GET – GREEN EFFICIENT TECHNOLOGIES EN 1/24

GREEN EFFICIENT TECHNOLOGIES
EN 1/24
Hydrogen and Process Technology
Energy and Heat Network
Energy Storage Solutions
Circular Economy Ressources Logistics
A dry (r)evolution
for LiB electrodes
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GET – GREEN EFFICIENT TECHNOLOGIES a publication of PuK

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Editorial
#MoveTheDate!
In a few weeks, it will be that time again - Earth Overshoot Day is on 1 August. Unlike other days of remembrance or
celebration, however, there is absolutely no reason to celebrate. At most, there is the fact that since 2013 we have regularly
reached it seven months after the beginning of the year - and not at the beginning of June, as the interpolation
from 1971 to 2013 gloomily announced. On Earth Overshoot Day, like a swarm of locusts, we have eaten up as many of
our planet's resources (the only one we have, by the way) as it can produce in the entire year. In other words, from this
day onwards, we are irretrievably destroying our children's reserves of raw materials. The fact that the trend has stagnated
since 2013 is due less to our efforts to save energy than to a chain of diseases, wars and climate catastrophes.
But what can be done?
Current research offers a colourful bouquet of technical solutions to save energy and raw materials. However, due to
human inertia and economic greed, these solutions are often only implemented if they bring a directly measurable
financial benefit for the user. A certain proportion of the potential savings can only be achieved by changing the behaviour
of the world's population. This requires education and the breaking down of entrenched traditional lifestyles. The
people behind the Global Footprint Network have done a lot of work on this. This open-ended examination often leads
to surprising results that shake many a well-held dogma. On the www.overshoot.footprintnetwork.org website, the
expected effects are neatly listed on the Solutions subpage.
There is immense power of possibility in the many existing solutions (below) that are ready to be deployed at scale. With
them, we can make ourselves more resilient and #MoveTheDate of Earth Overshoot Day.
The greatest leverage with a 63-day deadline extension is probably provided by the (moderate) pricing of carbon emissions,
as the introduction of an emissions trading system, as already implemented in Europe, for example, favours all
other savings opportunities. However, this measure harbours a huge risk for European industry - if the rest of the world
does not follow suit.
18 additional days could be gained by switching to hydrogen-based drives and e-fuels, although a switch to battery-electric
mobility is likely to be more favourable on a case-by-case basis.
7 days could be gained by a 50 per cent switch from meat-based to plant-based food. If a reduction in methane emissions
is also taken into account, the effect is even greater.
However, the list of examples also reveals some surprising facts. The effectiveness of many of the things that the public
media treat as the holy grail of energy saving is completely overestimated. Heat pump heating systems only extend
the deadline by a mere two days. One day's grace period is given for 50 per cent fewer holiday flights. A reduction in
global speed limits by 20 km/h would have practically no effect at all - driving at 30 km/h in urban areas or 110 km/h on
inter-regional roads would only add a little more than 12 hours.
We have many opportunities to make better use of our planet's resources. You will find some of them on the following
pages. However, we should quickly turn the big and the right screws, because the clock is running against us.
I hope you enjoy reading and wish you success in realising your plans.
Ottmar Holz
Editor
GREEN EFFICIENT TECHNOLOGIES 2024
3

GREEN EFFICIENT TECHNOLOGIES
Contents
Cover
A dry (r)evolution for LiB electrodes
Innovations for “greener” and more cost-effective batteries
Minimizing CO 2 emissions, saving resources and cutting costs are a
triple-header of key goals in which energy storage system makers are
now targeting. And one crucial area to leverage is electrode production
- where technological transformation continues apace. Here, dry
electrodes, which promise maxi mum economic efficiency, are gaining
ground. Meanwhile where mixing technology is concerned, the streamlined
and flexible slurry production capacity of the Maschinenfabrik
Gustav Eirich makes a perfect technology partner.
