” as well as to invest-ment and venture capital companieshave been established for the jointprovision of capital with customers,which will essentially benefit the rea-lization of projects.



”Congratulations” –The idea is excellent,business plan andfinancing are perfect –everything is readyfor launching theenterprise

Spin-offs

Project Funding/Spin-offs

For a showcase European project, tar-geted at the generation of renewableenergies, the provision of capital has tobe realized through participation of aninvestment company. The actual re-venues of the project may only coverthe operating costs. Consequently,additional income has to be achieved,in particular by the creation and marke-ting of emission certificates, in order tomake a potential investor participate insponsoring. Multilateral meetings todiscuss these issues are currently underway.

Spin-offs

The support of spin-offs from researchinstitutions is a core objective of theFraunhofer Society. Complementary tothe classic activities of contract research,this is to pave new paths for the transferof know-how and the marketing ofresearch results.

The measures to facilitate spin-offenterprises range from raising specialfunds for first equipment to the pro-curement of capital to co-finance furthertraining for spin-off enterprises in thefields of business planning or marketresearch.

The outsourcing of know-how or scien-tific results from Fraunhofer institutes isof significance, and also necessary, inthose cases where a marketable producthas been achieved. The marketing ofproducts in serial production may notbe executed in-house, as given by theFraunhofer rules and regulations.

Spin-offs with industrial partners arerealized in those cases where commonresearch results are to be brought tothe market.

Currently, there are 10 spin-off enter-prises from Fraunhofer UMSICHT whichare present on the market.

The most recent spin-off enterpriseis the DataPool Engineering GmbHcompany in Oberhausen, which isdedicated to software development,system analysis, and the related ITconsulting services.

ContactDipl.-Ing. Christian Wolf(+49 (0)2 08/85 98 -11 70)Dr.-Ing. Bernhard Dietz(+49 (0)2 08/85 98 -11 07)



Schultz, H. J.; Deerberg, G.;Schlüter, S.; Fahlenkamp, H.*:Program for the Simulation of GasHydrate EquilibriumGeotechnologien, Science Report, GasHydrates in the Geosystem, Status Se-minar; Kiel 6-7 May 2002,p. 116-118; ISSN 1619-7399* University of Dortmund

Schultz, H. J.; Deerberg, G.;Schlüter, S.; Fahlenkamp, H.*:Simulation of the Oceanic Gas Hy-drate Removal using the Mammoth-Pump-PrincipleGeotechnologien, Science Report, GasHydrates in the Geosystem, Status Se-minar; Kiel 6-7 May 2002,p. 113-115; ISSN 1619-7399* University of Dortmund

Spangardt, G.; Lucht, M.; Althaus, W.:Optimisation of Physical andFinancial Power Purchase Portfolioswww.optimization-online.org/DB_FILE/2002/10/550.pdf; (2002)

Weber, A.; Weiss, C.; Kümmel, R.:Crystallization in Compressed Gases –yet another Sprayprocess?In: Walzel, P. (Ed.): Proceedings “SprayDrying 01 and Related Processes“; Dort-mund 8-10 October 2001, p. 156-160;ISBN 3-8265-9922-5

Weiß, C.; Hennig, T.; Kümmel, R.:A Single Droplet Model to DescribeSpray Drying ProcessesIn: Walzel, P. (Ed.): Proceedings “SprayDrying 01 and Related Processes“; Dort-mund 8-10 October 2001, p. 16-22;ISBN 3-8265-9922-5

Wigbels, M.; Lucht, M.:Oberhausen District Heating SystemIn: Bøhm, B. (Ed.): “Simple Models forOperational Optimisation“, IEA Report2002: p. 1; Kopenhagen 2002;ISBN 90-5748-021-2

Publications

Chun, S. J. L.*; Wilkinson, G. T.*;Weber, A.:Recovery of Volatile Essential Oilsfrom Citron (Citrus junos) Peel withSupercritical Carbon DioxideProceedings of the 8th Meeting onSupercritical Fluids, Chemical Reactivityand Material Processing in SupercriticalFluids; Bordeaux, France 14-17 April2002, Paper E10. ISAFS, Tome 2,p. 879-884; ISBN 2-905267-34-8*Pukyong National University, Pusan,Korea

