FRAUNHOFER-GESELLSCHAFT PARTNER FOR INNOVATION

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The Fraunhofer-Gesellschaft The Fraunhofer-Gesellschaft carries out applied research of direct utility to private and public enterprises and to society Our customers:

 Industry  The service sector  Public administration

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The Fraunhofer-Gesellschaft Research and development  Application-oriented research of direct utility to businesses and society  Application-oriented basic research  Departmental research for the German Federal Ministry of Defense Business community  Institutes work as profit centers  One-third of the budget consists of income from industrial projects  Spin-offs by Fraunhofer researchers are encouraged Contracting partners / clients  Industrial and service companies  Public sector

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The Fraunhofer-Gesellschaft in Germany

Rostock

Itzehoe Lübeck Bremerhaven Hamburg Oldenburg

 60 institutes  more than 18,000 employees

Bremen Hannover

Braunschweig

St. Ingbert

Würzburg

Bronnbach

Teltow

Magdeburg

Bayreuth Erlangen

Kaiserslautern Fürth Saarbrücken Karlsruhe Pfinztal Ettlingen Stuttgart Freiburg Kandern EfringenKirchen

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Berlin

Cottbus Paderborn Oberhausen Halle Dortmund Schkopau Leipzig Duisburg Kassel Schmallenberg Dresden Jena St. Augustin Erfurt Freiberg Aachen Gießen Euskirchen Chemnitz Wachtberg Ilmenau Darmstadt

 Institutes and research establishments • Additional sites

Potsdam

Nürnberg

Straubing

Freising Garching Augsburg München Oberpfaffenhofen Prien Holzkirchen

Fraunhofer worldwide Göteborg Brussels Paris

San José

East Lansing

Plymouth Boston Cambridge Newark Maryland

Wrocław Vienna Budapest Graz Bozen

Porto

Seoul

Peking

Thessaloniki

Tokio

Cairo Dubai Bangalore

Selangor Singapur Jakarta

Santiago de Chile

Subsidiary

Center

Representative Office

Senior Advisor

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Sydney

Project Center / Strategic Cooperation

FRAUNHOFER INSTITUTE FOR CHEMICAL TECHNOLOGY ICT RESEARCHING WHERE IT`S FUN!

© Fraunhofer ICT

© Fraunhofer ICT

Main business markets of the Fraunhofer ICT

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Energy and environment

Defense, safety, security, air and space technology

Chemistry and process engineering

Automotive and transportation

Fraunhofer ICT organization chart Institute Director

Controlling

Prof. Dr. P. Elsner

C. Steuerwald

Deputy Directors Dr. H. Krause, Prof. Dr. F. Henning

Administration

General Management

Dr. B. Hefer, C. Steuerwald

Dr. S. Tröster

Energetic Materials

Energetic Systems

Applied Electrochemistry

Environmental Engineering

Polymer Engineering

Dr. H. Krause Dr. T. Keicher Dr. S. Löbbecke

W. Eckl G. Langer Dr. N. Eisenreich

Dr. J. Tübke Dr. K. Pinkwart

R. Schweppe Dr. J. Woidasky

Prof. Dr. F. Henning Dr. J. Diemert Dr. R. Bräuning

Project Group for Sustainable Mobility, FH Braunschweig-Wolfenbüttel, Wolfsburg

Fraunhofer Center for Chemical-Biotechnological Processes, CBP Leuna

Dr. J. Tübke

Prof. Dr. T. Hirth (IGB), Rainer Schweppe

Project Group for Functional Lightweight Design, FIL Augsburg

Project Group for New Drive Systems, NAS Karlsruhe

Prof. Dr. K. Drechsler (TUM), Prof. Dr. F. Henning

Dr. H.-P. Kollmeier Prof. Dr. P. Elsner, Prof. Dr. P. Gumbsch (IWM)

Fraunhofer Project Center, FPC London (Ontario)

Project Group for Electrochemistry, Munich (under development)

Prof. Dr. F. Henning, T. Potyra

Dr. J. Tübke, Dr. K.-C. Möller

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Fraunhofer Institute for Chemical Technology ICT