Contents
Editorial
#MoveTheDate! 3
Cover story
A dry (r)evolution for LiB electrodes 6
Disctrict heating
Every joule counts 10
Great climate from the cloud 13
Industrial heat storage
Thermal storage: building block for the decarbonisation of industrial process heat 15
Energy storage
Sustainable, well-cooled energy storage systems for commerce and industry 20
Hydrogen sensor technology
Putting the pressure on hydrogen 23
Hydrogen infrastructure
Ex-enclosures from ROSE protect the hydrogen infrastructure 26
Efficient drives
Reliable pump drives for sustainable fibres 30
PFAS
Removal of PFAS from drinking water with granulated activated carbon 32
Trade fairs and events
hy-fcell with renowned exhibitors and many new features 35
Filtration and separation: trends for the process industry 37
Companies – Innovations – Products 38
Index of Advertisers 44
Brand name register 44
Impressum
Publisher
Dr. Harnisch Verlags GmbH in cooperation with
Prof. (ret.) Dr.-Ing. Eberhard Schlücker, advisor
on hydrogen and energy issues
©
2024, Dr. Harnisch Verlags GmbH
Responsible for content
Ottmar Holz
Silke Watkins
Publishing company and reader service
Dr. Harnisch Verlags GmbH
Eschenstr. 25
90441 Nuremberg, Germany
Tel 0911 2018-0
Fax 0911 2018-100
E-Mail get@harnisch.com
www.harnisch.com
Errors excepted
Reprinting and photomechanical reproduction,even
in extract form, is only possible with
the written consent of the publishers
Editors
Ottmar Holz
Silke Watkins
Advertisements/Brand name register
Silke Watkins/Matti Schneider
Technical Director
Armin König
ISSN 2752-2040
4
GREEN EFFICIENT TECHNOLOGIES 2024

Save
the
Date
industrial valves &
sealing technology
/ 2nd – 3rd April 2025
/ Globana Eventhallen
Leipzig/Schkeuditz
/ 12th – 13th November 2025
/ Jahrhunderthalle Bochum
DIAM-DDM.DE

Cover story
A dry (r)evolution for LiB electrodes
Innovations for “greener” and more cost-effective batteries
Dr. Stefan Gerl
new development. Approximately 1.5
tera watt hours increase is forecasted
for Europe alone by 2030, which
equates to ten times the production
capacities currently available. Undeniably,
energy storage systems need
to become cheaper for cells to find
buyers. This is the reality confronting
battery makers in Europe, over
and above the need to reduce their
CO 2 footprint. Converting energy
infrastructure to run on renewably
sourced power is driving up elec tricity
prices.
Charting the right course
The 5-litre ‘CleanLine C5’ laboratory mixer leverages process technology to optimal effect.
This to promote lab research and development into the next generation of batteries. The
simple scale-up to later production quantities is a major advantage of Eirich technology.
Image: Eirich
Minimizing CO 2 emissions, saving
resources and cutting costs are a
triple-header of key goals in which
energy storage system makers are
now targeting. And one crucial area
to leverage is electrode production
- where technological transformation
continues apace. Here, dry
electrodes, which promise maximum
economic efficiency, are
gaining ground. Meanwhile where
mixing technology is concerned, the
streamlined and flexible slurry production
capacity of the Maschinenfabrik
Gustav Eirich makes a perfect
technology partner.
Under the ‘Green Deal’ umbrella,
the European Union is calling for
all 27 member states to become
climate-neutral by 2050. Its ambitious
target is to reduce greenhouse gas
emissions by 55% by 2030 compared
to 1990 levels. Achieving it will require
immediate and concrete action on
the part of both industry and society!
And these are requirements that
companies making lithium-ion battery
cells for electromobility and stationary
energy storage will also have
to meet.
The growing demand for
battery cells
A new wave of 'gigafactories' is
springing up around the globe,
spearheaded by China, the USA and
Europe. France and Germany are
particular hotspots for this exciting
Despite the significant upfront costs
and capital investment required to
transport cells from overseas, there is
still a compelling case for locating cell
factories close to major consumers
like automotive OEMs or electricity
grid operators. Keeping this in mind,
producing key market components,
i.e. batteries, locally makes sense as
a way of boosting supply chain security
and resilience when faced with
Asian competitors. This applies even
more if we assume the world political
map will remain as unstable as at
present and continues to constrain
supply routes and sourcing markets.