Dudlik, A.; Schönfeld, S. B. H.;Schlüter, S.; Fahlenkamp, H.*;Prasser, H.-M.**:Prevention of Water Hammer andCavitational Hammer in PipelineSystemsChemical Engineering and Technology25 (2002) 9, p. 889-890* University of Dortmund** Research center Rossendorf

Hiebel, M.; Bruinsma, A.;Keldenich, K.:Identification of optimization po-tential for thermal waste treatmentplants in Europe with the help ofbenchmarkingIn: VDI-GVC Preprints Konferenz»Die Zukunft der Abfallwirtschaft inEuropa«; Strasbourgh, France,7-8 October 2002, p. 235-238

Ising, M.; Unger, C.; Heinz, A.;Althaus, W.:Cogeneration from BiomassGasification by Producer Gas-DrivenBlock Heat and Power Plants

Bibliographic Survey of Activities

Proceedings of the 12th EuropeanConference and Technology Exhibitionon Biomass for Energy, Industry andClimate Protection; Amsterdam,Netherlands, 17-21 June 2002,p. 1 003-1 036

Issa, M.; Robert, J.; Denecke, M.*;Kümmel, R.:Water re-use in practice: closedloops in food industry, wastewaterreduction in composting plants,wastewater re-use for irrigationpurposesConference Reader of the 12. Euro-Arab Environmental Conference;Rostock 10-12 October 2002, p. 47-52* University of Essen, chair for WasteManagement

Kabasci, S., Kümmel, R.:Biogas – Energy from RenewableResourcesConference Reader “Days of TechnicalChemistry“; Veszprém, Hungary,16-18 April 2002, p. 17-18

Kapfenberger, J.; Sohnemann, J.;Schleitzer, D.; Loewen, A.*:Acid Gas Removal by CustomizedSorbents for Integrated GasificationFuel Cell SystemsConference Proceedings of the 5th Inter-national Symposium on Gas Cleaningat High Temperatures; Morgantown,West Virginia, USA, 17-20 September2002* Fraunhofer Center for Energy andEnvironment, Pittsburgh, PA, USA

Scheelhase, T.*; Bidlingmaier, W.*;Klümper, A.*; Maile, A.*;Rechberger, M.:Geotechnical Behaviour of Mechani-cally-Biologically Pretreated ResidualWasteIn: Christensen, T. H.; Cossu, R.;Stegmann, R. (Ed.): Proceedings of the8th International Waste Managementand Landfill Symposium;S. Margherita di Pula, Cagliari, Italy,1-5 October 2001* University of Essen, chair for WasteManagement

The following survey only includeslectures and publications which werewritten and/or delivered in English.For a complete bibliography, see theGerman version of our publication list2001.


Bundesministerium für Bildung, Wissen-schaft, Forschung und Technologie,Bonn

Bundesministerium für Wirtschaft undTechnologie, Bonn/Berlin

BWS Technologie GmbH, Grevenbroich

C.A.R.M.E.N. e.V., Straubing

CentrO Management GmbH,Oberhausen

Ciba Spezialitätenchemie LampertheimGmbH, Lampertheim

Clariant GmbH, Hürth-Knapsack

CP Kelco Germany GmbH & Co. KG,Hamburg

DBU, Deutsche Bundesstiftung Umwelt,Osnabrück

Degussa AG, Darmstadt/Frankfurt/Hanau-Wolfgang

Degussa INFRACOR GmbH, Marl

Delft University of Technology,Laboratory for Process Equipment,Delft, Netherlands

DELU, Deutsche Leckageortungs- undUmwelttechnik AG, Düsseldorf

De Lucia Italienische Feinkost-spezialitäten GmbH, Heiden

Deutsche Bank AG, InnovationsteamUmwelttechnologie, Munich

Deutsche Projekt Union GmbH,Cologne

Deutsche Structured Finance,Frankfurt a. M.

