Press Release

For the 3rd time in a row, Fraunhofer UMSICHT invites to the "Electrochemical Cell Concepts Colloquium – E3C": On May 19, scientists from Europe, Australia and America will come together virtually to discuss special designs and modifications of flow and non-flow reactors. The focus will be on CO2 conversion and capture, 3D printed electrodes as well as innovative cell und stack concepts.

In order to be able to manufacture more efficient solar modules, the photovoltaic industry is increasingly switching its production to larger wafer formats. Being able to guarantee the production of these solar cells with an edge length of up to 210 millimeters with consistent quality and cycle rate poses new challenges for equipment manufacturers. A research team at the Fraunhofer Institute for Solar Energy System ISE has now succeeded in implementing a novel system concept, whereby large-format solar cells are continually processed as they move at high speed under the laser scanner. The new system for solar cell processing can laser half a million contact openings per second and has an effective throughput of over 15,000 solar wafers per hour. Visitors to LASER World of PHOTONICS 2022 (April 26-29, Messe München) can learn more about the system concept at the Fraunhofer booth 441 in Hall A6.

With the decentralisation of power generation, distribution grid operators are increasingly required to mobilise reactive power depending on the situation. In the research project "RPC2", Fraunhofer IEE, together with partners from grid operation and the University of Kassel, has now developed procedures with which grid operators can control generation and other plants in the medium and high-voltage level in such a way that they provide reactive power according to demand. Another focus was on the exchange of reactive power between the different grid levels. In a cross-grid field test, AllgäuNetz and LEW Verteilnetz successfully tested the methods in practice.

Sensors that function reliably even at extremely high temperatures or in corrosive environments are in demand, for example, for use in energy technology, such as geothermal or turbine applications, or in chemical engineering. In a joint project, eight Fraunhofer institutes have developed a technology platform for the realization of suitable robust sensor systems. The Fraunhofer Institute for Microstructure of Materials and Systems IMWS in Halle (Saale) contributed its expertise in materials analysis and developed new possibilities for material characterization in the high-temperature range.

The conversion of renewable power into chemical energy sources through so-called Power-to-X processes is taking on an increasingly important role in Germany’s energy transition. As long-term storable, easy-to-transport, high-capacity energy sources, PtX maximize the potential of renewable energy utilization and enable the complete transformation of all sectors (power/transportation/ agriculture/ buildings). Future PtX plants will be built primarily in remote regions offering high potential for renewable energies, or ultimately offshore. For these chemical processes to be possible under such challenging conditions, innovative synthesis reactors and operating strategies are necessary. At the Fraunhofer Institute for Solar Energy Systems ISE, a universally applicable test stand for kinetic investigations has been developed to analyze catalytic fixed-bed reactions under dynamic operating conditions. The compact, mobile “KISS” system can also be used for technology demonstration on location in remote regions.

Currently, flatbed screen printing is the standard process used for the metallization of silicon solar cells and many other electronic components. Using a new production machine developed jointly with ASYS Automatisierungssysteme GmbH, researchers at the Fraunhofer Institute for Solar Energy Systems ISE have now managed to increase the print throughput by a factor of 1.5. In order to achieve this, rotation screen printing and flexographic printing were used for the first time. With the new machine, the research team achieved a cycle time of just 0.6 seconds per solar cell. The new process can also be used for functional printing in the areas of hydrogen technology, sensor technology and power electronics. Visitors to the LOPEC 2022 (March 23–24, 2022, International Congress Center Munich) can learn about the concept at the research institute's booth (FO.10).

Bremerhaven, March 18, 2022. Following successful conclusion of the contract, the first customer for the Fraunhofer Institute for Wind Energy Systems IWES’ new rotor blade test bench has now been decided: the Danish wind turbine manufacturer Vestas will be testing the rotor blade of the new V236-15.0 MW™ prototype in Bremerhaven later this year. The state-of-the-art test bench offers comprehensive testing possibilities for rotor blades measuring up to more than 120 meters. In addition to biaxial full-scale blade tests, manufacturers also have the option of testing individual segments of a rotor blade. The modular and adaptable design of the test bench allows the scientists at Fraunhofer IWES to react flexibly to requirements and further develop intelligent test methods. The rotor blade test bench currently still under construction is being funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK) to the tune of €14.8 million and has received €4 million in funding from the Ger-man Federal Ministry of Education and Research (BMBF).

While the trend in new car purchases is toward electric vehicles, liquid fuels will continue to be widely used in heavy-duty transport, shipping, aviation and stationary operations for some time to come. In this context, oxymethylene ethers (OMEs) as e-fuels can significantly reduce soot and nitrogen oxide emissions from diesel engines. One hurdle to their large-scale industrial production has so far been water management in the synthesis process. In the project "COMET- Clean OME Technology", the Fraunhofer Institute for Solar Energy Systems ISE and the industrial partners ChemCom Industries B.V. and ASG Analytik-Service AG have developed a technical solution that enables an OME production process on an industrial scale.To provide the necessary transparency in this discussion on the investment costs of water electrolysis, the Fraunhofer Institute for Solar Energy Systems ISE has set up a bottom-up cost model and performed a cost study on behalf of the NGO Clean Air Task Force (CATF). It can be used to build up a broad understanding of the cost structures of low temperature water electrolysis systems.

The production of green hydrogen by water electrolysis has gained enormous interest in recent years and considerable efforts are being made in the electrolysis industry to scale up cells and stacks and to significantly increase manufacturing capacities. Along with this, the current debate on the costs of electrolysis systems is characterized by contradictory statements with a wide range of price projections, making a reliable assessment of electrolyzers difficult. To provide the necessary transparency in this discussion on the investment costs of water electrolysis, the Fraunhofer Institute for Solar Energy Systems ISE has set up a bottom-up cost model and performed a cost study on behalf of the NGO Clean Air Task Force (CATF). It can be used to build up a broad understanding of the cost structures of low temperature water electrolysis systems.

Around ten thousand tons of silicon in discarded photovoltaic modules end up on the recycling market annually in Germany. This figure will rise to several hundred thousand tons per year by 2029. Currently, the aluminum, glass and copper of the discarded modules are reprocessed, however, the silicon solar cells are not. In order to be able to reuse the silicon, researchers from the Fraunhofer Center for Silicon Photovoltaics CSP and the Fraunhofer Institute for Solar Energy Systems ISE together with the largest German recycling company for PV modules, Reiling GmbH & Co. KG, have developed a solution, in which the silicon in the discarded modules was recycled on an industrial scale and reused to produce new PERC solar cells.