The FlexiSlag is a next generation fixed-bed slagging gasifier designed for high feedstock flexibility. It offers variable gas qualities for hydrogen application, syngas application (i.e. low dust, tar and phenols-free, low CxHy), or SNG and liquid products application (i.e. low dust, rich in light oil and CxHy). Additionally, it also exhibits high thermal and cold gas efficiency, low oxygen and steam con-sumption and practically no carbon loss. Furthermore, it has minimal environmental impacts as contaminants are contained in vitrified i.e. glassy slag.

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Enables mixed, contaminated and challenging carbon-containing waste materials which are not suitable for mechanical recycling and pyrolysis to be used as secondary raw material for chemical production.

The “FlexiSyn Gasoline” is a plant designed to demonstrate the production of high-octane gasoline. Originally, the synthesis route was separated into two steps: conversion of syngas (generated via ATR treatment of natural gas) into methanol followed by the subsequent innovative isothermal synthesis process of methanol to gasoline (MtG). Today, only the gasoline production operates using renewable methanol. Technology partner is the CAC ENGINEERING GmbH (former Chemieanlagenbau Chemnitz GmbH).

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Project DeCarTrans (Demonstrating a Circular Carbon Economy along the Value Chain) 2023-2026: Production of more than 300,000 litres of synthetic gasoline from renewable methanol for material, emission and car fleet tests by project partners/selected end users

The FlexiPOX plant is designed for high pressure partial oxidation of gaseous and liquid hydrocarbons. It can be operated in the autothermic catalytic reforming (ATR) mode, or in autothermic non-catalytic partial oxidation mode for natural gas (Gas-POX) or liquid hydrocarbons such as oil residues from refineries or pyrolysis oil from chemical recycling (MPG or Oil-POX).

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Unique optical devices enable real time determination and verification of flame conditions under high temperature and high pressure operating conditions using customer designed burners.

The FlexiEntrained (GSP gasification process) is an entrained-flow gasifier with a water-cooled cooling screen, a full spray water quench for gas cooling, a Sulferox plant for desulfurization as well as a waste water treatment plant. It operates with pulverized or liquid (slurry) feedstock. The generated syngas is free of hydrocarbons with very low amount of methane. It is able to convert a broad variety of carbon feedstock into a high-quality tar-free syngas and vitrified slag which is environmentally neutral. Furthermore, it features a pneumatic feeding
test rig of commercial scale.

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Technology is widely implemented commercially for coal-tochemicals today. Over 60 carbon feedstock (including different types of waste materials) were tested in over 100 test campaigns in the Freiberg facility.

The low temperature gasification (LTG) plant is a continuous mode pyrolysis plant to convert different carbon-rich biomass or waste into pyrolysis coke and tar-/oil-containing pyrolysis gas. It can be operated fully electric in allothermal mode or autothermal with agents to provide heat for pyrolysis. The LTG plant is part of the Fraunhofer IKTS pyrolysis platform.

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The IKTS pyrolysis platform serves both: the conversion of feedstock to char or to liquid products at a relevant scale.

The catalytic tribo-chemical (CTC) pyrolysis technology is used to convert different carbon-containing wastes into pyrolysis oil as steam cracker feedstock. Technology provider is the Carboliq GmbH. The CTC plant is part of the Fraunhofer IKTS pyrolysis platform.

The bench-scale plant comprises as first step a single-tube catalytic reactor that can operate in flexible configurations, e.g. as MtG - methanol to gasoline or MtO - methanol to olefins process. The second stage involves an olefin oligomerization as part of an olefins-to-jet (OtJ) process that can be supplied either by the first MtO stage or by a co-feed system targeting an oligomerizate product (mixture of jetfuel, diesel and gasoline components). Operation conditions can be varied within a wide range.

The FlexiFluidized plant is a fluidized-bed gasifier developed and designed by IEC-EVT. It combines an internal circulating fluidized bed with a moving bed gasification zone to achieve high carbon conversion rates for fine as well as coarse particles. It is especially suited for feedstock with high ash content.

The MultiFeed is an entrained-flow gasification test plant with optical access on multiple levels. It is designed to operate with gaseous (e.g. natural gas) as well as liquid (e.g. gasoil) and solid feedstock (e.g. coal) and is equipped with a refractory lined reactor vessel and a subsequent quench section.

The KIVAN gasifier is a high-pressure drop tube gasification reactor, especially designed for the determination of reaction kinetics and residence time behavior.