Deutz Energy GmbH, Mannheim


Selected Clients and Contacts

A. + E. Lindenberg GmbH & Co. KG,Bergisch Gladbach

ACCESS e.V., Aachen

ACROSS FINANCE AND TRADE GmbH,Hamburg

ADAC Test und Umwelt, Munich

AG Solar NRW, Jülich

Andritz AG, Vienna, Austria

AiF, Arbeitsgemeinschaft industriellerForschungsvereinigungen “Otto vonGuericke“ e.V., Cologne

AIR PRODUCTS GmbH, Hattingen andBasingstoke, Great Britain

Air Products PLC, Basingstoke,Hampshire

Akzo Nobel Central Research b.v.,Arnhem, Netherlands

Akzo Nobel Chemicals GmbH,Emmerich

AKZO Nobel, Sweden

ALSTOM Ballard GmbH, Bremen/Dortmund/Frankfurt

Altenburger Maschinen JäckeringGmbH, Hamm

Ansaldo Fuell Cells SpA (AFCo),Genova, Italy

ARCHITEC Architektur, Städtebau,Projektentwicklung, Rostock

A-TEC Anlagentechnik GmbH,Duisburg

Atofina Deutschland GmbH, Bonn

ATT Automationstechnik GmbH,Lutherstadt Wittenberg

AWAS-Ihne GmbH, Wilnsdorf

Axima Refrigeration GmbH, LindauBodensee

BASF AG, Ludwigshafen

Bauordnungsamt Aachen, Aachen

Bau- und Liegenschaftsbetriebe,Aachen and Dortmund

Baust Holzbetrieb GmbH, Eslohe-Bremke

Bayer AG, Leverkusen

Bayer 04 Leverkusen Fußball GmbH,Leverkusen

Behr & Partner, Schwerte

Benteler AG, Paderborn

Bezirksregierung Arnsberg, AbteilungEnergie, Arnsberg

BLB NRW, Bau- und Liegenschafts-betrieb NRW Düsseldorf, Düsseldorf

Boehringer Ingelheim Pharma KG,Ingelheim am Rhein

BRZ Bodenreinigungszentrum HerneGmbH & Co. KG, Herne

BTU, Brandenburgische TechnischeUniversität, Cottbus

Bückmann GmbH Sieb- undSeparationstechnik, Mönchengladbach

Bundesamt für Sicherheit in derInformationstechnik, Bonn



DFG, Deutsche Forschungsgemein-schaft, Bonn

DLR, Deutsche Forschungsanstalt fürLuft- und Raumfahrt e.V., Cologne/Bonn

DLR – Projektträger des BMBF fürInformationstechnik, Berlin

DMT, Deutsche Montan TechnologieGmbH, Bochum

DREWAG Stadtwerke Dresden GmbH,Dresden

Durit Hartmetall, Wuppertal

EdF, Electricité de France, Paris,France

EFA, Effizienz-Agentur NRW, Duisburg

EGG, Energieversorgung Gera GmbH,Gera

Empresa de Servicios TecnológicosLtda., Concepción, Chile

Empresarios Agrupados, Madrid,Spain

Entwicklungsgesellschaft Neu-Ober-hausen mbH – ENO, Oberhausen

Energieagentur NRW, Wuppertal

ENR, Energiegesellschaft nachwachsen-der Rohstoffe mbH, Dorsten

essent Milieu, Buggenum, Netherlands

E.ON Engineering GmbH, Gelsenkirchen

Europäische Kommission – Generaldi-rektion Enterprises, Brussels, Belgium

EUS GmbH, Dortmund

EVO, Energieversorgung OberhausenAG, Oberhausen

Fachhochschule Münster

