prof. dr. alexander michaelis - american ceramic...

From R&D to products: Innovation with FraunhoferFrom R&D to products: Innovation with Fraunhofer

Prof. Dr. Alexander Michaelis

Energy and environmental technology at IKTS.

Membranes Fuel CellsSupercaps

PV / Batteries

© Fraunhofer IKTS1

Fraunhofer is the largest organization for appliedh i E t f I tiresearch in Europe your partner for Innovation

DortmundDresden

Bremen

Hannover

Berlin

Rostock7 alliancesmicroelectronicsproduction

Darmstadt

Dresden

Saarbrücken Kaiserslautern

productioninformation and communicationmaterials and componentslif i

Karlsruhe

MünchenStuttgart

Freiburg

life sciences

surface technology and photonics

defence research and technology

59 Institutes at 40 Locations

18.000 staff 1,7 Bill. € Budget

© Fraunhofer IKTS2

Joseph von Fraunhofer

The Fraunhofer-Gesellschaft Fraunhofer

Research and

Gesellschaft ,Headquarter Munich(17871826)

Discovery of the “Fraunhofer lines” in the solar spectrum

Research and development on behalf of industry and state

Researcher

and state

mp3 music format, New methods for processing lenses

pwhite LED, high-resolution thermal camera

Inventor

i d

Research volume: approx. 1.7 billion €

Director and partner in a glassworks

annually of which 1.4 billion € is generated through contract research

Entrepreneur

© Fraunhofer IKTS3

From a small association to the leading organization for li d h i Eapplied research in Europe

58 60 59Number of institutes

8 13

0

7 15

0Staff

19 1927 27

3337

47 47

7 390

7 98

0

9 20

0 12 8

00

1817

0 19

19 19

49 54 59 64 69 74 79 84 89 94 99 04 09 10

3 20

135 700 1 25

0

1 67

5

2 21

3

3 47

7 6 3

49 54 59 64 69 74 79 84 89 94 99 04 09 10

16571617

Budget in € (millions)

49 54 59 64 69 74 79 84 89 94 99 04 09 10 49 54 59 64 69 74 79 84 89 94 99 04 09 10

580710

1069

0 2 8 17 52 95 180350

0,2

49 54 59 64 69 74 79 84 89 94 99 04 09 10

© Fraunhofer IKTS4

Fraunhofer worldwide

Brussels ViennaParis Budapest

Wrocław

Gothenburg

D b i

Beijing SeoulTokyo

BostonPlymouth

East LansingSan José

NewarkMaryland

Cairo

CambridgePorto

BolzanoGraz

Thessaloniki

Dubai

Bangalore SelangorSingapore

Jakarta

Santiago de Chile SydneySantiago de Chile y y

Subsidiary Center

Representative Office Senior Advisor

Project Center / Strategic Cooperation

© Fraunhofer IKTS5

p

Fraunhofer USA, Inc.fi t b idi t 1994first overseas subsidiary, est. 1994

Fraunhofer USA Headquarters

f i

Laser Technology CLT

Newark

Manufacturing Innovation CMI

Maryland

BostonPlymouthEast Lansing Cambridge

Heinrich HertzSan José

Sustainable Energy Systems CSE

Heinrich Hertz Institute (HHI) USA

Systems CSE

Molecular Biotechnology CMB

Coatings and Laser Applications CCL

Experimental Software Engineering CESE

Digital Media Technologies DMT

© Fraunhofer IKTS6

International Revenues 2010 by Countries – Top 20(without EU Commission) in million €

10 030,2

A t iUSA*

(without EU-Commission) in million €

5 55,96,2

7,910,0

Belgium without EUJapan

FranceSwitzerland

Austria

3 23,43,74,0

5,5

ChinaItaly

Great BritainNetherlands

Belgium without EU

2 32,82,83,03,2

NorwaySouth Korea

SpainSweden

China

1,11,21,31,52,3

Russian FederationPolandMexico

IsraelNorway

0,91,01,1

FinlandIndia

*USA: of which €19.6 million Fh-USAÖsterreich: of which €1.2 million Fh-Austria

© Fraunhofer IKTS7

Fraunhofer Institute of Ceramic Technologies and gSystems, IKTS

IKTS belongs to the top 5 Fraunhofer Institutes

IKTS budget (w/o invest)

IKTS belongs to the top 5 Fraunhofer InstitutesMain market of IKTS: Energy and environmental technology

Sites Dresden and Hermsdorf

Staff: 420T €

Budget: 32 Mio € w/o invest

ca 80 % revenue from contract research

(50 % directly from industry)(50 % directly from industry)