But as an industry supplier, nothing
beats the sight of industry achieving
its goals by optimizing the process
chain or achieving technological
leaps like a switch to dry electrodes.
Whatever route manufacturers take,
Eirich technology can help maximize
economic efficiency when producing
electrodes.
Slurry making streamlined
Eirich MixSolvers have now been
deployed in the UKBIC research factory
(see article ‘Smart to electrode
slurry’ in CITplus 1-2/2022) as well
as several gigafactories in Asia. They
now set the standard when it comes
to accurate information on energy
consumption in large-scale electrode
6
GREEN EFFICIENT TECHNOLOGIES 2024

Cover story
by planetary mixers (see diagram).
And cheaper power costs aren't the
only benefit. The CO 2 emissions generated
by electrode production are
also correspondingly lower. Annual
CO 2 savings of around 5000 tons as
shown in the above example equate
to 25 kg less CO 2 per vehicle produced.
There are numerous factors why
Eirich mixing technology excels. [10]
Its positive effects include:
Fig. 1: The secret of Eirich technology: The
rotating container transports the material,
while the mixing tool with flexible rotation
direction and speed takes care of the actual
mixing process. The static scraper keeps the
container walls and base clean and guides
the material back to the whirler tool.
Image: Eirich
slurry production. Energy consumption
values for planetary mixers, twinscrew
extruders and inline dispersers
are also published at symposia and
on machine manufacturer websites.
Comparing the values elicits relatively
clear results.
The MixSolver exceedingly outperforms
all of its rivals in terms of
low electricity consumption with a
total of 0.6 GWh/a (based on average
consumption values and 8500 operating
hours per year). The worst performer,
the PD or planetary mixer, is
the most frequently used as things
stand today. Twin-screw extruders
and inline dispersers each consume
around a third of the power required
• A combination of compact batch
mixers, e.g. the MixSolver RV12,
which are efficient and flexible,
• Just-in-time production, to minimize
reject rates,
• ContiFeeder technology for continuous
coater feeding of uniform
slurry quality at all times,
• A temperature-controlled process
that generally eliminates the need
for cooling,
• Less enclosed space.
Given the challenges facing the industry
in terms of both cost-cutting and
reducing greenhouse gas emissions,
it is imperative to continue to break
new ground and ensure our electrode
production evolves.
Potential savings with
dry electrodes
When it comes to electrode production,
the slurry made with the Eirich
MixSolver is not the end of the line.
New technologies like dry electrode
production promise further potential
savings in terms of energy consumption,
CO 2 reduction, production
Fig. 3: Structured electrode mixture produced
in the Eirich mixer. Image: Eirich
costs and the use of resources. [7] All
of which explains the acceleration of
research and development work into
dry electrodes. More and more, publicly
funded research projects such as
CircuBat, DryTreac and ProLit, which
Eirich is also involved with, are currently
underway. Alongside the intensive
industrial development work
involving Tesla, AM Batteries and
Licap among others, or as recently
publicised by PowerCo and other
European OEMs. The upcoming ‘Dry
Coating Forum’ in Dresden will see a
range of innovative solutions rolled
out, including by Eirich.
Structured electrode mixtures are
required
Two processes involving differing
concepts and levels of technology
readiness (TRL) compete when it
comes to producing dry electrodes:
Fig. 2: Total consumption of electrical energy per 10 GWh factory in GWh/a (blue) in electrode
production and the resulting CO 2 emissions in tonnes/a (green) depending on the type
of mixer used.
Graphics: Eirich
• Production of an electrode mixture
with subsequent powder
application by spraying, brushing
or applying electrostatics on
the arrester with subsequent hot
calen dering. [6]
• Production of an electrode mixture
with superimposed PTFE fibrillation
to produce a mouldable,
GREEN EFFICIENT TECHNOLOGIES 2024 7

Cover story
elastically plastic mixture, processed
into a free-standing film
with a calender gap, then laminated
onto a trap. [5]
Both cases require segregation-free
structured electrode mixtures. One
way to achieve this is to coat the
particle surfaces of active materials
with conductive carbon black.