Fachhochschule Niederrhein, Krefeld

famatic biotech energy AG, Nortorf

Fardis GmbH, Unna

FernUniversität GesamthochschuleHagen

FEE GmbH, Idar-Oberstein

Fernwärme Wien Ges.m.b.H., Vienna,Austria

fiatec Filter & Aerosol TechnologieGmbH, Mainleus

FKuR - Forschung und EngineeringGmbH, Willich

FN, Fernwärmeversorgung NiederrheinGmbH, Dinslaken

FNR, Fachagentur NachwachsendeRohstoffe e.V., Gülzow

Forschungszentrum Jülich GmbH, Jülich

Framatome ANP, Offenbach

Fritz Winter GmbH, Stadtallendorf

Fröschle Stahl- und MaschinenbauGmbH, Neusaess/Vogelsang

FW-Fernwärme-Technik GmbH, Celle

FZR-Forschungszentrum Rossendorf,Dresden

G.A.S. Energietechnologie GmbH,Krefeld

gct german carbon teterow GmbH,Teterow

GEA AG, Bochum

GEA Jetpumps GmbH, Ettlingen

GE Bayer Silicones GmbH & Co. KG,Leverkusen

GEfAS, Gesellschaft für Anlagenbauund Service mbH, Oberhausen

GEF, Gesellschaft für Energietechnikund Fernwärme mbH, Leimen

Gemeinde Greußenheim (Bayern)

Gesellschaft für TechnischeZusammenarbeit (GTZ) GmbH,Eschborn

GIGATON GmbH, Viernheim

Gmelich + Söhne GmbH, Großbottwar

Goshen Critech Corp., Seoul, Korea

H. Anger’s Söhne GmbH, HessischLichtenau

Hansa Consult mbH, Glinde

HdT Haus der Technik e.V., Essen

Heller Leder GmbH & Co. KG, Hehlen

Henkel KGaA, Düsseldorf

Herbold GmbH Meckesheim,Meckesheim

HEW, Hamburgische ElectricitätswerkeAG, Hamburg

Hosokawa Micron GmbH, Cologne

H.U.T. Heuwieser UmwelttechnikGmbH, Linsengericht

Hydac Technologie GmbH, Sulzbach/Saar

IEA, Internationale Energieagentur,Paris, France

IKA-Werke GmbH & CO. KG, Staufen


MTS Machinery Tools & Services AG,Oetwil am See, Switzerland

MVV InnoTec Systemanalyse GmbH,Berlin

Naue Fasertechnik GmbH & Co.KG,Lübbecke

NEUENHAUSER MaschinenbauGmbH & Co. KG, Neuenhaus

Nivelsteiner Sandwerke GmbH,Herzogenrath

Noll GmbH, Cologne

Norwegian University of Science andTechnology Trondheim, Trondheim,Norway

NOVEM, Nederlandse maatschappijvoor energie en milieu bv, Sittard,Netherlands

Novopart GmbH, Krefeld

n.s.w.energy gmbh, Herzogenrath

Ostendorf Biogas GmbH, Südlohn

Parsum GmbH, Chemnitz

Perlinger GmbH, Furth

Polytherm GmbH, Ochtrup

Pro2 Anlagentechnik GmbH, Willich/Dresden

Projektträger BEO (Biologie, Energie,Umwelt) des BMBF und des BMWI,Jülich

Provico GmbH & Co. KG, Nordhorn

Pulsar GmbH, Stuttgart

Rathgen-Forschungslabor, Berlin

RBG Strüder GmbH, Iserlohn


INEOS Phenol GmbH & Co. KG,Gladbeck

INFRASERV Dienstleistungen GeraGmbH, Gera

Ingenieurbüro Prof. Brachetti, SpringeInstitut für Marktscheidewesen, RWTHAachen, Aachen