 Established  Location

 Staff (full-time equivalent) Scientists, PhD candidates Graduates, laboratory technicians Workshop and laboratory assistants Administration Trainees Scientific assistants, work experience placements

 Budget 2013 (ICT Pfinztal only)  Total site area Laboratories, offices, pilot plants, workshops Test sites, infrastructure

February 2014

© Fraunhofer ICT

1959 Pfinztal-Berghausen

549 (approx. 402) 144 105 95 52 16 approx. 137

38.3 million € 200,000 m2 approx. 13,000 m2 approx. 12,000 m2

General Management and Administration General Management  Research planning Strategic planning, acquisition support, development of business units, project executive agencies, institute ambassadors

 Communication Printed information, press and public relations, trade fairs, conferences, visitors, VIPs, digital media

 International activities International contacts and collaborations

Administration  Personnel Personnel management, training and professional development, TheoPrax

 Finances Project controlling, budgeting, accounts, procurement

 Organization Catering, events, site security, building management, IT, library, technical workshop © Fraunhofer ICT

Department of Applied Electrochemistry  Primary and secondary batteries Material and system development, battery testing and service, new battery materials (e.g. for lithium-oxygen and lithium-sulfur batteries)

 Redox-flow batteries Investigation and development of alternative electrolytes, electrodes and membranes, design of process technology

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

 Sensor technology and analysis systems Electrochemical sensors, trace detection, pattern recognition, online analysis of volatile substances © Fraunhofer ICT

Department of Energetic Materials  Chemical process engineering for the safe production and refinement of energetic materials and fine chemicals

 Safety and security research from the detection of explosives to fire protection

 Defense research on explosives ensuring continued competence as a consultant and evaluator for the German Federal Ministry of Defense, and maintaining system capability from the raw material to the prototype

 Smart materials for the use of new functionalities based on micro and nanostructures

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Department of Energetic Systems  Defense research Ensuring continued competence as a consultant and evaluator for the German Federal Ministry of Defense, and maintaining system capability in the areas of interior ballistics, detonics and pyrotechnic systems

 Energy research Systems for thermal and material-based storage

 Functional layers Reactive energetic layers, high-temperature thermal insulation layers and nanoparticle coatings

 Safety Gas generator systems, hydrogen security and industrial safety

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Department of Polymer Engineering  Compounding and extrusion Materials and cutting-edge processing technology

 Nanocomposites Functional composites and their characterization

 Foam technologies Processes and materials for particle and extrusion foams

 Thermoplastic processing Injection and compression molding, thermoplastic composites

 Thermoset processing Process and material development, tailored SMC

 High-performance composites RTM processing chain, injection, preforming, prepregs

 Microwaves and plasmas Microwave technology, surface modifications

 Plastics testing Mechanical and rheological analysis, microscopy, DoE

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Department of Environmental Engineering  Reaction and separation technology Platform chemicals and monomers from renewable raw materials, mechanical and thermal separation processes

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

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

 Environmental simulation and product qualification Climate, vibration and shock tests, corrosive gas test, test of chemical stability, solar simulation, thawing

 Analytical characterization Chemical analytics, breakdown and analysis of biomass, plastic characterization, emission measurements © Fraunhofer ICT

Project Group for New Drive Systems NAS  Hybrid drive trains and e-mobility  Improving efficiency of electrified powertrains  Thermal management systems for EVs

 Conventional powertrains  Improving efficiency of conventional powertrains  Ics and partly electrified powertrain topologies

 Stationary drive trains and heat utilisation  Decentralised energy supply systems based on CHP  Electrical and thermal storage systems

 Lightweight powertrain design  Weight reduction of stationary and moving powertrain components © Fraunhofer ICT

Fraunhofer Center for Chemical-Biotechnological Processes CBP in Leuna  Simulation and construction methods, online process monitoring Numerical simulation and monitoring of the entire manufacturing chain and its influence on component quality and performance

 Material and testing technology Development of hybrid materials and joints, as well as material analysis and characterization across the entire processing chain

 Processes Development of composite lightweight structures with a view to industrial implementation

