F R A U N H O F E R I N S T I T U T E F O R C E R A M I C T E C H N O L O G I E S A N D S Y S T E M S I K T S

B U S I N E S S D I V I S I O N

ENERGY

1

ENERGYIn the “Energy” business div is ion, Fraunhofer IKTS offers innovat ive components, modules, and complete

energy systems that are engineered, bui l t and tested on a ceramic mater ia ls and technologies platform.

The appl icat ions range from energy storage and fuel ce l l systems to solar ce l l s , energy harvest ing mod-

ules and thermal energy systems to solut ions for bioenerget ic and chemical energy sources.

Completing the transition to sustainable energy resources is

one of the vital imperatives of the 21st century. To accomplish

this, renewable and conventional energies must be used in a

manner that is not only commercially viable but also achieves

the utmost efficiency while having minimal negative impact.

When converting and storing electrical and thermal energy,

the most salient issues are the robustness and the durability of

the systems, as well as the costs of production and operation.

As a full-range service provider, Fraunhofer IKTS tackles these

issues holistically because that is the only way to achieve truly

innovative solution approaches. This fosters considerable com-

petitive advantages specifically within the dynamic market seg-

ment of power generation and storage. In this regard, meticu-

lous analysis always gets top priority, along with the modeling

and simulation of ceramic components and systems where

applicable, so that the use of specific properties can be opti-

mized, as well as their integration into energy converters and

systems. Working in close collaboration with partners in indus-

try, Fraunhofer IKTS operates multiple pilot plants in which it

maps entire process chains for the cutting-edge production of

energy systems components. This offers the institute a unique

opportunity to partner with customers to test and optimize

the materials and processes it develops in-house within a

quasi-industrial environment.

Energy storage systems

Fraunhofer IKTS works on cost-effective, decentralized energy

storage devices by working with both lithium-ion batteries and

their production engineering, as well as batteries that use

ceramic sodium solid-state ionic conductors. Metal-air batter-

ies and super capacitors represent other focal points. Zeolites,

phase change materials and salt storage components are

offered for thermal storage. Development issues encompass

complete value-added chains for energy storage devices and

their production, from the laboratory scale to full-scale indus-

trial production.

Fuel cells

Power generation using SOFC and MCFC fuel cell systems is in

the first phase of market introduction. Current development is

concentrated on further reducing production costs, extending

fuel cell lifetime, easy-to-use fuels and systems integration.

With decades of solid experience, Fraunhofer IKTS is a leading

international contact for all of these concerns. The institute‘s

capabilities span the entire value-added chain: from detailed

knowledge of materials and processes to engineering of core

and process components as well as system design to prototyp-

ing, test operation and validation. IKTS systems cover a broad

spectrum of capacities, from portable devices in the 50 W

range to stationary systems on a MW scale. A wide diversity of

fuels are used, such as biogas, LPG and hydrogen.

Electrolysis and power-to-gas

Steam electrolysis and CO2 on a commercial scale is a key

technology that makes it possible to use surplus power. For

example, it can be converted into storable forms of energy –

such as hydrogen for feeding into gas networks, or for recon-

version. Alternatively, it can be realized as higher performance

power sources by converting it with CO2 through synthesis

gas. Fraunhofer IKTS‘s fuel cell stacks are superbly suited for

electrolysis operation. In the development of cells, intercon-

nectors and joining technologies, the experiences originating

from commercial SOFC technology facilitate swift design and

material iterations, as well as large modules.

Photovoltaics and solar thermal systems

The efficiency of solar cells is largely determined by the electri-

cal conductivity of metallic collector electrodes. In this area,

Fraunhofer IKTS develops pastes and inks for existing and new

cell designs. Highly efficient thick-film and direct-writing pro-

cesses enable an affordable metallization of the cells. In the

area of solar thermal energy, Fraunhofer IKTS is working on

receiver materials and high-temperature materials for heat

exchangers and heat accumulators. The integration of thermal

energy storage devices makes it possible to deliver energy pre-

cisely as needed.

High-temperature gas turbines and thermal energy

systems

In order to enhance the environmental friendliness, cycle sta-

bility and efficiency of hot gas turbines, and to reduce emis-

sions, higher process temperatures are necessary, as well as

materials with high thermal shock-resistance. This makes

monolithic ceramics and ceramic matrix composites (CMC) an

interesting alternative to metallic materials. In addition, Fraun-

hofer IKTS is engaged with the environmental barrier coatings

based on oxide and non-oxide ceramic systems. Additional

efforts are focused on high-temperature components, such as

heating elements, burners, and heat exchangers, for example.

2

AREAS OF APPLICATION

3 50 µm

4

Energy harvesting

To supply energy to decentralized microsystems – such as sen-

sors or medical and consumer devices – environmental energy

in the form of waste heat and motion can be used. Based on

its decades of experience with ceramic active materials (ther-

moelectric materials and piezoceramics), Fraunhofer IKTS real-

izes so-called energy harvesters, including thermoelectric gen-

erators and piezogenerators, for example.