Whichever approach is chosen, a
thoroughly mixed binder is crucial.
Moreover, if PTFE is used, it must be
broken down through targeted temperature
control and high shear to
create a spider web-like structure in
the mixture, making it mould able.
The Eirich mixer handles both tasks
seamlessly and couldn't be any
easier to control.
Solvent-free zone
Dry electrode production eliminates
the need for classic coating and drying
steps. As a rule, the electrode
mixtures are processed in modified
heated multi-roll calenders. Not
all the liquids used need to be completely
eliminated, vaporized or
condensed, nor is any solvent reprocessing
needed either. The process
thus takes place free of any NMP solvent
(N-methyl-2-pyrrolidone), which
is classified as toxic, particularly to
reproduction.
Space-saving
The 50-100 meter-long drying sections
between the coater heads,
Fig. 4: Eirich guarantees successful scale-up with mixer sizes for very small quantities, from
production testing to series production on a GWh scale. All sizes can be easily converted
from slurry to dry mixes.
Image: Eirich
which are typically for wet electrolysis
and a major factor in determining
building dimensions, are not
required for this process. The huge
hot-air generation and filter/condensation
systems for supplying or disposing
of drying air to the dryers, the
cold-water generators for the condensers
and the distillation systems
for recycling the NMP separated from
the exhaust air can also all be dispensed
with. All of which paves the
way to construct a far more compact
gigafactory. [7]
A convincing end solution:
The Eirich mixer
Given the relatively low mould
speeds involved, planetary mixers
do not lend themselves to producing
structured electrode mixtures.
That’s why combinations of simple
mixing systems, like V-mixers with
intensifier bars and downstream
air jet mills, are often proposed as
alternatives [9]. However, as grinding
technology applications show,
air jet mills are excessively costly. It
is also far from easy to ensure the
safe discharge and material handling
of the generated elastic plastic
masses. For an efficient alternative,
look no further than the Eirich
mixer.
The mixing process operates
at mould speeds of up to 45 m/s
when producing structured electrode
mixtures, which differentiates
from the MixSolver slurry production
process. The short dry mixing
phase at moderate mould speeds
serves only to homogenize the
powdery binder and deagglomerate
the coarse conductive carbon
black agglomerates at this stage.
Vigorous kneading during the highly
plastic phase is required to disperse
and adjust the electrode properties.
But back to dry processing; the Eirich
mixing principle allows processing
of all consistencies, including
the soft-plastic, fibrillated mix. It is
convertible into a granulate structure
that can easily be conveyed
and dosed via targeted temperature
control. It can then be fed uniformly
into calender gaps and rolled
into a film.
8
GREEN EFFICIENT TECHNOLOGIES 2024

Cover story
Author:
Dr. Stefan Gerl
Strategic Project Director Lithium
Ion Batteries + Head of Process
Technology Department,
Gustav Eirich Machine Factory
Fig. 5: The first hybrid mixing system for wet and dry electrodes in Germany was installed for
test purposes in the Eirich technical centre in the idyllic Odenwald municipality of Hardheim.
Image: Eirich
The wet to dry changeover
Both the MixSolver and Eirich
mixer evolved from identical basic
machines. The main differences
between the two are in the motorization
of the mixing tool, the discharge
of the mix and the wear protection
concept, primarily on the mixing tool.
With the right planning and design, a
wet processing plant with MixSolvers
can be converted to an Eirich mixer
with minimal effort and used to produce
dry electrode mixtures. This
helps to future-proof those using
Eirich mixing technology, regardless
of which technology prevails in the
medium to long term.