 Recycling Development of a lean, resource-efficient, comprehensive production chain for the manufacture of low-cost and environmentally-friendly recyclates

 Efficiency and life-cycle assessment Evaluation and optimization of composite processing chains in terms of their resource efficiency

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Project Group for Sustainable Mobility in Wolfsburg Components and materials for energy storage devices and converters  Metallic bipolar plates Corrosion-stable materials with good electrical and thermal properties, coating materials

 Functional polymers Specific polymers or polymer and metal compounds

 Characterization of materials and components Corrosion testing, electrochemical analytics (EIS, CV, I/E), polymer analytics (DSC, IR) and mechanical analytics (tensile/stretching tests)

 Projects carried out by school pupils (TheoPrax, Future Day)

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Project Group for Electrochemical Storage Devices in Garching  Materials for energy storage devices New electrode materials (alloy anodes, composite electrodes)

 Small-series production Production of cells

 Module and battery development Thermal, electrical design

 Testing of battery systems Test stands for operational stability and abuse tests on batteries >20 kWh  Post-mortem, aging Failure analysis of battery systems, analytics for aging investigations

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Fraunhofer Project Center @ Western in London, Ontario, Canada  Sheet molding compound SMC  Direct SMC technology  Conventional SMC  Formulation and process development

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

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

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DEPARTMENT APPLIED ELECTROCHEMISTRY Fraunhofer Institute for Chemical Technology ICT

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Applied Electrochemistry

Director Dr. J. Tübke, Dr. P. Pinkwart

Batteries

Fuel Cells

Redox-FlowBatteries

T. Berger

Dr. C. Cremers

Dr. P. Fischer

Sensors and Analytical Systems P. Rabenecker

Project Group „Mobility“ Wolfsburg

Project Group „Electrochemical Storage Systems“

Dr. J. Tübke

Dr. J. Tübke, Dr. Kai-Christian Möller

© Fraunhofer ICT

Applied Electrochemistry within Fraunhofer  Fraunhofer-Netw ork „Electrochem is try “ (Coordination – Dr. Kars ten Pinkw art)  Batteries, Fuel Cells

 Galvanic, Corrosion  Electrochemical machining  Sensors and analytical systems  Elektrochromic systems and polymer electronic  Fraunhofer Allience „Batteries “ (Coordination – Dr. Jens Tübke)  Material development, Simulation  Characterisation and Tests, Abuse test  Prototypes  Battery management  Studies, Roadmaps, Strategies © Fraunhofer ICT

Applied Electrochemistry Batteries

Materials

Cell Development

• Test cell development. material tests • Solid state ion conductors • S- und O- cathodes • Alkaline -anodes

• Pouch cells • Cell design > 40 Ah • Electrical and thermal cell characterisation

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Safety and Performance • Standard tests up to 40 kWh / module • Customer – specific measurements • Gas analysis • Simulation

Primary and secondary batteries Material development and testing  Electrochemical systems  Li-ion, Li-S, Na-ion, Si- and Sn-anodes, super-capacitors

 Electrolytes and separators  Organic electrolytes, ionic liquids, polymer gel electrolytes and ceramic separators (e.g. for lithium-ion and lithium- or sodium-metal batteries)

 Material testing  Testing and benchmarking of electrode materials, electrolytes and separators  Construction of laboratory test cells  Construction of demonstrator cells with a pouch design

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Primary and secondary batteries System development and testing  Safety concepts, fire protection, sensor systems on a cell and module level  Safety and abuse tests according to international standards (Transport Test UN 38.3, IEC62660)  Nail test, shaker tests, fall tests, crushing tests, overcharging, deep discharge, thermal abuse

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Primary and secondary batteries System development and testing  Modul development  Modules for different applications  Lithium-Ion, Ni-MeH, ...  Modul design

 Connections, Packaging  Cooling systems  Safety

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Primary and secondary batteries Analytics  In-situ analytics in conjunction with safety tests, or to determine the composition of electrodes / electrolytes  Ion chromatography (HF), GC (H2, O2, N2, CO, CO2, CHy)  Gas chromatography, mass spectroscopy (fluorinated hydrocarbons, organic carbonates, additives, intermediate products)  FTIR for in-situ measurements in abuse tests  SEM:EDX: Electrode materials