© Fraunhofer IKTS © Fraunhofer IKTS© Fraunhofer IKTS

Environmental Engineering and Bioenergy at IKTS

1. CO2-reduction in combustion plants / CCSgas filtration (O2-production)

Bioenergy at IKTS

gas filtration (O2 production)

2. Water technology (waste water, potable water)

3. Bioenergy (Biogas, Bioethanol, Biobuthanol, Biodiesel)3. Bioenergy (Biogas, Bioethanol, Biobuthanol, Biodiesel)

4. Diesel particle filter

5. Catalysis and membrane reactorsy

© Fraunhofer IKTS9

1 Nano-porous membranes

Examples for membrane-materialsused at IKTS

1. Nano porous membranes(Zeolite, carbon, CNTs, MOFs, amorphous oxides, …)

2 D i d d ti b 45Ceramic substrate tubes Nano-porous TiO2-membrane layer

2. Dense mixed conducting membranes(Perovskites, ZrO2, Tungstenates, …)

3. Metallic membranes 25

30

35

40

45

w [m

³/m²h

bar] ---

PT 1PT 2PT 3

H2

CO2

C3H8

(Pd, Ag/Pd, Cu/Pd, …)

4. Composite membranes(Zeolite/Polymer CNT/Polymer )

5

10

15

20

sing

le g

as fl

ow

N2

CH4

SF6

Separation performance of(Zeolite/Polymer, CNT/Polymer, …)

5. Catalysts on ceramic porous substrates(mixed oxides, precious metals, …)

02,5 3,5 4,5 5,5

kinetic diameter [Å]

Separation performance ofcarbon membranes

IKTS develops membranes and catalysts, produces and testscomponents at appication conditions

© Fraunhofer IKTS10

Formation of structural pores < 1 nm

Crystallographic Lattice plane distances Crystallographic Crystallographiccages/channels

Lattice plane distances Crystallographic defects (vacancies)

35 n

m0,

3

0,4 nm


From materials up to the systems / products

145 °C

From materials up to the systems / products

coolingwater30 °C

coldwater10 °C

coldwater4 °C

99.5 wt.% ETOH

Steam for start

110 °C, 85 wt.%

M

MRectificatio

M

Atmosphere

From mash column

(110,000 l/d)66 wt.% ETOH

Fusel oils and techn. alcohols

up and control

oncolum

n

MM

Lutter waterProduct (80,000 l/d)

99.5 wt.% ETOH

14 2°C

MM

MM MM

system / product

process

b

module

support

membrane


Profile of the Fraunhofer IKTS

Range of Services

R li ti f R&D j tRealization of R&D projects

Transfer to pilot scale

I t i S t I n n o v a t i o n S t a g e s

Idea, business case

Research &development

Prototype manu-facturing, pilot plant

Mass productionp g, p p

Development alliance Additional services IKTS:Prototype manufacturing and material development

Task of industry

C e r a m i c s D e v e l o p m e n t C e n t e r

and material development in pilot scale


Energy R&D at IKTS: Highlights

eneramic® Energy with ceramics

Thermoelectrical Generators, TEG

High Temperature-Fuel Cells (SOFC)

Bioenergy

Energy Harvesting (piezo-ceramics)

Low Temperature-Fuel Cells(Micro-PEM)

Photovoltaics


technology plattform functional ceramics / thick film (slurry) deposition

Micro- and Energy t2 t ti i ti1 pastes / slurry systems2 tape casting, printing1 pastes / slurry

Intelligente Materialien und Systeme

3 stacking 4 lamination, co-fire

Micro-Fuel Cells


Thick film technology for function integration

ents

Cost barrier for economic success

com

po

ne

cost

s fo

r o

du

ctio

n c

F ti

Pro

Functions


Screen Printing at IKTS

fScreen Printing of planar and tubular structures

Automatic positioning

Cleen Room facilities


Photovoltaics with Focus on BEOL (Contacting)

Materials for Thick Film Contacting / Issues

( g)

1. Cost Reduction, less Ag

2. Environmental friendly materials (Pb-free)

3. Higher lateral resolution

4. Better Yield

Production Processes

1 Higher throughput 1. Higher throughput

2. Non contact to improve yield

3. Automatization3. Automatization


Thick Film Technology for Contacting of Solar-cells

Screen printingScreen printing

FRT Microprof (opt. Profilometer)

fireing 4 zone IR-furnace

Electrical characterization


IKTS — Printing Technologies

Screen Printing Inkjet- Printing Aerosol Printing


Joint IKTS / Roth & Rau AG 10 MW PV pilot lineClosing the gap: From lab to fab C os g t e gap o ab to ab


