annual report 2003 - fraunhofer

UMSICHT Annual Report 2003 1

Annual Report2003

2 UMSICHT Annual Report 2003

The Institute

Preface 4Highlights 2003 6The Fraunhofer Institute for Environmental, Safety, and 8Energy Technology UMSICHTOrganizational Chart 9Competencies and Business Units 10Experiencing Development: In Dialogue with Dr.-Ing. Görge Deerberg 16Guidelines 18Between Expertise and Market: Strategic Planning 20Chemistry and Analytics 22Biotechnological Laboratory 23Marketing, Communication, Business Development 24IT Management 25Central Technical Facilities 26Library 27Fraunhofer Center Pittsburgh 28

Business Unit Environmental Technology

Adsorbents and Supercritical Fluids 32Mikro-Sieves and Confocal Microscopy 33Plastics Recycling 34Modeling of Spray Drying 35Environmental Technology in Chile 36Bottom Ashes 37

Business Unit Safety and Process Technology

Hot Smoke Tests 40Safety Concepts 41Pipeline Networks 42Information Networks 43Process Simulation 44Guideline for the Storage of Hazardous Substances 45

Contents


Business Unit Energy Technology

Cleaning of Sewage and Landfill Gas 48Energy from Low BTU Gases 49Gas Cleaning for the Use in Fuel Cells 50Cooling and Latent Cooling Energy Storage 51Supply Networks 52Climate Protection and Emissions Trading 53

Business Unit Knowledge andTechnology Transfer

International Project Development 56North Rhine-Westphalian Action Program for CEEC 57Learning on the Job – the TheoPrax® Model 58Distance Learning Program Environmental Sciences (infernum) 59Sound Immission Survey 60Environment – Technology – Recreation 61

Names, Data, Events

Publications 64Selected Clients and Contacts 65Patents 68Spin-offs 68How to Find Us 69The Fraunhofer-Gesellschaft 70Board of Trustees 72Imprint 73


Preface

The year 2003 was not all plain sailing forFraunhofer UMSICHT. Changed business environ-ments confronted us with the tasks of makingnecessary adjustments and initiating a process ofgradual strategic reorientation, without giving upour traditional strength concerning industrial re-turns and the aim of increasing scientific excellency.

Most notably, the public returns did not developin a satisfactory manner. One reason is that ourcompetitors on the R&D-market have been moresuccessful in some sectors. On the other hand,several promising projects could not be taken upas a consequence of financial shortages in publicspending even though all necessary positive ex-

pert opinions had been at hand. Oftentimes, the processing of applications for fun-ding takes much too long. The current volume of orders and the scope of ordersreceived give reason to expect noticable improvement for 2004.

We have started our own innovation offensive with a detailed analysis of the per-formance of our areas of expertise and a definition of central topics. Topics such as“Vision Energy 21”, “Bio-refinery”, “Intelligent Interfaces”, and “Networks” havebeen developed, and form the scientific backbone of a new business unit structurethat we are planning to implement at the beginning of 2004. These fields of workalso establish a basis for pilot projects of the type of the biogas plant Wissen Castle,for initiatives such as the Coal Mine Gas Days 2003, and the UMSICHT-Days “Biorefined!”, for the emissions trading training “Jupiter”, or for the BMBF-project“Aqua-latina”, that will open up the Latin American water and waste managementmarket for German technology suppliers. All of them will be our contribution tostrengthen the location North Rhine-Westphalia and will add to the strength of theFraunhofer Alliance “Production” that we are affiliated with since February 2003.


Strategic considerations played an important role in the past year. A detailed draftof the UMSICHT strategy plan for the coming five to ten years was completed.Progress was made in personnel and topical coupling with the universities of theRuhr area. There are clear concepts of bringing in our core competence processengineering with its constituting actors into the business model of the Fraunhofer-Gesellschaft. In North Rhine-Westphalia we are a valued contact of governmentdepartments, authorities, offices, technology and transfer centers respectively.Our activities abroad – in central and Eastern Europe, in Latin America, East Asia,and the Middle East have been expanded. The interdisciplinary distance learningprogram environmental sciences (infernum) that was started in the winter semesterof 2000/01 in co-operation with the open university in Hagen has been accreditedand now enables scholars to attain the degree “Master of Science”.

The Annual Report 2003 illustrates the Institute’s potential by means of a fewselected examples. This potential is based upon the creativity and optimism of ourstaff, and the encouragement by our numerous business partners and supporters.My special thanks go to all of them.

With kind regards

Yours

Rolf KümmelDirector Fraunhofer UMSICHT


In February, Stadtwerke Herne AG andFraunhofer UMSICHT give the symbolicstarting signal for emissions trading inGermany: Deputizing for Federal Ministerfor the Environment Jürgen Trittin, Minis-terial Counsellor Franzjosef Schafhausenaccepts the first subscription warranton one ton of carbon dioxide reductionat the international trade fair “E-worldenergy & water 2003”.

Under the topic “Bio – refined”things are centered around re-newable energies in July. Toursthrough laboratories and technicalworkshops fascinate pupils andteachers alike.

“Home match” for MinisterBärbel Höhn*: At theinternational “World Water Day”(March 22, 2003) citizens find outall about “the refreshing liquid”in the shopping mall CentrO.

*North Rhine-Westphalian Minister ofEnvironment, Conservation, Agriculture andConsumer Protection

Already for the third time, morethan 100 international guestsfrom research and practicecatch up on the chances of theclimate friendly energy sourcecoal mine gas in the context ofthe “Grubengastage 2003” (coalmine gas days) that are carriedout under the patronage of theBMU (Federal Ministry of theEnvironment).


Highlights 2003

German environmental technologyis in great demand in Asia:A contract between the Japanesecompany NEECO Inc. andFraunhofer UMSICHT on bench-marking of a waste incinerationplant is signed at the trade fair“Entsorga” in September.

Noblesse oblige – at the estates ofWissen Castle (Weeze at the LowerRhine) a biogas plant that generatespower from pig manure and renewableenergies, is officially inaugurated in July.

Fraunhofer UMSICHT goes international:In October, the focus is on water andwaste water technologies, solar coolingand energy generation at the QWETEXtrade fair in Qatar.


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 units 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 270 employees produced a turn-over of more than 23 m € in 2003.More than 50 % of this from industrialorders.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

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Core Competencies and Business Units


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

New Processes

Analysis of conventional production processes; development of low-emission syntheses; cristallization bymeans of supercritical fluids; microreaction technologyContact: Dr. rer. nat. Joachim Danzig; Phone: +49 2 08/85 98 -11 45; [email protected]

Particle Technology

Particle technology; crystallization processes; comminution; micro-encapsulation; spray drying; separation;sample processingContact: Dipl.-Ing. Jürgen Bertling; Phone: +49 2 08/85 98 -11 68; [email protected]

Adsorption/Gas Cleaning

Flue gas cleaning; gas washing and adsorption; catalytic conversion of gaseous airborne contaminants;production and characterization of adsorbents; adsorber modelingContact: Dr. rer. nat. Kai Keldenich; Phone: +49 2 08/85 98 -11 67; [email protected]

Six core competencies are the basis of the process-technological work in the business units.They find application in the project and theme-oriented areas of expertise.

Core Competencies

• Process and application development• Studies, expertises, and surveys for decision-making processes (process engineering, market)• Planning, construction, and operation of pilot and demonstration plants (PD plants)• System analysis, system technology• Software for process engineering• Project development and financing


Business Units

Waste Technology and Waste Management

Thermal waste treatment; waste reprocessing; waste confectioning; utilization of residues; looping;optimization of thermal processes; simulation of waste treatment processes; material flow managementContact: Dr. rer. nat. Kai Keldenich; Phone: +49 2 08/85 98 -11 67; [email protected]

Plastics Technology

Polymers from renewable materials; biodegradable polymers; product development; material, production, andrecycling-oriented design; computation; prototypes; material development; compounding; injection molding;extrusion; mechanical and rheological material testing; recycling concepts; market and technology studiesContact: Dr.-Ing. Edmund Dolfen; Phone: +49 21 54/92 51 -51; [email protected]

Bioengineering

Synthesis of valuable materials; reprocessing of biotechnological products; modeling; biological sewagetreatment, waste air and solid waste treatment; production of biogasContact: Dr.-Ing. Stephan Kabasci; Phone: +49 2 08/85 98 -11 64; [email protected]

Water Treatment/Membrane Technology

Development of new areas of application in membrane technology; linking of process water streams;reprocessing of pickling acids with membrane-combined processes; filtration of sewage system dischargefor the re-utilization of waterContact: Dipl.-Ing. Josef Robert; Phone: +49 2 08/85 98 -11 50; [email protected]

Special Polymers

Temperature sensitive/hydrophilic gels, superabsorbers, thermo chromate; syntheses; productcharacterization; analytics; application technologyContact: Dipl.-Ing. Holger Wack; Phone: +49 2 08/85 98 -11 21; [email protected]

Chemistry, Biology, Analytics

Thermal analysis; reaction calorimetry; rheological examinations; particle size distribution; testing ofcontaminants and summary parameters; characterization of products and residues; testing and online-analyses for processing systems; biological testing processes; analysis of organic materials; isolation ofcombined and pure-culture microorganisms; determination of combustion productsContact: Dr. rer. nat. Thomas Marzi; Phone: +49 2 08/85 98 -12 30; [email protected]: Dr. rer. nat. Ute Merrettig-Bruns; Phone: +49 2 08/85 98 -12 29; [email protected]


Business Units


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

Safety Analysis and Design

Safety of plants and plant components; transport and storage safety; safety analyses in compliancewith German regulations; thermal analysesContact: Dr.-Ing. Ulrich Seifert; Phone: +49 2 08/85 98 -11 27; [email protected]

Dynamic Processes

Pattern recognition; process control system protection and mitigation planning; model-basedmeasuring methods; simulation of plants and scheduling of production processes; substance dataprovision; layout/evaluation of ethoxylation processes; application of commercial simulation softwareContact: Dr.-Ing. Görge Deerberg; Phone: +49 2 08/85 98 -12 69; [email protected]

Software Development

GUI (graphical user interface) for Windows-NT and X-Windows systems; database technologies;client-server solutions; generic systems; software designContact: Dipl.-Phys. Thorsten Wack; Phone: +49 2 08/85 98 -12 78; [email protected]

Fire Safety and Explosion Protection

Fire safety concepts for buildings, smoke extraction; material behavior; fire and explosionprecaution policies for technical plants; consulting for fire brigadesContact: Dr.-Ing. Ulrich Seifert; Tel.: +49 (0) 2 08/85 98 -11 27; [email protected]

Technical Information Management

Information management for system security and process technology; advice concerning the stateof technology; support in legal permission procedures; graphically supported and dialog-basedguidelines; full-text information systems; e-commerce solutionsContact: Dipl.-Phys. Thorsten Wack; Phone: +49 2 08/85 98 -12 78; [email protected]

Pipeline Technology

Pipeline test area (temperature up to 200 °C, pressure up to 140 bar); water and cavitationhammer; layout of pipeline systemsContact: Dr.-Ing. Andreas Dudlik; Phone: +49 2 08/85 98 -11 25; [email protected]


Business Units


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

Use of Lean Gas

Coal mine gas (CMM); landfill gas; biogas; hazardous gases; thermal utilization concepts; burner technology,emission controlContact: Dipl.-Ing. Clemens Backhaus; Phone: +49 2 08/85 98 -11 88; [email protected]

District Heating/CHP (Combined Heat and Power Generation)

Generation; distribution; network concepts; GIS; leakage localization; energy supply concepts; solar/geo-thermal energies; local heating; refrigerants (ice-slurry); expert reports; energy trading; efficiency; energypoliciesContact: Dr.-Ing. Christian Dötsch; Phone: +49 2 08/85 98 -11 95; [email protected]

Cold Supply

Cold supply technologies; thermal cold production; steam jet refrigeration plants; cold storage and distribution;air conditioning technology; combined heat, cold and power generation (CHPC); solar thermal refrigeration;energy supply conceptsContact: Dipl.-Ing. Peter Noeres; Phone: +49 2 08/85 98 -11 87; [email protected]

Energy Management

Energy management; energy trading; power plant planning; optimized co-generation; IT solutions for energynetworks (consulting, realization)Contact: Dipl.-Ing. Michael Lucht; Phone: +49 2 08/85 98 -11 83; [email protected]

Energy from Biomass

Re-utilization concepts; power generation; combustion; gasification; gas generation using fluidized bedcombustion (FBC); hot gas and tar analytical testingContact: Dr.-Ing. Markus Ising; Phone: +49 2 08/85 98 -11 89; [email protected]

Fuel Cell Systems

Fuel cell systems: PEFC, MCFC, SOFC; regenerative gases, gas separation technology, system modeling andanalysis, flue bed combustion, computational fluid dynamics (CFD)Contact: Dr.-Ing. Ralf Hiller; Phone: +49 2 08/85 98 -12 73; [email protected]


Plant Systems Engineering

Process control and visualization; planning, construction and operation of pilot and demonstration plants;heating, refrigerating, and air conditioning technologiesContact: Dipl.-Ing. Adam Hadulla; Phone: +49 2 08/85 98 -11 94; [email protected]

Business Unit Knowledge and Technology Transfer

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

International Project Development

Head office of the German-Polish research association INCREASE; cooperation in the North Rhine-West-phalian action program for the promotion of external trade with central and Eastern European countriesCEEC; scientific alliances and business cooperation; consulting services to central and Eastern Europeancountries; European Union projectsContact: Dr.-Ing. Barbara Zeidler; Phone: +49 2 08/85 98 -11 43; [email protected]

Training Center

Knowledge, know-how, and expertise transfer; distance studies program Environmental Sciences (infernum);network programs with schools, universities, and private enterprises; vocational training programs; customizedcourses for industry; multi-media learning; seminars, workshops; coursesContact: Dipl.-Ing. Anja Gerstenmeier; Phone: +49 2 08/85 98 -11 11; [email protected]