Bibliography:
- [1] Mohsseni, A., Harper, C.: Pathways
to Reduce Energy Consumption
in Lithium-ion Battery Cell Manufacturing;
Whitepaper UKBIC case
study; www.ukbic.co.uk/newwhite-paper-published/
- [2] Haberzettl, P.; Scaling up Electrode
Slurries – From Beaker to Barrel,
Poster D1_5.23, IBPC Nov. 7/8,
2022, Brunswik
- [3] Polek, C.; Industrievortrag, Themenblock
2: Neue Technologien in
der Batteriezellproduktion, 5. In-
ZePro/Prozell Industrietag, Feb. 7,
2023
- [4] See MOFA Slurry Production
Equipment; www.siehesmart.com/
product_detail/mofa-slurrying
- [5] Yang, L., Chen-Zi, Z., Hong, Y.;
Jiang-Kui, H., Jia-Qi, H., Qiang, Z:
Dry electrode technology, the rising
star in solid-state battery industrialization;
Matter 5, pages 876–898,
March 2, 2022
- [6] Ludwig, B., Zheng, Z., Shou, W. et
al.: Solvent-Free Manufacturing of
Electrodes for Lithium-ion Batteries.
Sci Rep 6, 23150 (2016);
doi.org/10.1038/srep23150
- [7] Tesla, 2020 Annual Meeting of
Stockholders and Battery Day;
www.tesla.com/
2020shareholdermeeting
- [8] Gerl, S.: Smart zum Elektroden-Slurry.
CITplus 1-2/2022, pages
26-29. https://doi.org/10.1002/
citp.202200114
- [9] Patent WO 2005008807 A2
- [10] Gerl, S.: Wer wagt gewinnt.
PROCESS
Contact
Maschinenfabrik Gustav Eirich
GmbH & Co KG, Hardheim
Tel.: +49 6283 510
batteryexperts@eirich.de
GREEN EFFICIENT TECHNOLOGIES 2024 9

District heating
Every joule counts
Lemgo municipal utilities. At the time,
no comparable solution was available
from competitors on the market.
Heat from the wastewater of the
municipal sewage treatment plant
The district heating centre (above, centre) is part of a larger green energy network that generates
heat from a wastewater treatment plant in Lemgo, Germany. Photo: GEA/Tim Luhmann
The decarbonisation of district heating
networks appears simple at first
glance - but this is deceptive. As
practically all local authorities are
focussing on hydrogen, wood and
waste incineration, demand is likely
to outstrip supply in a flash. Clever
municipal utilities, on the other
hand, are using large heat pumps
to utilise energy sources that have
been available on site for a long
time and have so far gone unused.
In addition to the obvious utilisation
of waste heat from combined heat
and power plants, natural bodies
of water and the sewage pipes that
flow into them are also an option.
Lemgo heats with heat from water
By supplying two heat pumps, GEA
is helping the city of Lemgo on its
way to achieving climate neutrality
by 2035. Using GEA technology,
the city obtains heat from the effluent
of the sewage treatment plant,
waste heat from a large combined
heat and power (CHP) plant and from
the River Bega. The heat generated
by the large heat pumps is sufficient
to supply the historic town centre of
Lemgo with low-carbon heat as far
as possible. That is around 18 million
kilowatt hours of heat per year, which
saves 3,200 tonnes of CO 2 emissions
per year. The heat from the sewage
treatment plant’s effluent alone can
cover two thirds of the old town’s
heating requirements or twelve per
cent of the district heating network’s
total demand. The operating stra tegy
ensures that the heat pumps can
operate constantly for up to 7,500
hours per year to maximise the benefits
of the heat pumps.
GEA’s Malmö project attracts
attention
Stadtwerke Lemgo became aware
of GEA through the “Malmö” heat
pump project. Here, too, GEA technology
was used to generate heat from
the waste water of a municipal sewage
treatment plant in the Swedish
metropolis.
At an initial meeting on site in
Lemgo, GEA suggested to the customer
that the initially planned
low-pressure heat pump and
high-pressure heat pump be replaced
by a two-stage heat pump without
a lossy intermediate circuit. This
was quickly recognised by all those
involved as the much more advantageous
option in terms of energy and
economy. As a result, GEA only pursued
this customised solution for the
The recovery of heat from the waste
water of the municipal central sewage
treatment plant in Lemgo forms
an important part of the city’s district
heating production. The clean water
at the sewage treatment plant outlet
is highly suitable. The treated wastewater
has an average annual temperature
of around 13° C. Due to the
mixed water system, large quantities
of water (equal quantities of heat!)
are available. Almost 8,000 h/a provide
more than 1.5 MW of source
power. Furthermore, infrastructure
such as a combined heat and power
plant and district heating connection
are available at the sewage treatment
plant. Heat is only extracted downstream
of the treatment stages at
the outlet of the sewage treatment
plant. In this way, the highest possible
amount of heat can be achieved
with relatively little technical effort.