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Applied Electrochemistry Redox-Flow-Batteries

Materials • Electrolyte development • Bipolar plates, electrodes • New systems: „Li-Redox“ • Membranes

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Stack development and production • Simulation • Stack design • Demonstrators

System • • • • •

Simulation System design System automation Tests Demonstrators

Primary and secondary batteries Redox-flow battery Membrane Electrode

Electrolyte

Electrode

-

+

Pump

Electrolyte

Pump

Power source/load

Anode:

A x  A x  z  ze e -

Cathode: K y  ze e-  K y  z © Fraunhofer ICT

RT cox EE  ln ze F cred o

Primary and secondary batteries Redox-flow battery Redox S y s tem s

hydrogen generation

oxygen generation

V(2/3)

Zn(2/0)

-1.0

Cr(2/3)

-0.5

V(4/5) Fe(2/3)

S(0/1)

0.0

Br(1/0)

Ce(3/4) Ni(2/3)

Mn(2/3)

0.5

1.0

1.5

Various types with different electrolytes / electrodes  vanadium redox battery (VFuel)  zinc / halogen (ZBB Energy Corp, Premium Power Corporation)  bromine / sodiumpolysulfid (Regenesys Technologies Limited)  zinc / cerium (Plurion Systems Inc.) © Fraunhofer ICT

U [V] vs. 2.0 NHE

Primary and secondary batteries Redox-flow battery Energy Density of Electrolyte [Wh/L]

Current Density [mA/cm²]

Power Density [W/m² electrode]

Cell Voltage [V] (25°C, 1 mol/L electrolyte conc.)

EE

Vanadium / Vanadium

30

80

~ 800

1,40-1,60

70 – 90 %

Vanadium / Bromine

35-70

1,34

66 – 75 %

Iron / Chromium

40

40

~ 200

1,18

75 %

Polysulfide / Bromine

80

60

~ 800

1,52

60 – 75 %

Zinc / Bromine

80

>100

~ 1000

1,85

65 – 75 %

Type

Uranium

1,00

Neptunium Cerium / Zinc Lead

© Fraunhofer ICT

1,00-1,10 12-20 75

400-500

1200-2500

2,00-2,40

~ 1000

2,00

Primary and secondary batteries Redox-flow battery  Material development and testing  Electrode materials  Separators  Electrolytes  Long-duration tests, simulations, aging  Stacks and systems  Stack design and development  Construction of prototypes  Feasibility studies  System integration, battery management

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Primary and secondary batteries Redox-flow batteries  Development of large-scale redox-flow storage devices in the kW to MW range  Design of storage devices for houses; prototype development from the stack to the complete system

 Assistance in the approval process for the construction of storage solutions  Design and development of storage solutions in the MW range  Project “RedoxWind” to connect a 2 MW / 20 MWh redox-flow battery to a wind power unit

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Primary and secondary batteries 1 kW VRFB UPS for Telecommunication  Hybrid system VRFB – Supercaps  No self discharge of flow battery  Low maintenance cost  < 10 ms access time  scaleable

Load/Source

10 kWh

10 kWh 170 L 1,6 M V2+ / V3+

Control

Supercap 1,1 kW, 30 s 42 Stck, 310 F

1 kW 24 V; 42 A

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170 L 1,6 M VO2+ / VO2+

Primary and secondary batteries 30 kW VRFB for Field Camps  Technology demonstrator  24 Stacks (600 cm², 22 cells)  current  max. 360 A  potential  175 V  power  34 kW  Power denisty  30 kWh  1 reserve stack  autonomous operation

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Primary and secondary batteries 2MW / 20 MWh Redox-flow batteries Des ign of a battery s y s tem

P = 2 MW; W = 20 MWh; U = 1960 V; I = 1008 A; A = 3600 cm², 2 x 300 m3 electrolyte; 100 Cells / Stack; 7 Stacks serial / module; 8 modules) N2