Project funding/Spin-offs

Combined and single project funding; implementation of pilot and demonstration projects; financial support;consulting services to spin-off enterprises; finding business partnersContact: Dipl.-Ing. Christian Wolf; Phone: +49 2 08/85 98 -11 70; [email protected]

Administration

Human resources; project monitoring; research contracts; budgeting; purchasing; accountancy; business trips;infrastructure; controlingContact: Dipl.-Betriebswirt Andreas Weber; Phone: +49 2 08/85 98 -12 26; [email protected]

Business Units

Infrastructure


Business Units

Marketing, Communication, Business Development

Innovation management; market surveys and technology studies; project development; marketing concepts;sales; business field policies; strategic planning; intellectual property rights; public relations; compositionand layout of print media; media work; information medium internetContact: Dr.-Ing. Hartmut Pflaum; Phone: +49 2 08/85 98 -11 71; [email protected]: Dipl.-Chem. Iris Kumpmann; Phone: +49 2 08/85 98 -12 00; [email protected]

IT Management

Support of the IT infrastructure; user help desk; highly-efficient servers and services; software design;installation and support of LAN and WAN; development of web-applications; training of IT specialists;consulting in IT-specific projectsContact: Dipl.-Ing. Andreas Schröder; Phone: +49 2 08/85 98 -11 31; [email protected]

Central Technical Services

Project management; basic and detail engineering; sampling, analytical testing and pilot programs; technicalservices; central implementation of measurement and control and PLS (process control systems); internaltechnical services; mechanics and electric workshops; construction of demonstration and pilot plantsContact: Dipl.-Ing. Richard Sprick; Phone: +49 2 08/85 98 -11 82; [email protected]

Library

Information systems; online literature research; document supply; Fraunhofer Publica updating;UMSICHT publicationsContact: Dipl.-Bibl. Kerstin Hölscher; Phone: +49 2 08/85 98 -12 01; [email protected]

Occupational Safety and Environmental Protection

Coordination and advice in topics related to occupational safety: vocational training and on-the-job courses;registration and notification procedures; monitoring of legislative regulations; safety-relevant instruction ofthe staffContact: Dr.-Ing. Ulrich Seifert; Phone: +49 2 08/85 98 -11 27; [email protected]

Fraunhofer Center for Energy and Environment

Development of Fraunhofer technologies for the U.S. market: process water and sewage treatment; powergeneration from biomass; integrated energy supply concepts

Contact: Dr.-Ing. Achim Loewen; Phone: +49 2 08/85 98 -11 52; [email protected]


Experiencing DevelopmentIn dialogue with Dr.-Ing. Görge Deerberg

1. You deal with dynamic processes.Dynamics means driving power. Since2003 you are Director Science andTechnology at Fraunhofer UMSICHT.Where is your driving power aimed at inthis function?

It is my main task to further strengthenthe scientific force of FraunhoferUMSICHT also in times of narrow means.I should like to boost and challenge theprofitability which is present in the mindsof our staff.

2. Where are the Institute’s strengthsand where is it headed for in the future?

Our strengths are the team spirit andthe high multidisciplinarity of theinstitute. Networked areas of workguarantee that our resource“knowledge” is being incorporatedefficiently into products and services.Nevertheless, we have to strivetowards focusing on our core topics.Promising central topics could be:

Bio-refineryThis is about the vision of developingand providing products and closedproduction and recycling cycles from theplant to the product on the basis ofrenewable materials. We research onthe material and energetic aspects ofthis future topic.

Intelligent InterfacesWith respect to the catchword functional-ized interfaces we expand our know-how concerning the production of microand nano-scale structures with defined,profitable characteristics.

Local supply concepts with intelligentcomponentsSmart energy systems to us means

individually matching production anddemand of supply technologies forpower, heat, and cold, that flexibly linkthe productivity of local systems withthe strengths of national networks.

NetworksNetworked structures gain significantlyin importance even in environmentaltechnologies and process engineering.As is generally known, the total opti-mum is not the sum of all partialoptima, hence we try to utilize the po-tential hidden in the networks throughholistic reflection.

3. The catchword multidisciplinaritycould also be interpreted as: in coope-ration we are strong. Since February2003 UMSICHT is member of theFraunhofer Alliance “Production”, inwhich eight Fraunhofer Institutes haveaffiliated in order to conduct productionoriented research and developmenttogether. How is UMSICHT positionedin the Alliance “Production”?

We represent the topics safety, en-vironmental compatibility, and sustain-ability in the Alliance. To some extentthe other Alliance partners do this aswell, however, we complement theprofile of the Alliance and theFraunhofer Gesellschaft with an em-phasis on material and energy conver-sion very well. Especially in timeswhere the main focus is put on econo-my and efficiency of processes the as-pect of sustainability increasingly gainsin importance. The trend goes awayfrom a consumptive towards a sustain-able production.We have to work with raw materials,energies, and means of production ina way that resources are preserved forthe future.

4. “Sustainability” has become quite abuzzword. Is there not a risk of the termbecoming trivial and not being perceivedas important by society anymore?

Nowadays, society changes its notionsquickly, but no matter what you call it,sustainability, environmental protection,or protection of resources: Changingthe term does not change the task. Thetask is not new, though it will increas-ingly come into focus in the future, be-cause it is a fact: Resources are runningshort and for this reason their prices areincreasing. This is the need for actiontoday, which economy is fortunatelyrecognizing more and more. When wesupport sustained, and thus economic,management today, then this will be ofbenefit to our customers, does us good,and generations to come will profit aswell.

5. How do you judge trends in processengineering?

Process technologies are getting moreof a producing character. The trend inprocess engineering goes way frommass production towards a productionof small batches of special products.This is what brings product and indus-trial engineering, process and chemicaltechnology ever closer together.

In addition, technologies have to beintegrated further. In the past peopletried to separate process stages.Today it turns out that a processintegration is more favorable from atechnical point of view but above allfor economic reasons. This trend willcontinue and lead to multifunctionalapproaches with which not only onebut many different tasks can be solvedsimultaneously.


We as engineers will be more andmore required to consider completeprocess chains: from the process ideato the commercial process, and fromthe raw material to the recycling ofwaste material after product utilization.I can see enormous potential that hasto be set free when scientists frombasic research in chemistry and biologydevelop the utilization and provision ofnatural agents and materials togetherwith engineers. All researchers anddevelopers are called upon their abilityto see beyond the end of their nosesand to think more far-sightedly.

A few personal questions at the end:

6. What is your favorite book?

I cannot actually name “the” favorite

book of all time but “The Hitch Hiker’sGuide to the Galaxy” by Douglas Adamscomes pretty close.

7. Assuming you were a candidate in“Who Wants to Be a Millionaire?”, whatkind of question would make you askthe host Günther Jauch to call your tele-phone joker?

(laughs): Definitely a sports questions.I would call my father then.

8. What is your motto?

I would like to experience development.So a thought by Hans Pichler suits quitewell: Research is always on its way,never at the finishing line.

(Hans Pichler, 1882-1958)

Dr.-Ing. Görge Deerberg

Born in 1963, he studied chemicalengineering at the University of Dortmund.His promotion was on semi-batch processeswith gas/liquid systems. His main focus is onmodel-supported treatment of multiphasereactions and procedural processes.

Director Science and Technology atFraunhofer UMSICHT since 2003.


GuidelinesThe guidelines of the organization “Fraunhofer UMSICHT“describe the basic self-conception of the Institute andits staff. Therefore, they are kept in a general form andbuild a frame which is to be completed and acted outbut which also is to be advanced.

Guidelines are to bring continuity and stability into dy-namically changing requirements of environment anddaily routine. They are to accompany the Institute’swork beyond office hours and are to be communicated

inside and outside the Institute. Thus, mission,policies, and expectations the Institute operates withand wants to be perceived in its surroundings withare reflected in the guidelines.

The ten guidelines of the organization “FraunhoferUMSICHT“ are deduced from the regulations andguidelines of the “Fraunhofer Gesellschaft“ andconcretize them for the concerns of the Institute’swork.

Fraunhofer UMSICHT sees itself as a link between its business partners, staff members,the “Fraunhofer Gesellschaft“, the scientific community, and other social actors.

Fraunhofer UMSICHT wants to be a reliable research and development partner for its clients,relieve them during all project phases, give them all respective services from one hand,and support them in accessing subsidies and commercial funding.

Fraunhofer UMSICHT offers its clients qualitatively high-quality scientific, results-oriented, inter-disciplinary, and innovative research and development work. It provides them with competitiveadvantages through advance in know-how and recognized competence in problem solving.

The staff members form the Institute’s backbone. Fraunhofer UMSICHT encourages andchallenges the staff‘s professional, scientific, entrepreneurial, and social skills. These skillsdetermine the Institute’s efficiency. Fraunhofer UMSICHT wants to fill its staff with enthusiasmfor research and development.

Fraunhofer UMSICHT acts according to the principles of the “Fraunhofer Gesellschaft“ and con-tributes to enhancing the reputation of the “Fraunhofer Gesellschaft“. The institute cooperatesin partnership with the board of directors, headquarters, and other Fraunhofer Institutes andfacilities.

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Fraunhofer UMSICHT is actively committed to the formation of strategic alliances and networks in economy,science, politics, and society.

Fraunhofer UMSICHT forces up activities abroad in respect of project work and exchanging staff members(know-how transfer).

Fraunhofer UMSICHT acts actively in the scientific community. The institute cooperates with other researchfacilities, universities, technical colleges, and industrial partners in the national and international researchand development scene, and faces up to scientific debate.

Fraunhofer UMSICHT is independent. It supports clear, understandable, and interdisciplinary consolidatedpositions and aligns its objectives according to these positions. Fraunhofer UMSICHT aims at a long-termrealization of social visions through concrete innovations which can be efficiently transfered into economicallyutilizable progress and can be transfered into the environment.

Fraunhofer UMSICHT sees itself as a pathfinder for technical changes in the areas of environment, energy,process engineering, and safety. The Institute promotes effective management, environmentally friendlytechnologies, and environmentally conscious behavior in order to enhance society’s overall quality of life.

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Guidelines


Between Expertise and Market:Strategic Planning

Anyone can learn from the past. Todaywe have to be able to learn from thefuture.[Herman Kahn, 1922-1983]

Fraunhofer UMSICHT has already beenrunning a systematic strategy planningprocess since 1996. Its focus is onsetting up market-oriented businessunits from the Institute’s existing corecompetencies. These units are tosucceed in the competition with theirproducts and services.This strategic process is supported byintensive customer-oriented marketing.That way, the Institute’s aims and re-sources can be adapted to the quicklychanging chances on the market.Furthermore, risks can be identified atan early stage. The Institute’s strategicplanning initializes and integrates tacticoperative planning which is performedin the business units. The renownedmarketing expert Philip Kotler arrangesboth segments in a simple way:

“Following a strategy means doing theright things. Tactics means doing thingsright.”

By completing the first version of astrategic plan in the summer of 2003,Fraunhofer UMSICHT presented a self-contained management document.Analyses of the current status, market,and competition are linked with poten-tials of future trends in process engineer-ing and energy management in a singleperformance guideline. Highly com-pressed technology and performanceroadmaps form the “schedule” for thenext five years. They form the basis forthe Institute’s further economic andscientific planning. SWOT1 and portfolioanalyses are used to strategically ana-lyze Fraunhofer UMSICHT’s core com-petencies and business units. Throughthis, the market’s attractiveness andFraunhofer UMSICHT’s own power ofresources are compared and evaluated.

The market potential for research anddevelopment in process and energytechnology is calculated from the exter-

Strategy


nal research and development expen-ses of procedural branches and amountsto 170 million up to 1.6 billion Euro.The resulting market share of FraunhoferUMSICHT is about 1% (with regard toall external research and developmentexpenses) or 7% respectively (withregard to the external research anddevelopment expenses acquired byuniversities and research and develop-ment institutes).

All business units have the potentialfor intensively backed growth.Business units which are traditionallyrather scientifically-orientated perceivethe regressing public support mostnoticeably. Here, transfers into theindustrial sector need to be intensified.

Fraunhofer UMSICHT will consolidateand grow moderately on the basis ofits core competencies until 2008.Furthermore, the Institute will workeconomically-oriented and turn itsattention towards process developmentand associated systems engineering.The innovational potential which lies inthe method and system-oriented pro-cess engineering for sustainable pro-ducts, technologies, and services isenormous.

Anyhow, Fraunhofer UMSICHT needs tobe geared to the attractive and profit-able segments of process and energytechnology now. At present the follow-ing segments are being analyzed aspotential topics:• Intelligent materials, micro and

nano technology• New processes for the water and

wastewater sector• Bio refinery and bio fuels; polymers

and materials from renewableresources

• Vision Energy 21 – smart energysystems, security of supply, climateprotection,

• emergency and crisis management,and

• Chemtronics.

Competition tightens every day. All themore, it is important that unique sellingpoints for specified core competenciesare defined more clearly and “criticalmasses” are reached. That is whysuccessfully initiated processes for thebuilding of networks and strategicalliances – particularly in the internalFraunhofer and university sectors – aswell as equipment-related investmentsare unabatedly continued.

ContactProf. Dr. rer. nat. Rolf Kümmel(+49 2 08/85 98 -11 02)Dr.-Ing. Hartmut Pflaum(+ 49 2 08/85 98 -11 71)

1 strength | weakness | opportunities | threats

Business Units and Competencies

Environ-mental

Technology

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Safety andProcess

Technology

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EnergyTechnology

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Knowledgeand Technology

Transfer

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Process andapplicationdevelopment

Studies, expertises,expert reports

Planning, building anddistributing pilot, anddemonstration plants

System analysis undsystem technology

Software for processtechnology

Project developmentand financing

BusinessUnitsCore

Competency

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Chemistry and Analytics

Precise and reliable analytics area precondition for the solution ofenvironment-chemical questions.Scientists and technical staff worktogether in the highly qualified andexperienced team ”Chemistry andAnalytics” to complete this task.For this purpose, laboratories withan extensive instrumental equipment,among others state-of-the-art analy-tical system combinations, are avail-able at the Institute.