Crucially important: the wastewater
treatment process is also not affected
by the downstream heat extraction.
The biggest challenges for
Stadtwerke Lemgo and GEA - and
how they were overcome
During commissioning, it turned out
that the water quality of the heat
source from the sewage treatment
plant did not meet the original purity
expectations. The resulting contamination
of the evaporators meant that
the “pure water heat pump” could no
longer continue to operate. The task
now was to find a sustainable solution.
Of the options considered, joint
deliberations between Stadtwerke
Lemgo and GEA rejected the possibility
of an additional separating heat
exchanger or the conversion of the
heat pump and tube bundle evaporator
with a complex self-cleaning
10 GREEN EFFICIENT TECHNOLOGIES 2024

District heating
air heat pump. These will be connected
via direct cable to a wind turbine,
which is also in the planning
stage, in order to generate wind heat.
In addition, a wind power plant is to
contribute to hydrogen production -
further investments are planned in
a biomass boiler and a wood gasification
plant for road side wood in
order to achieve the goal of climate
neutrality.
Clever use of unusual sources
Fig. 1: The machine room with GEA heat pumps in the combined heat and power plant in
Lemgo, Germany.
Photo: GEA/Tim Luhmann
system. The decision was made in
favour of an additional filtration system,
which was then implemented.
Natural refrigerant ammonia
another plus point for environmental
protection
The fact that the GEA heat pumps are
also operated with the natural refrigerant
ammonia is another plus point
in terms of environmental protection.
Ammonia is an inorganic compound
of nitrogen and hydrogen, lighter
than air and easily soluble in water. EA
is leading the development of technology
solutions for natural refrigerants
such as ammonia to meet the environmental
targets for phasing out
the use of fluorinated gases (F-gases)
and reducing emissions to the atmosphere.
For example, the COP (coefficient
of performance) of an ammonia
heat pump operating under typical
conditions for a district heating network
or for process heat below 100
°C is 40 % higher compared to synthetic
refrigerants, which means 40
% fewer emissions, 40 % less energy
and 40 % lower costs.
Milestone achieved - but by no
means the “end of the line”
Stadtwerke Lemgo is not yet satisfied
with what it has achieved. The
next steps are already being planned
for the city’s CO 2 -neutral electricity
and heat supply: By 2028, more
than 55 per cent of the district heating
required is to be generated from
renewable sources. The Lemgo team
is relying on a large-scale solar thermal
system, another large heat storage
tank with an integrated PtH and
GEA is providing support by supplying
two large heat pumps for
the Neukölln district heating plant
(FHW). At the Weigandufer site,
seven large boilers use wood pellets,
heating oil and natural gas to generate
climate-friendly district heating
for households in the Neukölln
and Kreuzberg districts of Berlin. In
order to achieve the heat transition,
five combined heat and power plants
Background information
What exactly did GEA supply for the GEA RedAstrum stands for reliability,
Lemgo project?
low ammonia filling quantities and minimum
space consumption. Its flexibility
• A CHP heat pump
and efficiency make it suitable for a wide
GEA REDASTRUM HE, heat output range of heating purposes.
sink 785KW at 82°C flow and source
560 kW at 63°C, COPline 3.2, KM R717 The GEA RedGenium heat pump transfers
its heat output to a liquid heat
(ammonia)
• A pure water heat pump
transfer medium and delivers flow temperatures
between +55 and +80 °C for
GEA MX SP2VE6B(RP), heat output
sink 2372 KW at 82°C flow and source any industrial application where there is
1600 kW at 15°C, COPline 2.7, KM a need for process heat or where local
R717 (ammonia)
supply or district heating networks are
served.
What characterises the GEA RedAstrum
heat pump?