N2

AC DC RegelVentil

RegelVentil

Tank 2 M V2+/V3+ 3 M H2SO4 V = 299 m³

250 kW 980 V; 252 A

Tank 2 M V4+/V5+ 3 M H2SO4 V = 299 m³

250 kW 980 V; 252 A

N2

N2 RegelVentil

Pumpe 1

250 kW 980 V; 252 A

Pumpe 3

Pumpe 5

250 kW 980 V; 252 A

Pumpe 2

© Fraunhofer ICT

250 kW 980 V; 252 A

250 kW 980 V; 252 A

Pumpe 6

250 kW 980 V; 252 A

Pumpe 4

Pumpe 7

250 kW 980 V; 252 A

Pumpe 8

RegelVentil

Primary and secondary batteries 2MW / 20 MWh Redox-flow batteries

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S tand Aug. 2014 - Gebäude Batteriehalle

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Battery building 19.08.2014

Applied Electrochemistry Fuel Cells

Materials

Characterisation

System

• Catalyst development (DAFC) • Degradation studies • Coatings • O - Cathodes

• Materials • Degradation • System tests

• DAFC Systems up to 5 kW • Reforming • Degradation, Aging • Simulation

© Fraunhofer ICT

Fuel cells Material development and testing  Electrocatalysts for  Alcohol oxidation and oxygen reduction in alkaline fuel cells, without the use of noble metals  Alcohol oxidation and sulfurous reformates in HT-PEMFC

 Carrier materials for EMEL anodes and HT-PEMFC, binder materials for alkaline membrane fuel cells  Differential electrochemical mass spectrometry (DEMS) and HT-DEMS  Unique construction with a flow-through cell, e.g. for quantification of CO2 production  Product spectrum of alcohol oxidation; degradation investigations  DEMS measurements in the gas phase at high temperatures can at present only be carried out at Fraunhofer ICT

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Fuel cells Membrane electrode assemblies  Development of membrane electrode assemblies (MEAs) for the following cell types:    

LT-PEMFC HT-PEMFC AEMFC PEMEL

 Development of adapted coating processes    

Selection of binder Ink formulation Spray coating Thermal aftertreatment

 Partially-automated spray unit for small series

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Fuel cells System development (military)  Development of demonstrator system for military applications  portable power supply  tactical generators  range extenders for land and underwater vehicles

 Fraunhofer ICT employees participate in the relevant committees within NATO and the European Defence Agency  Consultancy for the German Ministry of Defense (BMVg) and the related industry

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Fuel cells Standardisation (military)  Fraunhofer ICT is actively participating in an UK / German standardisation committee for military fuel cells.  A generic standard on fuel cells has recently been published as British Def-Stan 61-23.  A first supplemental standard on Man Worn Man Portable Methanol Fuel Cell Systems (MWMPMFC) will be published shortly.

© Fraunhofer ICT

Applied Electrochemistry Sensors and Analytical Systems

Sensors

Analytical Systems

Others

• Electrochemical sensors • Bio sensors • Sensor systems

• Battery gases, fuel cell exhaust gases • Surface characterisation • GC, GC-MS, HPLC, IC

• Corrosion • Gas leakage • Electrochromic materials

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Sensor technology and analysis systems System development  Development of electrochemical sensors and methods for trace and process analysis  Analysis systems – combination of classical analytics with electrochemical methods  Pattern recognition (electrochemical noses and tongues)  Optimization and prototype construction for industrial customers  Market analysis

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Sensor technology and analysis systems Analytics  corrosion tests  undesired corrosion effects in batteries and many types of component parts  measuring leakage  density measurements on batteries in a vacuum  real-time monitoring of hydrogen  monitoring of hydrogen from fuel cells in realtime  imaging and surface analysis  analyse the surface properties of fuel cells and battery materials, and investigate surface-specific phenomena such as corrosion

© Fraunhofer ICT

© Fraunhofer ICT

Dr. Karsten Pinkwart Deputy head of department Applied Electrochemistry Fraunhofer-Institute for Chemical Technology - ICT Joseph-von-Fraunhofer-Strasse 7 76327 Pfinztal Germany

Tel.: +49 (721) 4640-322 Fax: +49 (721) 4640-318 Email: [email protected]

© Fraunhofer ICT