The wide spectrum of services offeredparticularly contains the development ofinnovative, custom-made methods,currently for example

• ultra trace analysis of pharma-ceuticals and endocrine matters inwastewater,

• characterization of secondary fuels,• plastics analysis and• biocide determination in art treasures

made from wood as well as• measuring of siloxanes in landfill

gases.

The validation of measurement resultsis carried out among others by com-parison with external laboratories(inter-laboratory tests).

We further focus on the optimizationof technical processes for qualitativeimprovement of products (ash, slag).

Our team offers analytical solutions,consulting services in the planning ofexaminations, and helps evaluatingyour analytical results.

Chemistry and Analytics


Biotechnological Laboratory

The biotechnological laboratory handlestasks on the cleaning of polluted media(water, soil, air), examines biologicaldecomposition and production poten-tials, and develops novel microbiolo-gical processes from laboratory to pilotplant scale.

New biotechnological processes andplants are planned step by step, de-signed and examined to ensure tech-nological feasibility at a high level ofefficiency and operational safety. Thebiotechnological laboratory can realizecreative and efficient solutions by co-operating with engineers and naturalscientists of the analytics and the engi-neering departments.

As an approved testing laboratory of“Bundesgütegemeinschaft Komposte. V.” (Federal association of compostquality standards), and approved tes-ting laboratory of DIN CERTCO fortesting of composting capability ofmaterials according to DIN V 54900-1to -3, ISO 13432, ASTM 6400 we offer:

• microbiological analyses accordingto DIN, ISO, OECD-processes,

• testing of biodegradability underaerobic and anaerobic conditions(e. g. AT4 and GB21 according to“Abfallablagerungsverordnung”[Regulations concerning wastedisposal]).

Contact us.

Biotechnological Laboratory


Marketing, Communication,Business Development

The marketing of products andservices, analyzing, and handlingof business sectors, developingnew market strategies, and finallyrepresenting the Institute in publicare the tasks of the department of“Marketing, Communication andBusiness Development“. Being di-rectly 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 new deve-lopments at an early stage.

Developing and preparing theInstitute’s public relation materialsand web appearance is among ourstrengths. Our web news regularlyand readily keep editors and journa-lists updated about the latest researchresults at Fraunhofer UMSICHT.To protect new developments fromplagiarism, our department is alsoresponsible for the registration of in-ventions, assistance in intellectualproperty rights, and in license agree-ments.

Innovation management and marke-ting are 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!

Marketing, Communication,Business Development


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.

The system comprises highly available fileservers with capacities in the terra-byte rangeincluding adequate band security, as well asintranet services, which are of increasingimportance.

The IT management also offers services toexternal customers, in particular to small andmedium-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 six traineeswho are becoming IT-specialists in the field ofsystem integration and applications develop-ment.

IT Management


Central Technical Facilities

The cycle times of technological inno-vations are minimizing rapidly in indus-trial and process engineering.In order to secure a technological head-start and not only keep pace withothers, a smooth and prompt reali-zation most be guaranteed.The central technical facilities realizetechnological know-how for internaland external costumers quickly andcompetently.

Specialized on the sector of test, pilotand demonstration plants our strenghtslie in:

• basic and detail engineering• implementation of process control

systems and• measurement, control technology and

control engineering.

Technical service is the basis of ourwork. Our team, consisting of elec-tricians, mechanics and engineers,accompanies you the whole way:starting with the consultation, overplanning and construction to the finalproduction of your plant, we try to findthe best solutions together with you.Among other things our repertoirecomprises the made-to-order productionof special components and the produc-tion of ready-to-operate technical plants.

We invest in the future by handing ourknow-how down to the succeedinggeneration. Trainees in different fieldshave set out on their way into thefuture in our facilities.

Central Technical Facilities


Library

Library –Specialist Information Service

“Knowledge” has long since become aneconomic factor securing technologicaladvantages of a location. For keepingthe scientific-technical qualification ofour staff always highly up to date, thescientific specialist library providesliterature on the UMSICHT-specific topicsenvironment, energy, safety and processtechnology as well as knowledge andtechnology transfer.At present our stock comprehendsapproximately

• 7 000 monographs,• 52 subscriptions to scientific journals,• 43 permanently updated loose-leaf-

collections,• 30 information services (among others

publication series of ministries,organizations, and institutions) and

• bulletins issued by government boardsin various research disciplines.

The Library

• supports scientific personnel in obtainingspecialist information in the Internet via anown Intranet-homepage serving as specialistportal,

• carries out literature and patent researches,• trains staff in researching in end user services

provided,• documents own publications for the world

wide accessible database Fraunhofer Publicaand

• is in charge of UMSICHT publications(conference transcripts, dissertations etc.)from advisory support the author to thedelivery of the printed copy to the“Technische Informationsbibliothek”(TIB, Technical Information Library) in Hanover.


Fraunhofer Center for Energy andEnvironment (CEE), Pittsburgh

Fraunhofer UMSICHT operates theFraunhofer Center for Energy andEnvironment in Pittsburgh, Pennsyl-vania, USA which offers UMSICHT’stechnologies and services on theAmerican market, handles projects inthe areas of energy technology andwastewater treatment, and supportsthe connection to the technologydevelopment in North America throughcooperation with project partners inboth countries.

One of the Center’s fields of work isconcerned with the treatment of pro-cess and wastewaters. In a coopera-tion project with the University ofPittsburgh micro-filtration membranesfor the treatment of municipal sewage(Combined Sewer Overflows, CSO)

have been examined. CSO emergewhen the sewer’s capacity has beentransgressed through high rainwaterquantities. They contain germs andbacteria that have to be separated.On the basis of various bacteria ser-ving as indicators it was demonstratedthat the quality of separation is veryhigh: all concentrations examined inthe permeate were below the detec-tion limit which makes the technicalfeasibility of the process apparent.

A process for the cleaning of waterbodies that have been polluted bymining is developed in the context ofa cooperation project with the Depart-ment of Agriculture and the Universityof Pittsburgh. In addition, metals canbe recovered with this process. Andthe call for action is urgent: in Pennsyl-vania alone more than 4 000 kilome-

The University ofPittsburgh with itslandmark the panther

Fraunhofer Center

On 1 March 2003 CEE movedinto new offices


Densely wooded NorthernPennsylvania offers a lot ofwood rests that can beused for energy generation.

ters of rivers as well as many surfacewaters have been severely damagedby acid mining erosions, so-called“Acid Mine Drainages”. When thepH-value and the oxygen entry in thepolluted water bodies are increased,iron hydroxides can be precipitated andused as raw material in the industriesor as fertilizer when mixed with manureor other biomasses.During process development the mosteffective and economical variant ofnumerous possibilities for precipitationand utilization of iron hydroxides isdetermined.

In a study, financed by the Departmentof Trade and Industry, Pennsylvania,CEE has generated an energy supplyconcept based on renewable resourcesfor Meadville, a small town in thenorth-west of Pennsylvania. In co-operation with Allegheny College, thelocal university, possible biomasssuppliers and potential consumers ofpower, heat, and cold have beenidentified. After developing severalscenarios for gasification and fermen-tation of biomasses and after extensiveeconomic consideration it showed thatan ideal concept was the operation ofa central fermentation plant on the siteof an animal food producer. In thisplant food leftovers from the productionprocess as well as manure and otheragricultural waste products from var-ious farms can be transformed into gasto replace natural gas which has beenused in the production process so far.

The Department of Environment,Pennsylvania has financed a study onwood gasification where CEE, in co-

Dr.-Ing. Achim LoewenFraunhofer Center for Energyand Environment5940 Baum Square, Suite7Pittsburgh, PA 15206Phone: 0 01 (4 12) 5 19 -86 72Fax: 0 01 (4 12) 3 62 -85 35

Fraunhofer UMSICHTPhone: (02 08/85 98 -11 52)

operation with the University of Pitts-burgh, examine the appearance ofwood rests in Clarion County andcarried out profitability considerationsfor various sites of a potential plant aswell. It could be shown that a plant ona production site with constantly highgas demands is economical when thewood gas produced replaces the na-tural gas being used so far. Looking atthe current wood rest, power, and gasprices power generation is not profi-table. Taking under considerationpossible aid money and an increase of20 % of power costs though, powergeneration for own consuption couldindeed become interesting in the future.

Pittsburgh


“Modern environmental technology is above allintelligent design of different inter-linked materialflows and energy fluxes.“

[Prof. Dr. Rolf Kümmel, Business Unit Manager Environmental Technology]

The business unit environmental technologydisposes of a repertoire of competencies andqualifications that can accomplish tasks both ofconventional and preventive environmental pro-tection. With the aim of reducing environmentaldamage through intelligent solutions and creatingmaterial value.

Since the foundation of the Institute a clearaccentuation of integrated environmental tech-nology, intelligent material flow management,and the identification of value added potentialhas taken place.


The Institute


Adsorbents and Supercritical Fluids

Micro-Sieves and Confocal Microscopy

Plastics Recycling

Modeling of Spray Drying

Environmental Technology in Chile

Bottom Ashes




Names, Data, Events


Adsorbents and Supercritical FluidsEnvironmental Technology

Silica gel as support (white)impregnated with redpigment yields the endproduct (right)

Impregnation of MicroporousAdsorbents from the SupercriticalPhase

Microporous sorbents such as activatedcarbon are impregnated to attain specialadsorption characteristics or to supportcatalysts. Usually, the impregnatingagents are transported into the adsor-bent’s pore system using liquid solu-tions, often requiring subsequent energy-intensive drying steps with solventresidues remaining in the solid. Usingsupercritical carbon dioxide (sc-CO2)above 74 bar and 31 °C as a solventoffers an economically as well asecologically attractive process alter-native. Having finished the impregna-tion, the solvent can be transfered intothe gas phase simply by reducing pres-sure. The gaseous CO2 often desorbescompletely and can be reused in aclosed CO2 cycle.

Fraunhofer UMSICHT develops proces-ses for modification of adsorbents bysupercritical solvent impregnation (SSI).A co-operation project concerning SSIwas supported by the Arbeitsgemein-schaft industrieller Forschungsvereini-gungen “Otto von Guericke “ e. V.(AiF). According to the results, activa-

ted carbon can be successfully impreg-nated from sc-CO2 with complexingagents such as hydroxiquinoline,thiazolylazonaphthole-compounds, andalkylphosphine-acids (Cyanex®) or withcatalysts such as metallocenes(application: olefine polymerization)and zinc acetate (application: polyvinyl-acetate-production), respectively.

In addition, the pore structure of activa-ted carbon can be influenced by super-critical impregnation with aromaticcompounds such as benzoic acid andsubsequent pyrolysis. Further studiesexamine the potential offering to super-critical solvent impregnation of othersorbents, such as silica gels as well asthe adsorptive immobilization of phar-maceuticals for controled releaseapplications for the human body.

Partners of the AiF project:• Deutsches Textilforschungszentrum

Nord-West (DTNW)• Department of Mechanical

Engineering – Division of Thermo-dynamics of the University of Siegen

• Institute of Pharmaceutical andMedicinal Chemistry of the SaarlandUniversity

ContactDr.-Ing. Volker Heil(+49 2 08/85 98 -11 63)Dr. Jochen Jakob(+49 2 08/85 98 -11 56)


Development and Application ofMicro-structured Systems inSeparation Technology and ProcessEngineering

The introduction of miniscule compo-nents, such as micro-blenders andmicro-pumps, has opened up theopportunity of realizing new productionprocesses for traditional processengineering ever since the boom inmicro-systems technology. Alongsidewith miniaturization, especially micro-structuring of materials (e. g. lotuseffect, shark skin) has gained greatimportance in process engineering.In the area of environmental technolo-gy novel methods for laser-supportedmicro-structuring are developed inorder to produce sieves of macroscopicsize with a multitude of more than100 billions microscopic holes persquare meter. The microsieves arecomposed of stainless steel and featurea custom-made pore geometry. Theyare characterized by high filtrate capa-

city (10 to 40 m³/hm²), high selectivity,great robustness (500 N/mm²), as wellas easy cleaning, and sterilization.A newly developed, laser-supportedmicro-welding method allows to weldthe microsieves into gas-tight compactfilter modules. The microsieve modulesare implemented in a filter system withoscillation-based anti-fouling processes.The promising results of permeationexperiments in laboratory scale werevalidated with various industrial productflows (e. g. laundry sewage). The im-plementation of such microsieve sys-tems in production scale for the area ofLife Science and the pharmaceuticalindustry are in preparation.

Process-accompanying and in coopera-tion with the company NanoFocus, aconfocal microscope as instrument forquality control of micro-structuredmaterials is currently being advanced.In addition, this optical 3D-measuringsystem provides the geometrical basicconditions for a planned computer-aidedprocess simulation.

ContactDipl.-Ing. Josef Robert(+49 2 08/85 98 -11 50)Dipl.-Ing. Ilka Gehrke(+49 2 08/85 98 -12 60)

SEM-micrograph of a laser-made microsieve, for sizecomparison: red blood celland unicellular organism

Environmental TechnologyMicrosieve and Confocal Microscopy


Environmental Technology

Studies on Utilization and Recycling of Plastic FuelContainers

For automotive manufacturers and their suppliers guidelinesconcerning the recycling ability of their products are mandatorysince the coming into force of the end-of-life vehicle directive(ELV) in July 2002. From 2005 onwards the creation of a recyclingconcept will be essential for the type approval of a new vehicle.

The implementation of the ELV demands component-orientedrecycling concepts already in the offering phase. For VolkswagenAG, two variants of the tank system of the new Touran (patroland diesel) were assessed theoretically and in practical exami-nations, and proof of recycling and utilization ability for the typeapproval were provided. Reference points for optimal extentof dismantling, quotas for the ways of utilization, and the esti-mated costs of the individual process steps were determined.Further on, adequate application areas for the recycled materials

Practical investigations forthe determination of theoptimal extent of dismantlingof a plastic fuel container

Plastics Recycling

were determined, and appropriate utilization anddevelopment partners for practical implementation,respectively, were recommended.

Considering possible ways of recycling for the plasticfuel containers (KKB) examined, it turned out thatmaterial as well as feedstock recycling are technicallypracticable.By application of feedstock recycling, higher recyclingquotas can be achieved. The guidelines of the ELV fortype approval are fulfilled with regard to componentsKKB of the Touran.