Thanks to the wide temperature range
available on the cold side between -10
GEA RedAstrum 2.0: This second generation
of screw compressor heat pumps lise all possible heat sources - whether
and +50 °C, the GEA RedAstrum can uti-
offers an optimised design, a new waste water, groundwater, river or lake
ammonia cascade evaporator (optional) water or a secondary refrigerant (coolant)
in the case of combined cooling and
and an extended model range. The
series is now available with seven screw heating applications. Alternatively, a
compressor types based on the successful
GEA Grasso M and GEA Grasso LT as an evaporator, with which hot ammo-
cascade heat exchanger is also available
series in a specific high-pressure design. nia gas can be fed directly from a refrigeration
system and thus waste heat can
Based on the successful GEA BluAstrum
concept with project-specific configured be utilised particularly efficiently.
and optimised heat exchangers, the
GREEN EFFICIENT TECHNOLOGIES 2024
11

District heating
power plant will soon go into operation
on the site of the Neukölln CHP
plant. The new combined heat and
power plant is ‘hydrogen-ready’. The
second GEA large heat pump forms
the centrepiece here.
Local companies are to feed
industrial waste heat into the
district heating network
Fig. 2: Higher target temperatures, an extended output range, maximum efficiency and
therefore greater sustainability at lower costs - these are the advantages offered by the
models in the GEA RedGenium heat pump series.
Photo: GEA/Cem Yücetas)
on the FHW site efficiently produce
heat and electricity using combined
heat and power (CHP). This combined
gene ration process enables a particularly
high degree of fuel utilisation.
But that's not all: one of the new
GEA large heat pumps is already
connected to the five combined
heat and power plants. It utilises
the waste heat from the charge air
cooling of the highly efficient combined
heat and power plants. This
increases the efficiency of the overall
system by around five per cent. As a
result, an additional 4,000 mega watt
hours of heat can be gene rated per
year for the neighbourhood from
waste heat that would otherwise be
lost.
Another new ‘hydrogen-ready’
combined heat and power plant
coming soon
Another new combined heat and
FHW Berlin-Neukölln is planning to
invest in the heating transition on
an ongoing basis. To this end, the
heat generation systems are being
replaced with new, environmentally
friendly systems and renewable
energy sources are being integrated
during ongoing operations. This
includes more flexible combined heat
and power plants, power-to-heat and
a second heat storage facility. This
will reduce the FHW’s CO 2 emissions
by 25,000 tonnes per year from 2025.
FHW Neukölln also wants to offer
local companies in which combustion
and heating processes take place the
opportunity to feed industrial waste
heat into the FHW district heating
system.
How the heat reaches Neukölln
households
The heat reaches the connected
households in the form of hot water
- there are around 55,000 of them in
the ‘neighbourhoods’ of Berlin-Neukölln
and Berlin-Kreuzberg. The water
releases its heat and flows back to
the FHW Neukölln in a circulation system.
Around 120 kilometres of pipes
have now been installed. Around two
to four kilometres are added every
year. The district heating network
now extends from the Landwehrkanal
in Kreuzberg via Grenzallee in
Neukölln, Reuterkiez and Körnerpark
to Tempelhofer Feld in Oderstraße.
Fig. 3: The Neukölln district heating plant relies on two GEA large heat pumps for the ‘ecological-social
energy transition’ project.
Photo: GEA/Cem Yücetas
GEA Group Aktiengesellschaft
Peter-Müller-Str. 12
40468 Düsseldorf, Germany
Tel. +49 (0)211-9136-0
Message via contact form
on the website
www.gea.com
12 GREEN EFFICIENT TECHNOLOGIES 2024

District heating
Great climate from the cloud
Photo: dataR
The electricity consumption of
German data centres rose from 11
to 18 billion kilowatt hours within
a decade by 2022 – and the trend is
still rising. Streaming services, cloud
solutions instead of local desktop
PCs and the rapid growth in digitalisation
mean that servers are still
hungry for electricity.
However, unlike most production
facilities, the electricity in data centres
is almost exclusively converted
into heat. To prevent the hardware
from overheating and being damaged,
they are permanently cooled.
Water is increasingly replacing the
previously dominant cooling medium
of air. This also changes the temperature
range of the dissipated
heat and, as a direct consequence,
the type of possible waste heat utilisation.