The Catalytic Steam Reformer/Methane Pyrolysis Plant is a highly flexible bench-scale plant for various applications such as catalytic steam reforming, methane pyrolysis, ammonia cracking and other homogeneous gas reactions or gas-solid reactions. Further applications are exposure tests of diverse materials (e.g. refractory, metals, catalysts) and the determination of reaction kinetics.

• Fixed Bed Plasma Gasification Plant (PLASTER)
• Lab-Scale Plasma Gasification Unit I
• Lab-Scale Plasma Gasification Unit II

• HTR drop tube reactor
• Gasification equipment for reduction in fixed bed (GeRix)
• Quartz glass reactors

The DPA is a pressurized pyrolysis plant that can be operated in drop tube or fixed bed mode. A multi-stage condensation system is available to capture the condensable volatile products.

The rotary kiln is a versatile pilot plant that can be used for various thermal processes such as pyrolysis and combustion. It is characterized by its high flexibility with regard to input materials and process parameters. The combination with three-stage condensation makes the system ideal for developing and balancing pyrolysis processes under realistic conditions. The rotary kiln is part of the Fraunhofer IKTS pyrolysis platform.

• Retort Oven (GERO)
• LPA fixed-bed reactor
• ALPA fixed-bed or drop-in reactor

• Simple Particle Disintegrator (SPaltor)
• Large Sample Furnace
• High Temperature Quench Furnace
• Pressurized Thermogravimetric, Thermographic and Spectroscopic Analysis (HITECOM)

• Sieve analysis
• Camsizers (particle size distribution)
• Sample dividers
• Mills (cutting mill, impact mill, ultracentrifugal mill, freezer mill)
• Tablet/pellet press
• High-temperature pressurized microwave-assisted acid digestion

• ETV-ICP OES – electrothermal vaporization – inductive coupled plasma – atomic emission spectroscopy for multielement-analysis, temperature dependent element release in combination with elemental speciation
• Elemental (ultimate) analyzer (for solids and liquids)
• Combustion calorimeter (for solids and liquids)
• Karl-Fischer titrator (for solids and liquids)
• Direct mercury analyzer (for solids and liquids)
• Coke reactivity index (CRI) and coke strength after reaction (CSR)
• Dilatometer (high temperature/Ruhr)
• Gieseler plastometer

• Surface area measurement (N₂ and CO₂ isothermes)
• Mercury porosimetry
• Helium pycnometry
• Density measurement
• Adsorption test facility for Hg and SO₂

• Gas chromatography (various micro gas chromatographs with different columns and detectors)
• Ion chromatography
• GCxGC-TOF-MS with pyrolyser
• GC-FID with headspace sampler
• ICP-OES
• Viscometer (temperature controlled up to 200 °C)
• Density measurement
• DHA with SimDist

• X-ray fluorescence analysis XRF
• X-ray diffractometry XRD with in-situ temperature/pressure chambers
• Electron microscopy (SEM, FIB-SEM)
• Thermo-optical measurement systems for surface tension and characteristic ash melting temperatures (TOMAC, TOMMI)
• High-temperature slag viscometers
• Leitz heating microscope (LEM) for determination of ash fusion-temperature (AFT) in oxidizing or reducing atmosphere

• Thermogravimetry (TG) for ambient & elevated pressure (up to 100 bar)
• Differential thermo-analysis (DTA)
• Differential-scanning calorimetry (DSC)
• Simultaneous analysis coupled with mass spectroscopy: TG-DTA-MS, TG-DSC-MS

• HP-TGA – DMT-TG (DMT Bergbauforschung mbH)
• HP-TGA – Discovery HP-TGA 7500 (TA Instruments and Waters Corporation)

• TG-DSC-MS – TG/DSC 1 HT (METTLER TOLEDO)
• TG-DTA-MS – STA 509 Jupiter (Netzsch)
• TG-DSC-MS – STA 449C Jupiter (Netzsch)
• TG-DTA-MS – STA 409 Skimmer (Netzsch)

Comprehensive Gas Chromatography is an instrumental-analytical method that is particularly used for the analysis of complex mixtures of organic compounds.

• AutoCAD
• AutoCAD P&ID
• Autodesk Inventor
• SolidWorks

• Aspen Engineering Suite: Aspen Plus, Aspen Dynamic, Aspen Custom Modeler, Aspen HYSYS
• Belsim Vali

• MathCAD
• MATLAB
• Origin
• Statgraphics
• Python
• MySQL database

• modeFrontier

• GaBi

• FactSage

• ANSYS Fluent
• StarCCM+
• ANSA