ContactDipl.-Ing. Carmen Michels (+49 2 08/85 98 -12 65)Dipl.-Ing. Thomas Eisenburger (+49 21 54/92 51 -27)

Typical material distributionof a plastic fuel container


Modeling of Spray Drying Environmental Technology

Modeling of the Particle Morphology in Spray Drying

Spray drying is a widely-used production process in thechemical, pharmaceutical, and food industry. In times ofsteadily rising market requirements the producers of solidscan be sure of a vital competitive advantage when productattributes can be predicted and controlled purposefully.Therefore, targeted prognosis and control of productattributes gain more and more in importance.

The development of a one-dimensional model for the dryingof a single droplet with simultaneous solid formation issupposed to contribute to a deeper physical understandingof the procedures during the spray drying process in orderto facilitate better control of the process. It is the aim topredict the emerging microscopic solid structure in the dropagainst the macroscopic process parameters and materialspecific properties. By integrating the single droplet-modelinto a commercial CFD-program it is possible to simulate acomplete spray dryer.In order to model the solid formation, the local andchronological concentration and temperature distributions inthe drop are calculated.

The material transport is accounted for by Fick diffusion andconvection, and the heat transmission by conduction aswell as mass transfer. For the modeling of the solidformation particle size distributions over the drop radius arecalculated with the help of population balances. Theexperimental validation of the model is carried out by dryingof mono-disperse solution and suspension drops created bya frequency controlled drop generator.

ContactDipl.-Ing. Philipp Seydel (+49 2 08/85 98 -11 75)Dipl.-Ing. Jürgen Bertling (+49 2 08/85 98 -11 68)

Oil-fielded dried salinesolution. Particles forma shell around a liquidcore

Density allocation of particle quantity inthe drop at drying gas temperatures of200 °C (top) and 100 °C (bottom)


Environmental Technology in ChileEnvironmental Technology

German-Chilean Co-operation Projects on Waste and WaterManagement

In 2001, Fraunhofer UMSICHT has signed a memorandum of co-operation with the Chilean Institute UDT of ConcepciónUniversity. Joint activities of applied industry research that werestarted in 1997 are to be further extended on the basis oftangible projects and a regular personnel exchange with currentemphasis on the areas of waste and water management.

In Chile more than 90 % of domestic, commercial, and industrialwaste are currently deposited on landfill sites that mostly do notmeet environmental standards. In the context of a researchproject supported by Volkswagen Foundation (Hanover)possibilities for establishing concepts of closed loop recyclingmanagement on the basis of regional waste streams areinvestigated. In the region around Concepción, municipal andindustrial waste sources are to be identified; technical as well aseconomical strategies for their linking-up with the producingindustries are to be developed.

Partial view on the UDT technicalshops: Pilot plants for wet oxidationof special refuse (in front) and forthe extraction of natural materials(background)

Tender beginnings: Separatecollection of paper, cardboard,and plastics waste by a recycl-ing-agency in Concepción

Since 2003, Fraunhofer UMSICHT has dealt witha project in the area of water treatment supportedby the BMBF (Federal Ministry for Education andResearch) for the development of an Internetplatform for water management in Latin America.www.aqua-latina.info is supposed to inform localauthorities and companies of technologies availablefor water/wastewater treatment in the future, andshall provide first conceptual designs for watermanagement adapted to their needs online.Algorithms for interpretation and economical-eco-logical assessment of “application clusters” are tobe developed and innovative technologies withGerman SME on location are to be realized in formof pilot plants.

ContactProf. Dr. Rolf Kümmel (+49 2 08/85 98 -11 47)Dr. Kai Keldenich (+49 2 08/85 98 -11 67)Dipl.-Ing. Jens Neugebauer (00 56/41/74 74 -55)


Bottom Ashes

Conventional aging andtreatment of bottomashes from thermal wasteincineration plants

Reduction of soluble coppercompounds in the Dutchelution test by treatmentwith carbon dioxide

Environmental Technology

Rapid Aging of Bottom Ashes for Immobilization ofEcologically Relevant Heavy Metals

The utilization of bottom ashes from thermal waste incinerationplants has been complicated increasingly by low-priced compe-titive products and requirements by the government over thepast years. This development led to considerations of decreasingthe share of leachable elements in bottom ashes in the past.Processes, such as integrated leaching, melting or sintering,though did not take hold due to high costs.

The popular practice at present is a mechanical treatmentwhich separates the ashes in different particle size fractions.

This treatment is combined with an upstream agingwhere the ashes are heaped up into heaps withthe height of several meters. Depending upon thelayer depth, two aging-mechanisms occur. At theheap’s surface, alkaline shares of the ash reactwith the carbon dioxide in the air to hardly solublecalcium carbonate. Through this the pH-valuedecreases and the solubility of amphoteric heavymetal compounds decreases. The formation ofhardly soluble sulfate compounds is dominant indeeper layers, since diffusion of carbon dioxide intothe heap’s inside is a very slow process.The compliance with limiting values for solubleheavy metal compounds is not guaranteed in thelower heap layers.

As the permitted amounts of copper, molybdenum,and antimony compounds for bottom ashes –which are used as building material – will bedecreased considerably in the Netherlands from2006 on, a large-scale experiment in cooperationwith a Dutch waste management enterprise wascarried out. Altogether, 170 t of bottom ashes weretreated with carbon dioxide-containing gas in acompost tunnel. Within a few days, a noticeablereduction of soluble shares of lead, zinc, copper,and molybdenum compounds was achieved.

In the future, especially carbon dioxide-containingmedia that are available cost-free such as landfilland biogases are to be employed. Thus, by com-bination of diverse waste-economic elements likewaste incineration and composting, a sensibleconcept for the cost-efficient quality improvementof bottom ashes can be established.

ContactDr. Thomas Marzi (+ 49 2 08/85 98 -12 30)

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“The networked information technology offersreasonable tools to entrepreneurs in order to gaincontrol of their documentation requirements andobligations in a cost-efficient way. That is safe to say!“

[Dr.-Ing. Stefan Schlüter, Business Unit Manager Safety and Process Technology]

The business unit safety and processtechnology is concerned with the technicaldesign, optimal operation, and safety evaluationof industrial plants and processes. Technicalprocesses need to be safe, reliable, and optimallycontrollable and optimal safety for the staff, theneighborhood of the plants, and the environmentneeds to be ensured.


The Institute


Business Unit Saftey and Process Technology

Hot Smoke Tests

Safety Concepts

Pipeline Networks

Information Networks

Process Simulation

Guideline for the Storage ofHazardous Substances



Names, Data, Events


Safety and Process Technology

Practical Testing of Smoke Management Systems inUnderground Building Structures

Special geometries and extraordinary evacuation routes in under-ground building structures often require specially adapted smokemanagement systems for each individual object.Fraunhofer UMSICHT was contracted to undertake practicalsmoke tests in underground caverns containing hydro powerstations. The performance of the installed smoke ventingsystems had to be evaluated with regard to an inclined accesstunnel and two different “machine caverns“.In the tests, pool fires of methylated spirits with a heat output ofup to 2,2 MW were used. Tracer smoke was added in order toillustrate the flow of hot air.Thus, the flow characteristics of the visible test smoke can beobserved; the data of smoke spread are verified by additionalmeasurements of the distribution of gas temperature and carbondioxide concentration in the object.Hot smoke test in

a machine cavern

The test in the access tunnel has revealed that no up-ward smoke spread would occur against the forcedairflow from the tunnel entrance to the machine cavern.In the machine caverns the stratification of hot smokeunder the ceiling and relatively clean air unterneath canbe used to assure the usability of evacuation routes inthe course of fire over a sufficient period of time. Basedon the test results, further improvements of the smokeventing system could be suggested (e.g. location of firedetectors, supply of make up air).The evaluation of smoke management concepts forunderground building structures often requires know-ledge about the effect of superimposed horizontalairflow on smoke spread. For systematic investigationof this phenomenon, a CFD-model has been created.The simulation results have permitted some generalizedconclusions concerning the influence of heat realeaserate and smoke temperature on the spreading charac-teristics of smoke.

ContactDr.-Ing. Ulrich Seifert (+49 2 08/85 98 -11 27)Dipl.-Ing. Jürgen Stein (+ 49 2 08/85 98 -11 28)

Hot Smoke Tests

Hot smoke testin a tunnel

CFD-simulation ofsmoke spread againsta forced airflow:Temperature profile ina tunnel


Safety Concepts Safety and Process Technology

Safety Concept for an OxidationProcess with Pure Oxygen

The efficiency of an oxidation processis determined to a high degree by theoxygen content of the oxidizing medium.An increased oxygen content, however,increases process hazards and narrowsthe limits for safe operation. When pureoxygen is used, even materials whichcannot be ignited at all under normalatmospheric conditions may becomeignitable and can create fires that arevery difficult to extinguish.

The application of pure oxygen in oxi-dation processes, on the other hand,

Process stream oxidationwith pure oxygen – safeand reliable!

offers the opportunity to reduce costs ofequipment and operation significantlydue to smaller devices and reduced off-gas flow rates.

In the framework of further developmentof the continuous oxidation of an organiccompound, Fraunhofer UMSICHT wascommissioned to investigate the physico-chemical properties of the substanceswith a particular view to explosionhazards and to perform a risk assesmentof the entire process.

Based on experimentally determinedproperties of the compound, such aswave propagation velocity, electricalconductivity, and auto-ignition tempe-rature, measured at atmospheric condi-tions and at process conditions, con-clusions for safe process design andoperation were derived.Risk assessment considered normaloperation as well as start-up and shut-down of the process and taken accountof possible causes for non-specifiedoperation.

Fraunhofer UMSICHT has contributedto the design of a new oxidationprocess in order to ensure safe andreliable operability.

ContactDr.-Ing. Ulrich Seifert(+49 2 08/85 98 -11 27)


Pipeline NetworksSafety and Process Technology

Large-scale test plantat Fraunhofer UMSICHT(below: partial view)

Dangerous States in Pipeline Systems –Detecting, Analyzing, Optimization

Pipeline systems are the highways for liquid and gas flow of allkind for modern industrial and consumer society. Unforeseendynamical straining like condensation of steam in power plants,sudden change of liquid speed (chemical industry, water supply)or plug flow of oil and gas may result in water hammer,cavitational hammer or condensation hammer in the pipeline.The risk of high pressure surges and forces to the pipe supports(noise, leakage, burst of pipe) is rising with increased length ofthe pipeline and increasing of the valve closing speed.

By using the measurement of water hammer on location, thereason of failure and the possibility of a failure in the pipingsystem can be determined. Due to close co-operation with otherscience institutes and measurement companies the latest state-of-the-art measuring equipment and analyzing equipment canbe used. The results of the water hammer measurement areanalyzed and evaluated by commercial computer software.High performance evaluation software for pipe systems andtheir components complete the technical spectrum.

Therefore, in the economic way (productivity) and the way ofplant safety, the customer receives an optimized pipelinesystem.References from chemical industry, water suppliers, power plantsand oil and gas industry do confirm the quality of the methodswe developed.

Our performance includes:• Planning and calculating of pipe systems (statically and

dynamical calculation)• Manufacturing and optimizing of pipe systems• Testing of fittings• Detection of leakage and on-the-spot measurement of force

and pressure (detection of water hammer)• Expert´s reports on the topics safety and availability of pipelines• Avoidance of water hammer and cavitational hammer by using

ABS-Armatur® oder KAVITAS®

• Scienctifical evaluation and validation of computer softwareusing our large-scale test plant (Pmax: 140 bar, Tmax: 200 °C)

ContactDr.-Ing. Andreas Dudlik (+49 2 08/85 98 -11 25)Dipl.-Ing. Ralf Müller (+49 2 08/85 98 -14 02)


Information Networks

DUBAnet® as an integrationmedium for operationalmanagement systems


A Network of Information to the Company-spe-cific Conformance of Statutory OrganizationDuties to the Industrial Safety and Environmen-tal Care as well as Maintenance of the Certifica-tion of Management Systems.

Employers in all commercial and industrial fieldsare obliged by the labour protection laws andoperational management systems to build upa suitable organization in their enterprise undersupply of the necessary means which ensureshealth protection and security for the employeesaccording to the state of the art. The fulfilmentof these duties is checked and supervized byauthorities and auditors. If lawful offense isascertained, legal proceedings can be taken.

On the market a huge number of engineeringutilities is available which support enterprises ingathering information, data management as wellas document preparation. Indeed, they considermostly only single aspects, so that several parallelsystems must be used in the company.The application of such systems is mostly time-consuming and can usually only be carried out withexpert’s knowledge. Often an adaptation of theengineering solutions to the company-specific work-flow is not possible.

With DUBAnet® an integrated solution was createdwhich supports the entrepreneur from gathering in-formation up to spreading information, so that afterthe initial system design and operational introduc-tion no further expert’s knowledge for maintenanceis necessary. At the same time an organizationalfault by breach of statutory duty is excluded.The company-specific design allows a workplace-related supply of information in daily business,searching times are avoided.

The method is directed mainly at small and medium-sized enterprises which are legally obligated to thekeep topical instructions and operating instructions,documentations, hazard (peril) evaluation etc. Thisincludes enterprises which are certified by GermanInstitute for Standardization ISO 9 000 or 14 0001.In particular security representatives and the mana-gers have a considerable time profit by using thesystem. Besides, the applicability of the procedureis not limited to certain industrial sectors.