Bioenergy

Fraunhofer IKTS delivers a rich diversity of process engineering

solutions for bioenergy technologies – such as disintegration,

mixing, and agitation processes – in order to facilitate the use

of lignocellulose substrates, along with other materials. The

treatment of biogas is optimized by using adsorptive and

membrane processes for methane enrichment, gas drying,

nutrient recycling and process water treatment. One focus lies

on the enhanced flexibility of biogas systems used for provid-

ing power precisely as it is needed. In addition, the manufac-

turing process for bioethanol is improved using membranes in

the production process – such as for saccharification, dehy-

dration and substrate processing. New kinds of organophilic

pervaporation membranes as well as ultrafiltration mem-

branes aid in designing the production processes to be effi-

cient.

Synthetic fuels

In the immediate future and over the medium term, chemical

fuels will retain their significance for mobility because of their

high energy density. Fraunhofer IKTS is working on technolo-

gies and reactor designs so that it can synthesize liquid energy

sources derived from alternative raw materials, H2, CO2 and

surplus energy. Among its scientific work, it combines water-

selective membranes with catalysts inside the membrane

reactor or membrane contactor. The staff additionally studies

catalyst systems and process engineering designs and systems

for the production of fuels and valuable materials, using

Fischer-Tropsch synthesis as a primary tool.

Deep geothermics

In deep geothermics systems, extreme conditions – such as in-

tense pressures, high temperatures and excessive saline con-

tent – frequently trigger corrosion and encrustation, compro-

mising the feasibility and operational safety of these systems.

Thanks to its decades of experience with encrustation phe-

nomena, and its superior analytic facilities, Fraunhofer IKTS

focuses on corrosion-resistant components and systems, as

well as process configuration. Using experimental findings

and corrosion test results, IKTS is capable of providing real-

time monitoring on-site. In conjunction with membrane elec-

trolysis processes, this leads to a reduction of toxic substanc-

es, which means that system downtime can be considerably

lowered while optimizing processes in the areas of fracking

and deep geothermics.

1 Development of high-

temperature batteries.

2 Fuel cell systems in test oper-

ation mode.

3 Microstructures of a fiber

composite used for high-

temperature turbines.

4 Firing of metallization pastes

and inks.

Production processes

- Thin-film technology (thermal CVD, PECVD, thermal ALD, PVD, LPD)

- Thick-film technology (tape casting, screen printing, dispensing, roll coating)

- Deposition techniques (aerosol and inkjet printing, plasma spraying, wet powder spraying)

- Packaging techniques at high and low temperatures

- Technologies for ceramic high-temperature materials and components (monolithic and

CMC)

Materials and semi-finished products

- Functional ceramics (powders, slurries, pastes, inks, tapes)

- Structural ceramics (bulk, fibers, composite materials – for high temperatures in particular)

- Special materials (solid-state ionic conductors, thermoelectric and electrode materials)

- Protective and functional coatings (sealing glasses, solders, barrier coatings)

Components

- Fuel cells (electrolytes, joining elements, MEAs, stacks, systems engineering)

- Batteries (electrolytes, active masses, electrodes, joining elements, cells, modules)

Characterization

- Thermochemical and mechanical characterization

- Evaluation and assessment of fuel cell and battery components (performance,

degradation, lifespan, cycles)

- Evaluation and assessment of the energetic potential of substrates in bioenergy

technology

Systems and consulting

- System definition, simulation and modeling, plant engineering

- Design (CAD) and prototyping of individual systems, through to pilot production

- Measurement, automation and control systems

- Function testing and validation of components and systems

- Conceptual design and administration of tests, test stand construction and operation

- Consulting and market analysis

5

5 Optimizing the preparation

processes in biogas plants.

EXPERTISEInfrastructure

- Pilot plants for battery

production (lithium-ion and

sodium batteries)

- Fuel cell test center

- Bioenergy Application

Center

- Membrane Technology

Application Center

- Geothermic test stands

FRAUNHOFER IKTS IN PROFILEThe Fraunhofer Institute for Ceramic Technologies and Systems IKTS conducts applied

research on high-performance ceramics. The institute‘s three sites in Dresden and Herms-

dorf (Thuringia) represent Europe‘s largest R&D institution dedicated to ceramics.

As a research and technology service provider, Fraunhofer IKTS develops modern ceramic

high-performance materials, customized industrial manufacturing processes and creates

prototype components and systems in complete production lines from laboratory to

pilot-plant scale. Furthermore, the institute has expertise in diagnostics and testing of

materials and processes. Test procedures in the fields of acoustics, electromagnetics,

optics, microscopy and laser technology contribute substantially to the quality assurance

of products and plants.

The institute operates in eight market-oriented business divisions to demonstrate and

qualify ceramic technologies and components as well as non-destructive test methods

for new industries, product concepts and markets beyond the established fields of appli-

cation. Industries addressed include ceramic materials and processes, mechanical and

automotive engineering, electronics and microsystems, energy, environmental and process

engineering, bio- and medical technology, optics as well as materials and process analysis.

CONTACTBusiness Division

Energy

Dr. Mihails Kusnezoff

Fraunhofer Institute for

Ceramic Technologies and

Systems IKTS

Winterbergstrasse 28,

01277 Dresden, Germany

Phone +49 351 2553-7707

mihails.kusnezoff@

ikts.fraunhofer.de

Dipl.-Ing. Thomas Pfeifer

Fraunhofer Institute for

Ceramic Technologies and

Systems IKTS

Winterbergstrasse 28,

01277 Dresden, Germany

Phone +49 351 2553-7822

thomas.pfeifer@

ikts.fraunhofer.de

www.ikts.fraunhofer.de

COVER Efficient energy supply

with high-temperature fuel cells.