Institute for Environmental Science andEngineering, Singapore

Institute for Refactory MaterialsGliwice, Poland

Interdisziplinäre Dortmunder Energie-forschung, DIE e.V., Dortmund

Isobrugg Stahlmantelroht GmbH, Lehrte

IUTA, Institut für Energie- und Umwelt-technik e.V. Duisburg

Jenbacher AG, Jenbach

Jenbacher Energiesysteme GmbH,Mannheim

Johnson Controls GmbH, Burscheid/Grefrath

Jülich Fine Chemicals, Jülich

Kautex Textron GmbH + Co. KG, Bonn

KFKI Atomic Energy Research Institute,Budapest, Hungary

KITECH, Korea Institute of IndustrialTechnology, South Korea

Koch AG, Wallisellen, Switzerland

Kompetenz-Netzwerk BrennstoffzelleNRW, Düsseldorf

Krupp Uhde GmbH, Dortmund

Landesinstitut für Bauwesen desLandes NRW (LB), Aachen

Landgericht Heilbronn, Heilbronn

Laserzentrum Münster, Münster

LEM, Ingenieurbüro Last- und Energie-management, Leipzig

Loick AG, Dorsten

LUA, Landesumweltamt Nordrhein-Westfalen, Essen

LÜNTEC, Technologiezentrum LünenGmbH, Lünen

Malvern GmbH, Herrenberg

Mann + Hummel GmbH, Speyer

MAT-TEC Engineering GmbH, Willich

Materialprüfungsamt NRW, Erwitte

Medizinische Einrichtungen der HeinrichHeine Universität, Düsseldorf

Merck KGaA, Darmstadt

Metall-Technik GmbH, Düsseldorf

Milupa GmbH, Friedrichsdorf

Ministerium für Schule, Wissenschaftund Forschung des Landes NRW(MSWF), Düsseldorf

Ministerium für Umwelt und Natur-schutz, Landwirtschaft undVerbraucherschutz des Landes NRW(MUNLV), Düsseldorf

Ministerium für Arbeit, Soziales, Quali-fikation und Technologie des LandesNRW (MASQT), Düsseldorf

Ministerium für Verkehr, Energie undLandesplanung des Landes NRW(MVEL), Düsseldorf

Mogensen GmbH & Co KG, Wedel



Research Institute of Chemical andProcess Engineering, Veszprem,Hungary

Rethmann Rohstoff GmbH, Nordwalde

Retsch GmbH & Co. KG, Haan

Rettenmeier AG, Wilburgstetten

Ruhrgas AG, Essen

Ruhr-Universität Bochum, Institut fürThermo- und Fluiddynamik

RWTH Aachen, Institut für Aufbereitungund Recycling fester Abfallstoffe

Saarberg Fernwärme GmbH,Saarbrücken

Schering AG, Bergkamen

Siemens AG ISS, Karlsruhe

SILOXA AG, Essen

Solarc GmbH, Berlin

Stadt Bergheim

Stadtwerke Bochum GmbH

Stadtwerke Dinslaken GmbH

Stadtwerke Duisburg AG

Stadtwerke Frankfurt/Main AG

Stadtwerke Hannover AG

Stadtwerke Herne AG

Stadtwerke Lünen GmbH

STEAG, Essen

Studsvik Scandpower AS, Kjeller,Norway

TECHNIP Deutschland GMBH,Düsseldorf

Technical University of Lodz, Faculty ofProcess and Environmental Engineering,Lodz, Poland

Technische Akademie Esslingen

Technische Fachhochschule Bochum

Technische Universität Wien, Institut fürVerfahrens-, Brennstoff- und Umwelt-technik, Vienna, Austria

Technoplast Engineering AG,Diepoldsau, Switzerland

Technopool SchwimmbadtechnologieGmbH, Bissendorf

TODA KOGYO Europe GmbH,Düsseldorf

Tractebel, Brussels, Belgium

TU Bergakademie Freiberg, Institut fürEnergieverfahrenstechnik undChemieingenieurwesen