Further information at: www.dubanet.de

ContactDipl.-Ing. Thorsten Wack (+49 2 08/85 98 -12 78)Dr.-Ing. Ulrich Seifert (+49 2 08/85 98 -11 27)

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Process SimulationSafety and Process Technology

Dynamic Process Simulation of Oceanic Gas Hydrate Winning

It is assumed that gas hydrates contain more than twice as muchcarbon as all other fossil energy resources, so the controlled useof gas hydrates as a natural resource could guarantee the world-wide energy supply.The proposed gas hydrate winning method is based on themammoth-pump principle. A concentric tube arrangement is usedto feed the gas hydrate deposit with warmed sea water in orderto de-stabilize the solid gas hydrate and to set free the gas com-ponents, predominantly methane gas. The rising gas bubblesaccelerate the fluid of the surrounding area. A circulating flowprocess is induced by the difference of mean fluid density in thetwo flow sections of the tube arrangement (downcomer: liquidphase; riser: liquid, gas, [solid] phase). The gas won flowsthrough the riser (outer annulus in figure 1) and reaches the topof the apparatus, where it is separated and supplied to furtherutilization.A dynamic process simulation of the proposed winning apparatuscan be realized by using a multi-section cell net model. The cellnet based discretization of the apparatus sections enables thecalculation of pressure, concentration, temperature and velocityprofiles as function of time and position. A detailed modeling ofthe multi-phase flow and the complex interaction between theflowing phases is included. The model implementation as a com-puter code enables the evaluation and optimization of the proposedgas hydrate winning technology.Knowledge about gas hydrate stability is very important, with res-pect to realizing controlled de-stabilisation as well as to developingprocedures to avoid new gas hydrate formation inside the apparatus(plug).The investigation of the proposed gas hydrate winning apparatusby intensive application of the process simulation program permitsthe conclusion that the innovative process is technically wellsuited for natural oceanic gas hydrate winning. All in all, thewinning process can be evaluated as safe and economical in theenergetic sense.

ContactDr.-Ing. Görge Deerberg (+49 2 08/85 98 -12 69)Dr.-Ing. Stefan Schlüter (+49 2 08/85 98 -11 26)

Relevant interactionsof the process

Gas hydrate winning apparatusbased on mammoth-pumpprinciple

Multi-section cell net modelused for process simulation


Guideline for the Storage of HazardousSubstances


LAGERguide – Knowledge-based Guideline for the Storageof Hazardous Substances and Waste

The storage of hazardous substances and waste must meetnumerous state-of-the-art security requirements. Therefore it isessential to have a precise knowledge of the relevant regulationswith their different protection purposes and security measures.For the user who deals with this complicated topic only briefly orwith varying questions the gathering of information is mostlytime-consuming and labor-intensive.

For gathering information concerning certain problems in the areaof hazardous substance storage professional databases with freetext search are often used. These systems do not need any addi-tional amount of maintenance except text actualization.Furthermore they facilitate the navigation in the technical corpusof legislation for the experienced user in comparison with classicalprint media. Indeed, the full text databases do not provide anyintelligent algorithm which could support the inexperienced userin acquiring information.

On the basis of experiences in the expert systemdevelopment the state of the art for storage prob-lems was illustrated in rule-based and object-oriented knowledge. For the navigation through thestructures of the knowledge bases modern Internettechnologies are used in form of so-called “clickablemaps“. Besides, the easy processing of the graphicaldisplay of decision workflow allows the inquiry ofall relevant measures.

Supported by this IT-tool questions can be answeredcomprehensively for the compilation of legal-corres-pondent protection systems concerning the storageof waste and hazardous substances. Thus, targetgroups are storage operators in the area of chemi-cal industry, manufacturing companies, plasticsprocessing, energy providers, logistics service provi-ders as well as engineering consultants involved inplanning of storages.

ContactDipl.-Ing. Thorsten Wack (+49 2 08/85 98 -12 78)

Graphically supportedguideline with LAGERguide


In the business unit energytechnology application-orienteddevelopments in power, heat,and cold supply are carried out.With highly efficient energysupply in combination withrational application, maximumefficiency and high sustainabilityare achieved.

The motto is to successfullyposition companies in thechanged energy market with thehelp of smart energy technology.

“There is no technological progress without sustainable and competitive

energy technology. Therefore, it is important to integrate energy

systems in an intelligent way.“

[Dr.-Ing. Wilhelm Althaus, Business Unit Manager Energy Technology]


The Institute




Cleaning of Sewage and Landfill Gas

Energy from Low BTU Gases

Gas Cleaning for the Use in Fuel Cells

Cooling and Latent Cooling Energy Storage

Supply Networks

Climate Protection and Emissions Trading


Names, Data, Events


Removal of Organic Silicone andHalogen Hydrocarbon Compounds

Sewage and landfill gases cause diffi-cult problems to gas engines whenthey contain organic silicone. Hard andabrasive silicone oxides are formedduring combustion and settle on thevalves, pistons and turbos and catalystscausing severe engine damages.Frauhofer UMSICHT is testing a newmethod to remove organic silicon fromthe fuel gas. The capacity of activatedcarbon filters is significantly increasedby a catalyst step. Halogenous hydro-carbons are also eleminated. Due tovery promising results of practical testson various landfill sites the constructionof a demonstration plant is intended.

Within the EU-Project EROB a modulartesting plant was constructed in co-operation with 5 project partners forresearch on gas cleaning processes.Low temperature and energy savinggas scrubbing methods can now beinvestigated on site in different processarrangements. For adsorptive gascleaning with activated carbon a mo-

Landfill and sewagegases are cleanedwithout the useof cleaning andsoftening agents

Energy Technology Cleaning of Sewage and Landfill Gas

dular “ready-to-fit” filter system wasdeveloped which can easily be filledand changed by big bag units.

Network for Renewable GasesReGasNet

Fraunhofer UMSICHT is building up thenetwork ReGasNet which developssolutions for the cleaning of renewablegases, which are to be used for powergeneration.

Feeding of Biogas into the NaturalGas Net

The scope of the study performed werethe boundaries and restrictions underwhich renewable gases, which arelisted in the EEG (German RenewableEnergies Law), can be fed into thenatural gas net in order to promotethe substition of fossil fuels.

Oxygen Enrichment ofCombustion Air

A new technology for oxygen enrich-ment of combustion air with hollowfibre membranes has been developedand realized in the form of a containersystem. This technical prototype is tobe used for various applications forexample combustible gas with a lowenergy density. We are testing the useof landfill gas in plants based on gasengines, as well as the increase ofthe firing temperature for metallurgicapplications.

ContactDipl.-Ing. Peter Schwerdt(+49 2 08/85 98 -11 73)Dr.-Ing. Ralf Hiller(+49 2 08/85 98 -12 73)Dipl.-Ing. Clemens Backhaus(+ 49 2 08/85 98 -11 88)

In the membrane planta number of hollow fibremembranes (see partialview) enriches the airwith oxygen


Energy from Low BTU Gases Energy Technology

Inspection of Tightness at Filled Mine Shafts

Coal mine gas that escapes from abandoned pits contains thehigh potential climate gas methane, which in some cases has tobe sucked off for avoiding endangerments or which is used forpower production. To ensure that only a minimum of the coalmine gas escapes uncontrolled, Fraunhofer UMSICHT developeda technique to prove the tightness at filled coal mine shafts.

Pre-gasification of Solid Biomass and RDF

Pre-gasification is an effective way of utilizing several feed-stocks which are difficult to handle by converting them to com-bustible gases. Appropriate gas treatment enables gas utiliza-tion in different downstream processes (i.e. lime/cement kilns,gas engines, fuels cells, or chemical synthesis). For gas utili-zation in IC engines for CHP-generation e.g. can be fed withgasification gas which has passed a special reforming stage.Pre-gasified sewage sludge e.g. can be used for power gene-ration by partially substituting biomass in grate combustionboilers. For scientific investigation and further developmenta novel test plant is available at Fraunhofer UMSICHT. It is amodular fluidized bed plant for both gasification or combustionof biomass or RDF.

Direct Biological Hydrogen Production

A look into the future unveils the hydrogen production by greenalgae. Fraunhofer UMSICHT works on the assessment of diffe-rent bio-reactors and the possibilities to generate electricityeconomically.

Efficient Automation Solutions for Biogas Plants

Within the scope of detail engineering of biogas plants extensiveoperational experience in automation solutions was gained.Based upon this experience optimization of plant operation andthe automation system was carried out.Using remote maintenance, notice of malfunction via sms-mes-sages and straight handling idea, maximum possible operationalavailability of the biogas plants is achieved.

ContactDr.-Ing. Markus Ising (+49 2 08/85 98 -11 89)Dipl.-Ing. Clemens Backhaus (+49 2 08/85 98 -11 88)Dipl.-Ing. Adam Hadulla (+49 2 08/85 98 -11 94)Dr.-Ing. Ralf Hiller (+49 2 08/85 98 -12 73)

Drillmasters work day andnight in order to get the coalmine gas out of abandonedmine shafts

Fluidized bed plant forgasification or combustionof biomass feedstocks


Energy Technology

Additive Natural Gas and Coal Mine Gas Processingfor a PEMFC

A gas cleaning system, which fulfills the requirements of fuelcells, always represents a special challenge. Some PEM fuel cellsystems need natural gas with H-quality.At locations with L-quality and especially fueled with coal minegas or biogas a fuel processing system is unavoidable beforefeeding these gases into a PEM fuel cell. Nitrogen, oxygen,carbon dioxide and odorants must be removed since they areunwanted accompanying components. For operating a 250 kW-PEM fuel cell, type Alstom Ballard P2B, an activated carbon THTfilter and after this a two line pressure swing adsorption planthas been installed.

Gas Cleaning with MCFC Pilot Plant Testing

The process analysis reveals that MCFC high temperature fuelcells are particularly suitable for CO2-containing gases (e.g.biogas, coal mine gas, sewage gas, landfill gas). The use ofstandardized gas cleaning modules is requested by ourcustomers.The starting point of the development was the analysis of theminor quantities with an error of less than 1 ppm. On this basisan innovative gas cleaning system has been designed, which is

A digestor of a sewageplant in the sun

Gas Cleaning for the Use in Fuel Cells

being tested at a sewage plant together with the MCFCfuel cell at the moment.From the first promising results a good reliablity andeconomy can be expected. The current investigationsfocus on the effect of varying gas compositionson the electrical output and efficiency of the stack.

Multi Fuel Reformer

For testing purposes of different reforming processes amodular and transportable test facility has been erected.With this facility different catalysts and gas compositionscan be investigated with regard to the suitability forhydrogen production. Furthermore the feeding of welldefined portions of pollutants allows lifetime tests. Thetest facility is equipped with a gas mixing system, gashumidification, a tempering device up to 1,200 °C and aflexible and highly-precise gas analysis system (GC, MS,NDIR).

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

The PEM-fuel cell hastaste for bio andsewage gas processedin a two-line pressureswing adsorption


Cooling and Latent Cooling Energy Storage Energy Technology

Ice-Slurry Technology

With brine ice mixtures (ice slurries) Fraunhofer UMSICHT combines highstorage density of ice with pumpability of water to make it usable forrefrigeration technology. The rheological behavior of different ice slurrieswas patterned in a physical model, basis for the piping system layout andoptimization of operating parameters of technical supply systems. In a pilot-plant for an air-conditioned laboratory important planning characteristic valueswere attained. Ice slurries enable a simple and low-priced retrofit of existingplants. Further on the efficient ice slurry production is part of the research,e.g. in rugged and efficient steam jet injectors.

Phase Change Material (PCM) Cold Storage for Air-conditioning

Instead of ice slurries, PCMs with high melting temperatures, for exampleparaffins, can be used in air-conditioning applications. Experiments with PCMemulsions and micro-encapsulated paraffin have shown a very good rheologicalbehavior and a three times increased thermal transport capacity, compared tocold water networks, within a 25 vol.-% mixture. As a result, the costs of thecold supply can be reduced. Alternative possibilities of applications are storageelements filled by the PCMs and used for example in cooling systems. Duringnight time, the obtained cold of free cooling is stored by freezing of the PCMs.This could be used for an inexpensive way of air-conditioning or process cooling.The tooling up of an existing cooling tower is already planed.The combination of operating experiences and computed simulations helpedoptimizing operation and plant design.

Thermally Driven Container Chiller Plant

An effective integration of thermally driven chiller plant into an existing supplysystem can be obtained by container modules. Fraunhofer UMSICHT is developinga water-LiBr absorption chiller plant (30-150 kW) as well as a steam jet ejectorchiller (50-250 kW) inform of a container module. Both plants dispose of thechiller as well as the necessary auxiliaries for cold generation, therefore onlythe connection to the power and heat supply has to be realized.

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

Not only famous on TV:Engineers specializing onchilling technologies like con-tainers as well, since theyare an ideal home for chillingmachines and storage tanks

Shaken, not stirred:According to this famous quotationin the ice-slurry-reactor theaqueaous suspension consisting oftiny ice crystals is always ready totransport cold.


Supply NetworksEnergy Technology

There are many ways tooperate economically – PortO.helps to find the best

Dies ist Blindtext und darfnur zu Layout-Zwecken verwwerden.Dies ist Blindtext unddarf nur zu Layout-Zweckenverwendet

Strategic Supply Temperature Optimization –Heat Storage within the Pipeline System

On the basis of the detailed knowledge within the field of unitcommitment and the optimization of energy supply systems amodel describing the characteristics of district heating systemshas been developed. With this approach it is possible to modelthe dynamic heat storage capacities of the pipeline system of adistrict heating network. By application of systematic networkaggregation methods the calculation time was significantlyreduced. The aggregated non-linear model describing the dyna-mic characteristics of the pipeline system enables the optimiza-tion of heat storage processes with respect to a minimization ofrunning costs. Applying this software prototype a potential toreduce operating costs was determined for different existingdistrict heating systems.

Leak Detection with Dissolved Helium at Earthlaid Pipelines

Detection and precise localization of leaks is an arduous task forowners and users of pipeline systems. Fraunhofer UMSICHTdeveloped a new method which does not require to interrupt theservice during leak search at district heating pipelines. Heliumwhich is dissolved in water is released at any of the leaks and isspread in the underground by diffusion. Leaks can thus be loca-lized at the surface by mobile Helium detectors. In coorporationwith district heating utilities and industrial partners many appli-cations were successfully carried out.

For Local Heat Supply

Specialized knowledge is the basis to decide on investments.www.nahwaerme-forum.de provides users, decision makers andnon-professionals with information about technology andeconomical as well as legal conditions of a local heat supply.Therewith alternative solutions can be evaluated and technicallyand economically interesting options can be identified. In theforum visitors can discuss questions, socialize with other userse.g. constructors/manufacturers, planers, etc. and present theirown projects and products.