Solid Oxide Fuel Cell (SOFC) value chain

Material

MEAMEA

System

Stack

System

Take over of Siemens AG planar SOFC Technologyplanar SOFC Technology including IP and some assets in 1998


Fuel cell systems at IKTS

1 W 10 W 100 W 1 kW 10 kWH d h ld t bl t ti1 W 10 W 100 W 1 kW 10 kWH d h ld t bl t tiHand held portable stationaryHand held portable stationary

Hydrogen PEFC

Tubular SOFC

LPG SOFC

Natural gas SOFC

Biogas SOFC


Fuel cell systems at IKTS

1 W 10 W 100 W 1 kW 10 kWbil t bl t ti

1 W 10 W 100 W 1 kW 10 kWbil t bl t timobile portable stationarymobile portable stationary

Hydrogen PEFC

Tubular SOFC

LPG SOFC

Natural gas SOFC

Biogas SOFC


Bioenergy Application Center at „Pöhl“ in Saxony

Synergy bewteen structural + functional

Energy Storage:Redox - Flow Battery

Umweltverfahrenstechnik Funktionskeramik / Strukturkeramik

Synergy bewteen structural + functional

ceramics

yNaS Battery

Strukturkeramik


Environmental Processing Technology at Fraunhofer IKTS –

ENERGY/ENVIRONMENT/AGRICULTURE => Project „ More biogas at higher energy level way to efficient power production“ higher energy level –way to efficient power production

LAB-scale PILOT

F ll lFull scale


IKTS integrated technology line along complete value h ichain

Thick film glas sealing electrochemistry CAD + Simulation System technology process technology

test facilities


Storage technology:Li-Ion Battery value chain / technology lineLi-Ion Battery value chain / technology line

powder- Thick film- Cell assembly Electrochemical System-processing deposition

ystacking initializing

ydesign

Hydro-metalurgy Slurry preparation Tape handling Electrolyte filling Battery managementy gyCalzinationMilling Granulation

y p pCasting processingRoll to rollIn-line QS/QM

p gLamination / StackingThermal managementIn-line QS/QM

y gChargeingQuality check

y gThermal managementContainmentSafty

30 % 10 % 10 % 40 %10 %30 % 10 % 10 % 40 %10 %


Technology platform for battery systems

powder-processing

chemical synthesis

calzination

milling, granulation

electrochemistry electrochemistry


Powder Processing

Objective: refining and shaping of precursors and product powders

Approach: using pilot-plant scale processing technology at IKTS

IKTS scope:

Milling, granulation, shaping and coating using spray dryer / fluidizes bed reactors

Developing cost effective, eco-friendly, proprietary processing methods

Advantage:

Tight interface to production process, no end-of-pipe innovation

Systematic approach to complete powder production process

Large scale pilot spray drier/coater Fluid bed reactor In-process control and measurement


Powder Processing – Shape control

Objective: generate controlled-shape powders, characterisation of powders

Approach: using IKTS know-how from other powders

IKTS scope:

Developing process windows for controlled shapes using state-of-the art machinery

Using IKTS high-end characterisation methods

Advantage:

Tight link between powder shaping, characterisation and electrochemistry

D t h d P h d

Single granule mechanics

P i l hDonut shaped Potato shaped Precise granule shape measurement

Nano coatings Hollow and graded

EQPC 187.955µmSphericity 0.889Aspect ratio 0.892Convexity 0.937Image Number 706


g g

Electrochemistry at IKTS

Objective: electrochemical performance of cathode powders and electrodes

Approach: using high-end electrochemical and battery research methods

IKTS scope:

Electrochemical assessment of performance in short iteration loops

Understanding of structure-performance relationships

degradation mechanisms, post-mortem-analysis

Advantage:

First hand, independent information on powder performance

3 5

4,0

/ V

0 50 100 150 200 250 3000,0

0,51,0

1,52,0

2,53,0

3,5

OC

P vs

. Li/L

i+

Large scale battery testers

2

3

4

tage

U /

V

time t /s

particle

microcapillary

RE

CE

Quick check cell setup Standard tests

0,0 0,5 1,0 1,5

1

2

cell

vol

capacity q / mAhcm-2

1st charging cycle 2nd charging cycle 3rd charging cycle

particle

WE substrate

High end micro equipment


Quick-check cell setup Standard tests High end micro equipment

partnerships

Project LiFab

Pilot scale production of Li-Ion-Batteries p

Process- and technology development

ThyssenKrupp System EngineeringThyssenKrupp System EngineeringThyssenKrupp Drauz Nothelfer


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prof. dr. alexander michaelis - american ceramic...

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