Uhde Hochdrucktechnik GmbH, Hagen

Umweltbundesamt, Berlin

Universidad de Concepción,Facultad de Ingeniería Industrial, Chile

Universidad de Concepción,Unidad de Desarrollo Tecnológico,Chile

Unikliniken in Bonn, Düsseldorf,Cologne, Dortmund

Universität des Saarlandes, FachbereichPharmazeutische und MedizinischeChemie

Universität Dortmund, Lehrstuhl fürEnergieprozesstechnik

Universität Dortmund, Lehrstuhl fürThermische Verfahrenstechnik

Universität Dortmund, Lehrstuhl fürUmwelttechnik

Gerhard-Mercator-Universität Duisburg,Fachgebiet Instrumentelle Analytik

Universität Essen, Lehrstuhl für Um-weltverfahrenstechnik und Anlagen-technik

Universität Essen, Lehrstuhl für Abfall-wirtschaft und Abfalltechnik

Universität Essen, Lehrstuhl für Techni-sche Chemie

Universität Köln, Institut für Physikali-sche Chemie, Cologne

Universität Rostock, Abteilung für Ana-lytische, technische und Umweltchemie

Universität Siegen, Institut für Fluid-und Thermodynamik

University of Pittsburgh, School ofEngineering, Pittsburgh, Pennsylvania,USA

Urenco Deutschland GmbH

VdS Schadenverhütung, Cologne

Volkswagen AG, Wolfsburg

WAM Technik GmbH, Hilden

WEIMA Maschinenbau GmbH, Ilsfeld

Westfalia Foodtec GmbH, Oelde

Wupperverband, Wuppertal

ZERMA ZerkleinerungsmaschinenbauGmbH, Sinsheim-Dühren



DataPool Engineering GmbH,OberhausenSoftware development, system analy-ses, EDP-consulting

ENR – Energiegesellschaft nachwach-sende Rohstoffe mbH, DorstenPlanning and set-up of biogas plants,including consulting, concession, andfunding; agricultural nutrient balancesand area management; commissioningand management

FKuR Forschung und EngineeringGmbH, WillichInnovative solutions concerningplastics and recycling; comminutiontechnology; extrusion, injectionmolding; elastomer recycling; materialanalyses; test technology; recyclingconcepts

gct german carbon teterow GmbH,TeterowDevelopment and production of high-performance cylindrical activatedcarbon; production of special activatedcarbons; development of adsorptionprocesses

invenio KUNSTSTOFF ENGINEERING,ErwitteProduct development and optimizationof plastics components with numericalanalyses; FEM structure analyses, in-jection molding analyses; construction

VENTAX Big-Bag NetworkGmbH & Co. KG, WillichBig-Bag cleaning facilities, reusable Big-Bag, packaging systems

WAGRO Systemdichtungen GmbH,DortmundExpansible polymere seals; sewer andbuilding refurbishment; consultation,planning, and implementation;development and production of sealingsystems (area of application:engineering and pipeline construction)

Patents 2002

Issued Patents:

Process for the production of nano-scale solid materials in powder form(Weber)

Arrangement for PreventingUndesirable Pressures when Blockingoff or Throttling the Transport of Liquidin a Pipeline (Prasser, Schlüter, Dudlik)

Diaper with a pH-sensitive super-absorber (Groß, Wack, Althaus)

Trademarks:

PEM-Oberhausen (symbol and wordtrademark)

Human Life Park (word trademark)

BrandO. (word trademark)

SOLARCTIC (word trademark)

Human World(International word trademark)

Human Park(International word trademark)

Spin-offs

Andreas Schröder IT-ConsultingGmbH, SchermbeckCounseling and service in the area ofinformation and telecommunicationtechnologies

A-TEC Anlagentechnik GmbH,DuisburgInnovative solutions concerning coalmine gas; hazard prevention: analyses,extraction, safety concepts; utilizationfor power and heat generation: energyconcepts, design and operation of plants


How to Find Us

By car

Freeway A 42: Exit Oberhausen-Oster-feld/Neue Mitte. At the end of the exitturn onto Osterfelder Straße towards“Neue Mitte“ or Oberhausen-Zentrum/Essen respectively. Follow the road forapproximately 1,5 km (behind the sign“Fraunhofer UMSICHT“) turn left intothe parking lot of the institute.

Freeway A40: Exit Mülheim-Dümpten;coming from Dortmund turn right atthe end of the exit. At the nextintersection turn left onto MellinghoferStraße and at its end turn left ontoEssener Straße. At the next majorintersection turn right onto OsterfelderStraße. At the first traffic light turnright into the parking lot.