Optimizing the Portfolio of Energy Products

Since the liberalization of the European energy market manypower purchasers change over their purchase strategy from long-term contracts to a structured purchase strategy using power ex-changes and financial derivatives to hedge against the resultingprice risks. The portfolio optimization tool PortO. supports anefficient portfolio management. PortO. is based on price scenariosand stochastic optimization models with regard to the integratedoptimization of profit and risk.

ContactDipl.-Ing. Michael Lucht (+49 2 08/85 98 -11 83)Dr.-Ing. Christian Dötsch (+49 2 08/85 98 -11 95)

With the help of adequatesoftware you do not losesight of the optimal operationwithin the energy supplygrid


Climate Protection and Emissions Trading

Symbolic starting signalfor emissions trading inGermany: the first sub-scription warrant on oneton of carbon dioxidereduction

Enterprises joinedthe emissions tradingtraining camp “jupiter“in order to be preparedfor the trading withemissions starting in2005

Energy Technology

The “jupiter“ Emissions Trading Training

The Emission Trading Scheme of the European Union starting in2005 implements economic instruments for climate protection.The “jupiter“ emissions trading training (www.jupiter nrw.de)prepares concerned emissions-intensive enterprises in NorthRhine-Westphalia for this market. It offers an Internet-based,realistic simulation of the emissions trade including CDMJI andtechnical emissions reduction projects. Extensive training andconsultation helps the participating enterprises to develop theirstrategic goals in the CO2-emissions market and to test suitablework-flow schemes practically.

New Business Models in Emissions Trading

Fraunhofer UMSICHT is founder member of the GermanEmissions Trading Association and possesses expertisein the field of emissions trading. Fraunhofer UMSICHTtook part in a valuation project for the Joint Implemen-tation and Clean Development Mechanism approvalprocess of the German ministry for the environment.Together with the power producer ”Stadtwerke Herne”Fraunhofer UMSICHT presented the first warrant for aGerman Joint Implementation project. Together withthe power producer ”Stadtwerke Unna” FraunhoferUMSICHT brings the idea of emissions trading to thehousehold level. Stadtwerke Unna pays their customersa premium dependent on the individual emissions re-duction reached by exchanging old oil fired heatings bymodern gas fired heatings. Fraunhofer UMSICHTdeveloped the calculation tool for the expectedemissions reduction due to heatings change-over.

Technical Optimization of Systems

The lack of energy data is the most common causefor misplaning of energy systems. Besides energysaving potentials cannot be evaluated especially incase of properties spread over several locations.Fraunhofer UMSICHT acquires and evaluates dataconcerning energy use and costs for such premisese. g. the Caritas Wohn- und Werkstätten Niederrheinand shows opportunities for achieving potential energyand cost savings.For operators of complex energy supply systems thereare always a number of possibilities to reduce theenergy demand. In case of a chilled water network ofa large university hospital energy saving potentials andstarting points to optimize the operation were workedout by conducting an inventory survey and simulatingthe pipeline system characteristics based on a smallnumber of measuring points.Based on the experiences in energy supply conceptsthe Institute developed the energy supply concept andaccompanied the basic engineering for the design of anew complex of buildings for two vocational schoolswith 4,000 pupils and is now working on the develop-ment of the model house for the German-Japaneseproject “Eco City“.

ContactDipl.-Ing. Michael Lucht (+49 2 08/85 98 -11 83)Dr.-Ing. Jürgen Meyer (+49 2 08/85 98 -14 17)Dr.-Ing. Christian Dötsch (+49 2 08/85 98 -11 95)


The business unit knowledgeand technology transfer pur-suits the goal of marketingknow-how acquired within theInstitute and spreading itsutilization. This marketing isdone by transfer “into heads“(further education), transfer intoother countries (internationalproject development), and viatransfer of the know-how intocompanies (spin-offs). Moreover,the knowledge about the designof research and developmentprocesses and the implementationof innovations for interestedcustomers is directly offered asa consulting-service.

“Ideas develop in our heads. To make money with them,though, we need to individually realize and market themall over the world. To me that is innovation!“

[Dr.-Ing. Bernhard Dietz, Business Unit Manager Knowledge and Technology Transfer]


The Institute




Business Unit Knowledge andTechnology Transfer


North Rhine-Westphalian Action Program for CEEC Countries

Learning on the Job – the TheoPrax® Model

Distance Learning Program Environmental Sciences (infernum)

Sound Imission Survey

Environment – Technology – Recreation

Names, Data, Events


Knowledge and Technology Transfer

Globalization and international competition represent thechallenge of today’s economic and cultural activities andaffect the scientific community in market positioning andasserting in an international development. Establishing thedepartment ”International Project Development” atFraunhofer UMSICHT in 1997 has been one measure toaddress this development.

The department focuses on internal and external services inthe fields of scientific and economic co-operation respon-ding to the requirements of the scheduled enlargement ofthe European Union and European research policy.

In projects involving multiple institutions such as theGerman-Polish research network INCREASE and the North-Rhine Westphalian Action Program efficient networkingplatforms are established that include political and scientificinstitutions as well as economic and scientific organizations.Internal and external clients benefit from these networks.

Activities focus predominantly on the central and EasternEuropean countries CEEC.

Doc. dr. hab. inz. LudgardaBuzek, head of the Polish headoffice of INCREASE (holdingflowers) is bid farewell by Prof.Dr. Stanislaw Ledakowicz,University of Lodz; ElzbietaSobótka, Polish Consul General;Prof. Dr. Rolf Kümmel, head ofFraunhofer UMSICHT; Dr.-Ing.Barbara Zeidler, head of theGerman head office of INCREASE,Fraunhofer UMSICHT;Prof. Dr.-Ing. Andrzej Górak,University of Dortmund


INCREASE

”Addressing current environmental problems and advancingthe relations between Germany and Poland through co-operation in joint projects”. This is the guideline of theGerman-Polish research network INCREASE (InternationalCooperation on Research in Environmental Protection,Process Safety and Energy Technology), established inWarsaw in 1997. Today, more than 30 scientific institutionsof both countries are members of the INCREASE network.

The access of Poland to the European Union in 2004will bring a new dimension to German-Polish coopera-tion. Under the leadership of the Chairmen of the SteeringCommittee, Prof. Dr.-Ing. Andrzej Górak (University ofDortmund) and Prof. doc. Dr. hab. inz. Jacek Laczny(Institute for Ecology of Industrial Areas, Katowice), thefocus on integrating INCREASE projects into Europeanprograms will be further emphasized.

Fraunhofer UMSICHT as the German head office ofINCREASE, collaborating with the Polish head office atthe Institute for Ecology of Industrial Areas in Katowice,will actively contribute to this reorientation process.Bi- and multilateral collaboration in projects with Polishpartners will be continued.


North Rhine-Westphalian Programfor the Promotion of Foreign Tradein CEE Countries

North Rhine-Westphalian Program for thePromotion of Foreign Trade in CEE Countries

The North Rhine-Westphalian (NRW) Program for thePromotion of Foreign Trade in CEE Countries is a bi-lateral initiative launched in January 2001 on behalfof the NRW State Ministry for Economy and Labor.The program has been set up to support Europeanenterprises in the environmental, energy and transportsectors in initiating and implementing projects in thetarget countries Hungary, Czech Republic, Romania,and Poland. In addition to environmental, energy,transport, and financing matters, activities alsocomprise political support. Assistance is provided bya project group consisting of four partners, withFraunhofer UMSICHT acting as consultant for environ-mental and energy technologies.

The program is politically anchored in the ”MutualAgreements on Economic Co-operation” issued bythe state of NRW and the target countries or regions.Since the program started, several of these agreementshave been signed. In compliance with the proceduresset therein, early project information is researched andreadily made available to the interested enterprises.Successful approaches developed within the projecthave been published in two Guidelines on ”Openingup wind energy resources in CEEC” and ”Opening upresources for energetic use of biomass in CEEC”.

Further assistance and information on market potentials hasbeen provided in workshops and publications. Among thetopics addressed are:• Renewable energies in CEEC: Current state, general

framework, programs, perspectives• Utilization of combustion residues (venue: Hungarian

Ministry for Environment, Budapest) and emission trading –new opportunities for NRW enterprises in CEEC countries(venue: NRW Ministry for Transport, Energy and SpatialDevelopment)

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



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. Workinggroups are formed among students towork on problems set by the industrial

partners. The workshops are co-ordi-nated and normally tutored byUMSICHT.

What are the Benefits of TheoPrax®?

TheoPrax® provides an early basicunderstanding of real world work andhelps students develop key practicalskills such as creativity, conflict mana-gement, communicative and teamskills and other soft skills. When enter-ing their professional career, studentsare better prepared and know what isreally required in practice. TheoPrax®

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

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

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

TheoPrax®


In collaboration with the FernUniversität in Hagen (OpenUniversity), Fraunhofer UMSICHT has introduced theinterdisciplinary distance learning program Environ-mental Sciences (infernum) in November 2000.This four-semester course aims at providing updated,practical and comprehensive environmental know-howto students both in their own and related disciplines andis equally designed for engineers and natural scientistsas well as for economists and graduates from humani-ties and law. The students are trained in interdisciplinaryskills, which are indispensable for solving complex envi-ronmental problems.

In October 2003 infernum has been granted the accredi-tation to confer the degree ”Master of Science“. Thusinfernum is to date the only Master’s degree distancelearning program in the field of environmental studiesavailable in Germany.

infernum has encountered wide-spread interest andacceptance both nationally and internationally, forinstance from Austria, Switzerland, the U.S., China, andSouth Africa. Students enrolled display a variety ofqualifications from different disciplines, ranging from

engineering, sciences, business studies and economy,medicine, theology to educational sciences.

Workshops that are regularly conducted at Oberhausen andother German cities offer the opportunity to meet fellowstudents and teaching staff, and to deepen the knowledgegained through printed study materials and informationconveyed via the Internet and to practise the work in inter-disciplinary teams.

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

The innovative training model infernum has become animportant building block in the scientific life of the Rhine-Ruhr area, acting as a transregional pole of attraction forthe site of Oberhausen.

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

infernum


SoundImmissionenSurvey

Knowledge and Technology Transfer Sound Immission Survey

Sound Immission Survey fora Planned Leisure Park

An enterprise plans to build up amodern leisure park in an area whichwas previously intended to be anindustrial area. The park will be openall the year. Apart from attractions withlocal character (like theme parks,markets) there will be opportunities toarrange events indoor or outdoor.A hotel with conference and meetingrooms is planned close by the park.Large parking-lots for cars and busesbelong to the park, too.There is a residential area nearby theplanned leisure park. Already in theprevious urban planning for theindustrial use of the area an extensivenoise control concept was compiled, inorder to co-ordinate the different typesof use and prevent harmfulenvironmental impacts by noise.

In the survey conducted by FraunhoferUMSICHT the sound emission and thesound immission within the intendedpark area and in the neighborhoodcaused by operating the park including

traffic noise was determined. Especiallythe impact of the changed usecompared to the former planning as anindustrial area in reference to the soundimmission situation was evaluated.

The expected sound immission in theneighborhood of the park wasdetermined based on a noisepropagation with statistically securedcalculation methods. The noisepropagation and noise mapping wascalculated with special software forcomputer-aided sound immissionprognosis.

In the result of the calculationspossibilities to optimize theenvironmentally compatible adaptationof the leisure park to the presentneighborhood were pointed out.

ContactDr.-Ing. Ulrich Seifert(+49 2 08/85 98 -11 27)



Environment TechnologyRecreation

Environment – Technology – Recreation

Solutions for Major RecreationalProjects

Besides “classical” singular leisurefacilities, facilities containing a wholerange of offers gain in importanceincreasingly. These can range fromtheme parks over gastronomy, andhotel businesses to sports, wellness,and even shopping. In order to operatesuch complex facilities failure-free,among other things, intelligent conceptsfor the management of waste, water,energy, noise and fire protection areneeded.

Fraunhofer UMSICHT develops theseconcepts for several major projects,among others the International Enter-tainment Center Krefeld IEC, the Light-house Park Rostock, and the ICE-TowerBahrain, and in this connection setsecological benchmarks through prefer-ably environment-friendly and at thesame time cost-saving solutions.

The basis for these activities alwaysis the assessment of local boundaryconditions, which besides the ascer-tained demands of the respectiveproject also includes legal and geo-graphic factors – for the fulfillment ofrefrigeration needs in the case ofKrefeld for example the waste heat ofan adjacent steel work can be utilizedby means of combined heat, power,and cold generation, whereas employ-ing solar-power-heat-cold-couplingwould provide a solution in Bahrain.

The development of these conceptstakes place in close collaboration of thesingle specialist departments.That way, Fraunhofer UMSICHT ensuresthat interfaces between specific partialconcepts can be identified, and syner-getic solutions can be developed at anearly stage. Examples of such inter-faces are the energetic utilization ofbiomass or the snow-snowmelt-cycle inthe ICE-Tower.

