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
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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.
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AREAS OF APPLICATION
3 50 µm
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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
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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.