Address

Fraunhofer UMSICHT

Director:Prof. Dr. rer. nat. Rolf KümmelDirector Science and Technology:Dr.-Ing. Görge DeerbergDirector Business and Administration:Dr.-Ing. Bernhard Dietz

Osterfelder Straße 346047 Oberhausen

Phone: + 49 (0)2 08/85 98 -0Fax: + 49 (0)2 08/85 98 -12 90

Office “Essener Straße“:Essener Straße 9946047 Oberhausen

Phone: + 49 (0)2 08/46 84 8 -0Fax: + 49 (0)2 08/46 84 8 -3 63

Website: www.umsicht.fhg.deE-mail: [email protected]

By train

From Oberhausen Central station toUMSICHT with bus no. 185 (directionEssen Borbeck Bf.), bus no. 957(direction Kiebitzstraße), no. 958(direction Spechtstraße) to bus stop“UMSICHT“

By plane and train/car

From Düsseldorf Airport terminal A/B/Ctake the Skytrain to Düsseldorf AirportStation, then change to the RegionalExpress to Hamm or Wesel respec-tively. Leave the train at OberhausenCentral Station; to continue see:By train or if you are traveling by cartake Freeway A 44 from the airport tillyou reach intersection “Düsseldorf-Nord“. Take freeway A 52 (directionEssen/Oberhausen). At intersection“Breitscheid“ change onto freewayA 3 and keep going until you get tointersection “Oberhausen West“;From there turn onto freeway A 42(direction “Dortmund“) and take theexit “Oberhausen-Osterfeld/NeueMitte“; to continue see: by car.


The Fraunhofer-Gesellschaft


The Fraunhofer-Gesellschaftundertakes applied research of directutility to private and public enterpriseand of wide benefit to society. Itsservices are solicited by customers andcontractual partners in industry, theservice sector and public administration.The organization also accepts com-missions and funding from Germanfederal and Länder ministries andgovernment departments to participatein future-oriented research projectswith the aim of finding innovativesolutions to issues concerning theindustrial economy and demandsfaced by society in general.

By developing technological inno-vations and novel systems solutionsfor their customers, the FraunhoferInstitutes help to reinforce thecompetitive strength of the economyin their local region, and throughoutGermany and Europe. Through theirwork, they aim to promote theeconomic development of industrialsociety, paying particular regard tosocial and environmental concerns.

The Fraunhofer- Gesellschaft

As an employer, the Fraunhofer-Gesellschaft offers a platform thatenables its staff to acquire thenecessary professional and personalqualifications to assume positions ofresponsibility within their Institute, inindustry and in other scientificdomains.

At present, the Fraunhofer-Gesellschaftmaintains roughly 80 research units,including 57 Fraunhofer Institutes, atover 40 different locations inGermany. A staff of some 13,000,predominantly qualified scientists andengineers, work with an annualresearch budget of around one billioneuros. Of this sum, approximately€900 million is generated throughcontract research. Roughly two thirdsof the Fraunhofer-Gesellschaft’scontract research revenue is derivedfrom contracts with industry and frompublicly financed research projects.The remaining one third is contributedby the German federal and Ländergovernments, asa means of enabling the Institutes topursue more fundamental research inareas that are likely to become rele-vant to industry and society in five orten years’ time.



��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

!"��

�"��

��

��

#��

�$��%&��

��"��

��'(��

&�� )$��

&��

#��$��

��

*"��

+�,$�$$��$��

!��

#��

+��

)��

��

��

-��

��(��

Affiliated Research Centers and LiaisonOffices in Europe, the USA and Asiaprovide contact with the regions ofgreatest importance to future scientificprogress and economic development.

The Fraunhofer-Gesellschaft was foun-ded in 1949 and is a recognized non-profit organization. Its members in-clude well-known companies andprivate patrons who help to shapethe Fraunhofer-Gesellschaft’s researchpolicy and strategic development.