ContactDr.-Ing. Bernhard Dietz(+49 2 08/85 98 -11 07)Dipl.-Ing. Ulrike Wilms(+49 2 21/2 60 57 97)


»A book is like a gardencarried in a pocket.«

[Arabian proverb]


The Institute





Names, Data, Events

Publications

Selected Clients and Contacts

Patents

Spin-offs


Issa, M.; Robert, J.; Denecke, M.*; Kümmel, R.:Water re-use in practice: Closing loops infood industry, wastewater reduction incomposting plants and municipalwastewater re-use for irrigation purposesIn: Management of Environmental Quality 14(2003), no. 5, p. 571-576*University of Duisburg-Essen, Campus Essen

Jelen, E.; Weber, A.*; Unger, A.**;Eisbein, M.***:Detox cure for art treasureIn: Pesticide outlook 14 (2003), no. 1, p. 7-9*GoshenBiotech, Korea**Rathgen Forschungslabor, Berlin***Landesamt für Denkmalpflege Sachsen,Dresden

Lewandowski, I.*; Heinz, A.:Delayed Harvest of Miscanthus – Influenceson Biomass Quantity and Quality and Envi-ronmental Impacts of Energy ProductionIn: European Journal of Agronomy 19 (2003),p. 45-63*University of Utrecht, Netherlands

Spangardt, G.; Lucht, M.; Althaus, W.:Optimization of physical and financialpower purchase portfoliosIn: Central European Journal of OperationsResearch 12 (2003), no. 4, p. 335-350

Strohm, H.*; Sgraja, M.; Bertling, J.;Löbmann, P.*:Preparation of TiO2-polymer hybridmicrocapsulesIn: Journal of Materials Science 38 (2003),no. 8, p. 1605-1609*University of Würzburg, Chair of SilicateChemistry

Publications

Bergant, A.*; Dudlik, A.; Pothof, I.**;Schoenfeld, S.-B.; Tijsseling, A.S.***;Vardy, A.E.****:Case studies of fluid transients in subcooledpipe flowEindhoven: University of Technology, 2003(Reports on Applied and Numerical Analysis.RANA 03-10)*E.I. d.o.o., Slovenia**Delft Hydraulics***TU Eindhoven****University of Dundee

Bergstedt, U.; Deerberg, G.; Fahlenkamp, H.*:A systematic approach for modeling andsimulation of biological productionprocesses in stirred tank reactorsIn: Deutsche Gesellschaft für ChemischesApparatewesen, Chemische Technik und Bio-technologie e. V. -DECHEMA-, Frankfurt/Main:27th International Exhibition-Congress onChemical Engineering, EnvironmentalProtection and Biotechnology ACHEMA 2003.Frankfurt, 19-24 May 2003; p. V25*University of Dortmund

Deerberg, G.; Bergstedt, U.; Fänger, C.;Wack, H.; Heinemann, M.*; Eberhard, W.*;Büchs, S.*; Steinsiek, S.*; Schumacher-Ansorge, M.*:Stereospecific production of hydrophobiccompounds with immobilized biocatalystsin stirred tank reactorsIn: Deutsche Gesellschaft für ChemischesApparatewesen, Chemische Technik und Bio-technologie e. V. -DECHEMA-, Frankfurt/Main:27th International Exhibition-Congress onChemical Engineering, EnvironmentalProtection and Biotechnology ACHEMA 2003.Frankfurt, 19-24 May 2003; Frankfurt/Main,2003, p. 58*RWTH Aachen

Deerberg, G.; Grän-Heedfeld, J.; Wack, T.;Schwichtenberg, H.*; Winter, G.*:SimCARE – Software tool for developmentand implementation of lasting simulationmodels in process technologyIn: Deutsche Gesellschaft für ChemischesApparatewesen, Chemische Technik und Bio-technologie e. V. -DECHEMA-, Frankfurt/Main:27th International Exhibition-Congress onChemical Engineering, Environmental

Protection and Biotechnology ACHEMA 2003.Frankfurt, 19-24 May 2003; Frankfurt/Main,2003, p. 246*Fraunhofer SCAI

Deerberg, G.; Schlüter, S.:Dynamic simulations of two-phasesemibatch processes for safety relatedanalysisIn: Deutsche Gesellschaft für ChemischesApparatewesen, Chemische Technik und Bio-technologie e. V. -DECHEMA-, Frankfurt/Main:27th International Exhibition-Congress onChemical Engineering, EnvironmentalProtection and Biotechnology ACHEMA 2003.Frankfurt, 19-24 May 2003; Frankfurt/Main,2003, p. 58

Dudlik, A.; Schoenfeld, S.-B.; Hagemann, O.;Fahlenkamp, H.*:Water hammer and cavitational hammer inprocess plant pipe systemsIn: Kerntechnik 68 (2003), no. 3, p. 91-96*University of Dortmund

Dudlik, A.; Schlüter, S.; Hoyer, N.*;Prasser, H.-M.**:Pressure surges – experimental investigationsand calculations with software codesIn: International Association of Hydraulic Engi-neering and Research -IAHR-, Work Group onthe Behaviour of Hydraulic Machinery underSteady Oscillatory Conditions; InternationalRound Table on the Behaviour of HydraulicMachinery under Steady Oscillatory Conditions:11th International Meeting of the Work Groupon the Behaviour of Hydraulic Machinery underSteady Oscillatory Conditions, Stuttgart, 2003*Studsvik Scanpower, Norway**Forschungszentrum Rossendorf

Ehrenstein, U.; Kabasci, S.; Kreis, P.*;Dörmö, N.**; Bélafi-Bakó, K.**:Development of a process for the productionof natural flavour compounds by enzymaticesterification with continuous water removalusing pervaporationIn: VDI-Gesellschaft Verfahrenstechnik undChemieingenieurwesen; IVT, Institut für Ver-fahrenstechnik der RWTH Aachen:9. Aachener Membran-Kolloquium 2003;Aachen, 2003, article P4.5*University of Dortmund**University of Kaposvár, Hungary

Hessel, G.*; Kryk, H.*; Schmitt, W.*; Seiler, T.*;Weiß, F.-P.*; Hilpert, R.**; Roth, M.**;Deerberg, G.:Monitoring system for multiphasehydrogenation in chemical plantsIn: Preprints of the 5th IFAC Symposium on FaultDetection, Supervision and Safety forTechnical Processes <2003, SAFEPROCESS>*Forschungszentrum Rossendorf**Degussa AG, Düsseldorf

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

Names, Data, Events

Publications


Names, Data, Events

Selected Clients andContacts

Selected Clients and Contacts

AA. + E. Lindenberg GmbH & Co. KG,Bergisch GladbachACCESS e.V., AachenACROSS FINANCE AND TRADE GmbH, HamburgADAC Test und Umwelt, MunichAGFW, Arbeitsgemeinschaft Fernwärme,FrankfurtAG Solar NRW, JülichAndritz AG, Vienna, AustriaAiF, Arbeitsgemeinschaft industriellerForschungsvereinigungen »Otto vonGuericke« e. V., CologneAIR PRODUCTS GmbH, HattingenAir Products PLC, Basingstoke, Hampshire,Great BritainAKNZ, Akademie für Krisenmanagement,Notfallplanung und Zivilschutz,Bad Neuenahr-AhrweilerAKZO Nobel Central Research b.v., Arnhem,NetherlandsAKZO Nobel Chemicals GmbH, EmmerichAKZO Nobel, Stockholm, SwedenALSTOM Ballard GmbH, Bremen/Dortmund/FrankfurtAltenburger Maschinen Jäckering GmbH,HammAnsaldo Fuell Cells SpA (AFCo), Genova, ItalyArrotrass GmbH, CologneASEW, CologneA-TEC Anlagentechnik GmbH, DuisburgATT Automatisierungstechnik GmbH,Lutherstadt WittenbergAutobar Group, Brentford, Great BritainAWAS-Ihne GmbH, WilnsdorfAxima Refrigeration GmbH, Lindau, Bodensee

BBAFA, Bundesamt für Wirtschaft und Ausfuhr-kontrolle, EschbornBASF AG, LudwigshafenBauordnungsamt AachenBau- und Liegenschaftsbetriebe, Aachen andDortmundBaust Holzbetrieb GmbH, Eslohe-BremkeBayer AG, LeverkusenBayer 04 Leverkusen Fußball GmbH,LeverkusenBenteler AG, PaderbornBerufsfeuerwehr DüsseldorfBezirksregierung Arnsberg, Abteilung Energie,DortmundBiofam Company Ltd, Bangkok, ThailandBIOPOS Forschungsinstitut Bioaktive Polymer-systeme e. V., Teltowbiorefinery.de GmbH, TeltowBLB NRW, Bau- und LiegenschaftsbetriebNRW DüsseldorfBoehringer Ingelheim Pharma KG, Ingelheimam RheinBRZ Bodenreinigungszentrum Herne GmbH &Co. KG, HerneBTU, Brandenburgische TechnischeUniversität, Cottbus

Bückmann GmbH Sieb- und Separations-technik, MönchengladbachBundesamt für Sicherheit in der Informations-technik, BonnBundesministerium für Bildung, Wissenschaft,Forschung und Technologie, BonnBundesministerium für Wirtschaft undTechnologie, Bonn/BerlinBWS Technologie GmbH, Grevenbroich

CCargill Dow BV, Naarden, NetherlandsC.A.R.M.E.N. e. V., StraubingCelanese Chemicals Europe GmbH,OberhausenCentrO Management GmbH, OberhausenCiba Spezialitätenchemie Lampertheim GmbH,LampertheimClariant GmbH, Hürth-KnapsackCOESFELD MATERIALTEST, Coesfeld GmbH &Co. KG, Dortmund

DDBU, Deutsche Bundesstiftung Umwelt,OsnabrückDegussa AG, Darmstadt/Frankfurt/Hanau-WolfgangDegussa INFRACOR GmbH, MarlDelft University of Technology, Laboratory forProcess Equipment, Delft, NetherlandsDELU, Deutsche Leckageortungs- undUmwelttechnik AG, DüsseldorfDe Lucia Italienische FeinkostspezialitätenGmbH, HeidenDeutsche Bank AG, Innovationsteam Umwelt-technologie, MunichDeutsche Projekt Union GmbH, CologneDeutsche Structured Finance, Frankfurt a. M.Deutz Energy GmbH, MannheimDFG, Deutsche Forschungsgemeinschaft,BonnDKR, Deutsche Gesellschaft für Kunststoff-recycling mbH, CologneDLR, Deutsche Forschungsanstalt für Luft- undRaumfahrt e. V., Cologne/BonnDLR – Projektträger des BMBF für Informations-technik, BerlinDMT, Deutsche Montan Technologie GmbH,BochumDole Fresh Fruit Europe OHG, HamburgDPU, Deutsche Projekt Union GmbH, CologneDREWAG Stadtwerke Dresden GmbHDurit Hartmetall, Wuppertal

EEastman Chemical Co., Kingsport, Tenn., USAECOMARES GmbH, BüsumEdF, Electricité de France, Paris, FranceEFA, Effizienz-Agentur NRW, DuisburgEGG, Energieversorgung Gera GmbHEmpresarios Agrupados, Madrid, SpainEntwicklungsgesellschaft Neu-OberhausenmbH – ENO, OberhausenEnergieagentur NRW, Wuppertalessent Milieu, Buggenum, NetherlandsENR Energiegesellschaft nachwachsenderRohstoffe mbH, Dorsten

E.ON Engineering GmbH, GelsenkirchenEuropäische Kommission – GeneraldirektionEnterprises, Brussels, BelgiumEUS GmbH, DortmundEVO, Energieversorgung Oberhausen AG

FFachhochschule Münster, Münster/SteinfurtFachhochschule Niederrhein, Krefeldfarmatic biotech energy AG, NortorfFernUniversität in HagenFEE GmbH, Idar-ObersteinFernwärme Wien Ges.m.b.H., Vienna, AustriaFITR, Forschungsinstitut für Tief- undRohrleitungsbau Weimar e. V.FKuR - Forschung und Engineering GmbH,WillichFN, Fernwärmeversorgung Niederrhein GmbH,DinslakenFNR, Fachagentur Nachwachsende Rohstoffee. V., GülzowForschungszentrum Jülich GmbH, JülichForsthandel und Dienstleistung Lucht,VorderhagenFramatome ANP, OffenbachFritz Winter GmbH, StadtallendorfFröschle Stahl- und Maschinenbau GmbH,Neusaess/VogelsangFW-Fernwärme-Technik GmbH, CelleFZR-Forschungszentrum Rossendorf, Dresden

GGas-Wärme-Institut, Essengct german carbon teterow GmbH, TeterowGEA AG, BochumGEA Jetpumps GmbH, EttlingenGE Bayer Silicones GmbH & Co. KG,LeverkusenGEfAS, Gesellschaft für Anlagenbau undService mbH, OberhausenGEF, Gesellschaft für Energietechnik undFernwärme mbH, LeimenGemeinde Greußenheim (Bavaria)GIGATON GmbH, ViernheimGoshen Critech Corp., Seoul, Korea

HH. Anger’s Söhne GmbH, Hessisch LichtenauHansa Consult mbH, GlindeHdT Haus der Technik e. V., EssenHeller Leder GmbH & Co. KG, HehlenHenkel KGaA, DüsseldorfHerbold GmbH Meckesheim, MeckesheimHEW, Hamburgische Electricitätswerke AG,HamburgHosokawa Micron GmbH, CologneH & R, BannewitzHubert Loick, VNR GmbH, DorstenHumana AG, HerbornHüttenwerke Krupp Mannesmann GmbH,DuisburgH.U.T. Heuwieser Umwelttechnik GmbH,LinsengerichtHydac Technologie GmbH, Sulzbach/Saar


IIBEK Verpackungshandels GmbH, MarktErlbachIEA, Internationale Energieagentur, Paris,FranceIKA-Werke GmbH & CO. KG, StaufenIllertaler Biomasseheizkraftwerke Bau GmbH,Immenstadt/Oberallgäuimat-uve GmbH, MönchengladbachINEOS Phenol GmbH & Co. KG, GladbeckINFRASERV Dienstleistungen Gera GmbH, GeraIngenieurbüro Prof. Brachetti, SpringeInstitut für Marktscheidewesen, RWTH AachenInstitute for Environmental Science andEngineering, SingaporeInstitute for Refactory Materials Gliwice, PolandInterdisziplinäre Dortmunder Energie-forschung, DIE e.V., DortmundIntracar GmbH, Marlinvenio Kunststoff Engineering GmbH, ErwitteIÖWg GmbH, Institut für gemeinnützigeWirtschaftsforschung, BerlinIsobrugg Stahlmantelroht GmbH, LehrteIUTA, Institut für Energie- und Umwelttechnike. V., DuisburgIZES e. V., Saarbrücken

JJenbacher AG, JenbachJenbacher Energiesysteme GmbH, MannheimJohnson Controls GmbH, Burscheid/GrefrathJülich Fine Chemicals, Jülich

KKautex Textron GmbH + Co. KG, BonnKerm GmbH, HerneKFKI Atomic Energy Research Institute,Budapest, HungaryKITECH, Korea Institute of IndustrialTechnology, Chonan, South KoreaKnippers Metall-Chemie o.H., Mülheim a. d. R.Koch AG, Wallisellen, SwitzerlandKompetenz-Netzwerk Brennstoffzelle NRW,DüsseldorfKrupp Uhde GmbH, Dortmund

LLandesamt für Denkmalpflege Sachsen,DresdenLandesinstitut für Bauwesen des Landes NRW(LB), AachenLandgericht HeilbronnLaserzentrum Münster, MünsterLEM, Ingenieurbüro Last- und Energie-management, LeipzigLoick Holding AG, DorstenLUA, Landesumweltamt Nordrhein-Westfalen,EssenLÜNTEC, Technologiezentrum Lünen GmbH

MMalvern GmbH, HerrenbergMAN Turbo, OberhausenMann + Hummel GmbH, SpeyerMAT-TEC Engineering GmbH, WillichMaterialprüfungsamt NRW, Erwitte

Medizinische Einrichtungen der Heinrich-Heine-Universität, DüsseldorfMerck KGaA, DarmstadtMesser Griesheim GmbH, KrefeldMetall-Technik GmbH, DüsseldorfMinisterium für Schule, Wissenschaft undForschung des Landes NRW (MSWF),DüsseldorfMinisterium für Umwelt und Naturschutz,Landwirtschaft und Verbraucherschutz desLandes NRW (MUNLV), DüsseldorfMinisterium für Verkehr, Energie und Landes-planung des Landes NRW (MVEL), DüsseldorfMinisterium für Wirtschaft und Arbeit desLandes NRW (MWA), DüsseldorfMogensen GmbH & Co KG, WedelMTS Machinery Tools & Services AG, Oetwilam See, SwitzerlandMVV InnoTec Systemanalyse GmbH, Berlin

NNaue Fasertechnik GmbH & Co. KG, LübbeckeNEUENHAUSER Maschinenbau GmbH & Co.KG, NeuenhausNiederrheinische IHK, DuisburgNivelsteiner Sandwerke GmbH, HerzogenrathNoll GmbH, CologneNorddeutsche Affinerie AG, HamburgNorwegian University of Science andTechnology Trondheim, NorwayNOVEM, Nederlandse maatschappij voorenergie en milieu bv, Sittard, Netherlandsn.s.w.energy gmbh, HerzogenrathNUON Vertrieb GmbH, DüsseldorfNUTECH Solutions GmbH, Dortmund

PPacovis AG, Stetten, SwitzerlandParsum GmbH, ChemnitzPro2 Anlagentechnik GmbH, Willich/DresdenProjektträger PT3 des BMBF und des BMWA,JülichPolyplast Müller GmbH, StraelenProvico GmbH & Co. KG, NordhornPulsar GmbH, Stuttgart

RRalf Hacker Edelstahl, HüllhorstRathgen-Forschungslabor, BerlinRBG Strüder GmbH, IserlohnResearch Institute of Chemical and ProcessEngineering, Veszprem, HungaryRethmann Rohstoff GmbH, NordwaldeRetsch GmbH & Co. KG, HaanRETTENMAIER UND SÖHNE GmbH & Co.,Holzmühle b. EllwangenRhein-Plast GmbH, Bad DürkheimRosenbergRheinhalle GmbH, WülfrathRuhrgas AG, EssenRuhr-Universität Bochum, Institut für Thermo-und Fluiddynamik und Botanisches Institut,BochumRWTH Aachen, Institut für Aufbereitung undRecycling fester Abfallstoffe, AachenRWTH Aachen, Lehrstuhl für Biotechnologieund Bioverfahrenstechnik, AachenRWTÜV Systems GmbH, Essen

Names, Data, Events


SSaarberg Fernwärme GmbH, SaarbrückenSchering AG, BergkamenSiemens AG ISS, KarlsruheSILOXA AG, EssenSolarc GmbH, BerlinSolvay Intra GmbH, RheinbergStaatliche Museen zu Berlin, Rathgen-Forschungslabor, BerlinStadt BergheimStadtentwässerungsbetriebe Cologne, (AöR)Stadtwerke Bielefeld GmbHStadtwerke Bochum GmbHStadtwerke Dinslaken GmbHStadtwerke Duisburg AGStadt Düsseldorf, Stadtentwässerungsbetrieb,Chemisch-biologische LaboratorienStadtwerke Düsseldorf, GmbHStadtwerke Frankfurt/Main AGStadtwerke Hannover AGStadtwerke Herne AGStadtwerke Unna GmbHStadtwerke Schwerin GmbHSTAWAG Stadtwerke Aachen GmbHSTEAG, EssenStudsvik Scandpower AS, Kjeller, NorwaySYSTEC, Der Grüne Punkt - Gesellschaft fürSYStem TEChnologie mbH, Cologne

TTECHNIP Deutschland GMBH, DüsseldorfTechnische Akademie EsslingenTechnische Fachhochschule BochumTechnische Universität Wien, Institut fürVerfahrens-, Brennstoff- und UmwelttechnikTechnoplast Engineering AG, Diepoldsau,SwitzerlandTechnopool Schwimmbadtechnologie GmbH,BissendorfTFI, Deutsches Teppich-Forschungsinstitute. V., AachenTODA KOGYO Europe GmbH, DüsseldorfTönsmeier Dienstleistung GmbH & Co. KG,Porta WestfalicaTractebel, Brussels, BelgiumTriavel Energie trading GmbH, AachenTU Bergakademie Freiberg, Institut fürEnergieverfahrenstechnik und Chemie-ingenieurwesen

UUhde Hochdrucktechnik GmbH, HagenUmweltbundesamt, BerlinUnikliniken in Bonn, Düsseldorf, Cologne,DortmundUniversidad de Concepción, ChileUniversität Berlin, Lehrstuhl für MathematikUniversität des Saarlandes, FachbereichPharmazeutische und Medizinische ChemieUniversität Dortmund, Lehrstuhl fürEnergieprozesstechnik, Thermische Verfah-renstechnik und UmwelttechnikUniversität Duisburg Essen, Standort DuisburgInstitut für instrumentelle AnalytikUniversität Duisburg Essen, Standort Essen,Lehrstuhl für Umweltverfahrenstechnik undAnlagentechnik


Universität Duisburg Essen, Standort Essen,Lehrstuhl für Abfallwirtschaft und Abfall-technikUniversität Duisburg Essen, Standort Essen,Lehrstuhl für Technische ChemieUniversität Köln, Institut für PhysikalischeChemieUniversität Rostock, Abteilung für Analytische,Technische und UmweltchemieUniversität Siegen, Institut für Fluid- undThermodynamikUniversity of Pittsburgh, School ofEngineering, Pittsburgh, Pennsylvania, USAUrenco Deutschland GmbH, Gronau

VVdS Schadenverhütung, CologneVKU, CologneVolkswagen AG, Wolfsburg

WWAM Technik GmbH, HildenWEDECO Umwelttechnologie GmbH, HerfordWEIMA Maschinenbau GmbH, IlsfeldWestfalia Foodtec GmbH, OeldeWirtschaftsministerium Mecklenburg-Vorpommern, SchwerinWS Wärmeprozesstechnik GmbH, RenningenWuppertaler Stadtwerke AGWupperverband, Wuppertal

ZZERMA Zerkleinerungsmaschinenbau GmbH,Sinsheim-Dühren

Names, Data, Events



Names, Data, Events

PatentsSpin-offs

Patents 2003

Issued Patents:

Method for the air-conditioning of vehiclesand adsorption chiller machine for theimplementation thereof (Wigbels, Hölder,Dietz, Giebelhausen*, Spieker*)

Powder-like material for producing high-temperature super conducting coatingsand/or bodies (Bertling, Kümmel)

Method and device for the purification ofbiogas (Schwerdt, Doczyck*)

Method for the cleaning of a solid mattersystem and device for the implementationthereof (Balke, Heunemann, Ising, Unger)

Demonstration device modelling a livingorganism (Weinspach) – Russia, USA, Australia

* = external inventors

Trademarks:

DUBANET® (word trademark)

MARS® (word trademark)

Kid’s Light® (symbol and word trademark)

Glass Giant® (international word trademark)

KAVITAS® (word trademark)

Human Park® (US-word trademark)

Human World® (US-word trademark)

Spin-offs

AIROX GmbH, AlpenSystems for oxygenation

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

A-TEC Anlagentechnik GmbH,DuisburgInnovative solutions concerning coal minegas; hazard prevention: analyses, extraction,safety concepts; utilization for power andheat generation: energy concepts, designand operation of plants

DataPool Engineering GmbH,OberhausenSoftware development, system analyses,EDP-consulting

Emissions-Trader ET GmbH, AlpenEmissions trading

ENR – Energiegesellschaft nachwachsenderRohstoffe mbH, DorstenPlanning and set-up of biogas plants, includingconsulting, concession, and funding;agricultural nutrient balances and areamanagement; commissioning and management

FKuR Forschung und Engineering GmbH,WillichInnovative solutions concerning plastics andrecycling; comminution technology; extrusion,injection molding; elastomer recycling; materialanalyses; test technology; recycling concepts

gct german carbon teterow GmbH,TeterowDevelopment and production of high-performance cylindrical activated carbon;production of special activated carbons;development of adsorption processes

IDESYS Ingenieurgesellschaft fürdezentrale Energiesysteme mbH,OberhausenPlanning, development, production, installationof local energy systems and plants

inecs GmbH, DortmundInnovative energy technology, consulting &systems, fuel cell systems

invenio KUNSTSTOFF ENGINEERING, ErwitteProduct development and optimization ofplastics components with numerical analyses;FEM structure analyses, injection moldinganalyses; construction

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

WAGRO Systemdichtungen GmbH,DortmundExpansible polymere seals; sewer and buildingrefurbishment; consultation, planning, andimplementation; development and productionof sealing systems (area of application:engineering and pipeline construction)


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 at theend of the exit. At the next intersectionturn left onto Mellinghofer Strasseand at its end turn left onto EssenerStrasse. At the next major intersectionturn right onto Osterfelder Straße. Atthe first traffic light turn right into theparking 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 2 08/85 98 -0Fax: + 49 2 08/85 98 -12 90

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

By train

From Oberhausen central station toUMSICHT with bus no. 185 (directionEssen Borbeck Bf.), no. 957 (directionKiebitzstrasse), no. 958 (directionSpechtstrasse) 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.

Names, Data, Events

How to Find Us


The Fraunhofer-Gesellschaft

The Fraunhofer-Gesellschaft under-takes applied research of direct utilityto private and public enterprise and ofwide benefit to society. Its services aresolicited by customers and contractualpartners in industry, the service sectorand public administration. The organi-zation also accepts commissions andfunding from German federal andLänder ministries and governmentdepartments to participate in future-oriented research projects with the aimof finding innovative solutions to issuesconcerning the industrial economy andsociety in general.

By developing technological innovationsand novel systems solutions for theircustomers, the Fraunhofer Instituteshelp to reinforce the competitivestrength of the economy in their localregion, and throughout Germany andEurope. Through their work, they aim

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The Fraunhofer- Gesellschaft

to promote the successful economicdevelopment of our industrial society,with particular regard for social welfareand environmental compatibility.

As an employer, the Fraunhofer-Gesellschaft offers a platform thatenables its staff to develop the pro-fessional and personal skills that willallow them to take up positions ofresponsibility within their institute, inother scientific domains, in industryand in society.

At present, the Fraunhofer-Gesellschaftmaintains roughly 80 research units,including 58 Fraunhofer Institutes, atover 40 different locations in Germany.A staff of some 12,500, predominantlyqualified scientists and engineers,

Names, Data, Events



USA and Asia provide contact with theregions of greatest importance tofuture scientific progress and economicdevelopment.

The Fraunhofer-Gesellschaft wasfounded in 1949 and is a recognizednon-profit organization. Its membersinclude well-known companies andprivate patrons who help to shape theFraunhofer-Gesellschaft’s researchpolicy and strategic development.

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

work with an annual research budgetof over 1 billion €. Of this sum, morethan € 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. Theremaining one third is contributed bythe German federal and Ländergovernments, as a means of enablingthe institutes to pursue more funda-mental research in areas that are likelyto become relevant to industry andsociety in five or ten years’ time.

Affiliated research centers and re-presentative offices in Europe, the

Names, Data, Events


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Trustees

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

Burkhard Drescher(Mayor of the City ofOberhausen,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, Memberof the 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 ofthe 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 second meeting of the Board of Trusteestook place on 28 November 2003 at FraunhoferUMSICHT in Oberhausen.

Names, Data, Events

Board of Trustees – Fraunhofer UMSICHT


Fraunhofer Institute forEnvironmental, Safety, andEnergy Technology UMSICHT

Osterfelder Strasse 346047 Oberhausen

Phone + 49 2 08/85 98 -0Fax + 49 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, K. Hölscher,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:UDT: p. 36Abteilung 8, Bergbau und Energie;RP Arnsberg: p. 49www.photocase.de: Titel, p. 1,p. 19, p. 20, p. 22-26, p. 38, p. 39,p. 41, p. 46, p. 54, p. 55, p. 60, p. 61all other photographies:© Fraunhofer UMSICHT

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

The Directorate

Director:Prof. Dr. rer. nat. Rolf Kümmel

Director Science and Technology:Dr.-Ing. Görge Deerberg

Director Business and Administration:Dr.-Ing. Bernhard Dietz

Names, Data, Events

Imprint

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

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UMSICHT-Jahresbericht 2001 3

Staff

At a Glance: Facts and Figures

Number

1611083122

1121316462413

273

Staff at Fraunhofer UMSICHT 2003

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

Expenditure and Returns

Expenditure 2003

Operational Budget- Staff costs- Other costs

Investments

23.39.3

14.0

1.2

(m €)

Returns Operational Budget 2003

- Industrial returnssmall and medium-sized enterpriseslarge enterprises

- Public returns- Others (EU, communities)- Basic funding

Total Returns

12.110.12.02.21.67.4

23.3

(m €)

At a Glance: Our Business Units

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