The organization takes its name fromJoseph von Fraunhofer (1787-1826),the illustrious Munich researcher,inventor and entrepreneur.


Board of Trustees – Fraunhofer UMSICHT

Trustees

Ernst GerlachChairman(Landesbank NRW,Member of the board,Düsseldorf)

Burkhard Drescher(Mayor of the cityOberhausen,Oberhausen)

Dr. Jochen Hamatschek(Westfalia SeparatorFood Tec GmbH,Managing Director,Oelde)

Jörg Hennerkes(North Rhine-WestphalianMinistry of Economy and Work,State Secretary, Düsseldorf)

Prof. Dr.-Ing. Helmut Hoyer(The FernUniversity of Hagen,Principal, Hagen)

Dr.-Ing. Harald Irmer(North Rhine-Westphalia StateEnvironment Agency NRW,President, Essen)

Dr. Gerd Jäger(RWE Power AG, Member ofthe Board, Essen)

Dr.-Ing. Karl-Ulrich Köhler(ThyssenKrupp Stahl AG,Chairman of the Board,Duisburg)

Hartmut Krebs(North Rhine-WestphalianMinistry of Science andResearch, State Secretary,Düsseldorf)

Hubert Loick(Loick Holding AG,Chairman of the Board,Dorsten)

Dr.-Ing. Thomas Mathenia(EnergieversorgungOberhausen AG, Memberof the Board, Oberhausen)

Prof. Dr.-Ing. Thomas Melin(RWTH Aachen, Head of Chair I andthe Institute of Process Engineeringof RWTH Aachen, Aachen)

Prof. Dr.-Ing. Volker Pilz(Bayer AG, Director for Securityof Site Services/retired since 8/2002,Leverkusen)

Dr. rer. nat. Franz-Josef Renneke(Schering AG, Plant Manager,Bergkamen)

Dr. iur. Jürgen Rüttgers(Chairman of the CDU-parliamentaryParty NRW, Vice Chairman ofCDU Germany, Düsseldorf)

Dr.-Ing. Andreas Schütte(Agency of Renewable Resources(FNR) e.V., Managing Director,Gülzow)

Udo Völker(Ferrostaal AG, ChiefRepresentative, Essen)

The set-up meeting of the Board of Trusteestook place on 13 December 2002 at FraunhoferUMSICHT in Oberhausen.


Fraunhofer Institute forEnvironmental, Safety, andEnergy Technology UMSICHT

Director:Prof. Dr. rer. nat. Rolf KümmelDirector Science and Technology:Dr.-Ing. Görge DeerbergDirector Business and Administration:Dr.-Ing. Bernhard Dietz

Osterfelder Straße 346047 Oberhausen

Phone + 49 (0)2 08/85 98 -0Fax + 49 (0)2 08/85 98 -12 90

Website www.umsicht.fhg.deE-mail [email protected]

Editing & Layout:Dr.-Ing. H. Pflaum (responsible),S. Althoff, C. Beier,Dr. rer. nat. J. Danzig, I. Kumpmann,B. Vatter

Printed by:Frank Zelle Medientechnik, DüsseldorfThe paper used for this report wasbleached without chlorine.

Copyright: Fraunhofer UMSICHTConcept, layout:Fraunhofer UMSICHTSources of photographies:DBU: p. 44; DLR: p. 41; EKATO-Rühr- undMischtechnik GmbH: p. 33;Koch AG Verbrennungstechnik: p. 29;Medienverlag Köhler, Tübingen: p. 33Roland Punge: p. 23all other photographies:© Fraunhofer UMSICHT

Use of photographies, graphicsand texts in any form – even inextracts – only by previous writtenpermission by Fraunhofer UMSICHT

Imprint

Department of Environmental Technology

Department ofSafety and Process Technology

Department of Energy Technology

Department ofKnowledge and Technology Transfer

Directorate

Your contact persons

Documents

Annual Report 2002 - Fraunhofer UMSICHT - Energie ... UMSICHT Annual Report 2002 Competencies Six areas of expertise are the basis of the process-technological operation in the business