Air-cooled systems release
heat at a temperature of around 30
degrees Celsius. This low temperature
level is suitable, for example, for
surface heating in new buildings or
drying systems. To heat existing residential
or office buildings, the waste
heat must first be heated to almost
double this temperature using heat
pumps. The waste heat from watercooled
server cabinets, on the other
hand, can reach up to 60 degrees.
This makes it easier to feed it directly
into local heating networks, as their
previous, significantly higher flow
tempera ture level is increasingly
reduced.
Increasing profitability
Although the current Energy Efficiency
Act does not (yet) stipulate that
data centre operators are obliged to
connect to a local heating network,
the probability of this happening is
increasing from year to year. The CO 2
tax and thus the value of waste heat
also increases every year. It therefore
makes sense to look for a possible
heat sink in the surrounding area
as early as the site planning stage, as
energy and resource efficiency will
play a decisive role in the data centre
of the future.
Data centre with “Blauer Engel”
certification
The co-location data centre operator
dataR is relying on the expertise of
ENGIE Deutschland GmbH at its new
Rellingen site in the north of Hamburg.
Together with its partner Kähler
Bau, ENGIE Deutschland is developing
and building a data centre in
Rellingen with a connected load of
over six megawatts, which will meet
demanding requirements in terms
of operational reliability, efficiency
and sustainability. After completion
in March 2026, the data centre will
be certified by TÜV SÜD in accordance
with availability class VK-3 in
GREEN EFFICIENT TECHNOLOGIES 2024
13

District heating
accordance with the European standard
for data centres DIN EN 50600.
The building will also be awarded
the “Blauer Engel DE ZU-228” eco-label,
which is awarded by the German
Federal Ministry for the Environment
for particularly environmentally
friendly products and services.
Andreas Janker, Managing Director
at dataR, said at the ground-breaking
ceremony on Thursday, 7 March
2024: “We are proud that dataR is
building one of the most energy-efficient
data centres in Germany. With
ENGIE Deutschland, we have exactly
the right partner at our side to
achieve a new level of efficiency and
sustainability in our sensitive digital
infrastructure.”
dataR and ENGIE on the road to
climate neutrality
The dataR data centre covers a total
of 8,200 square metres. Of this, 2,500
square metres are accounted for by
the white space with 25 rooms in
which the servers, switches and data
storage are housed. The remaining
space is divided into the grey space
with the cooling systems, the systems
for the uninterruptible power supply
and other operating equipment, as
well as the offices. The highly complex
technical equipment, which ENGIE
Deutschland designed and whose
installation the on-site team will
coordinate and supervise during the
entire construction phase, includes
a redundant emergency power supply
(three systems of 3,500 kilovolt
amperes each), water-cooled chillers
with the natural refrigerant ammonia
and with free cooling (six systems of
850 kilowatts each) and dry cooling
units (four systems of two megawatts
each). This makes it the first data
centre in Germany to use a natural
refrigerant (Global Warming Potential
(GWP) = 0) to this extent. Another special
feature is the use of waste heat on
site: the data centre will provide several
megawatts of waste heat, which
can be used to supply heat to the
surrounding buildings. Maximilian
Busch, Head of Sales & Engineering
in the Building Technologies business
unit and respon sible for the project at
ENGIE Germany, says: “Data centres
in Europe are facing the challenging
task of becoming climate-neutral by
2030. Our project with dataR shows
that the climate-neutral data centre
is absolutely possible for any size of
data centre, even under complex conditions
– and thus sets an example for
the industry.”
Retrofitting in existing buildings
The electrical energy used to operate
the data centre is ultimately almost
completely converted into heat. This
heat is either generated directly by
the IT technology and is transferred to
cooling water transmitted to cooling
water heated up to 50°C. Or it is dissipated
indirectly via cold water and
then reaches the condensers of the
chillers at around 46°C. Theoretically,
100 percent of the heat can be transferred
to the waste heat consumers.
At the moment, Rellingen is already
planning to take around 30 percent
of the waste heat; depending on further
planning of the heating network
by the municipality, the proportion
could increase. One limitation here
may be the guaranteed availability of
waste heat as a heat source for the
heating network.
According to ENGIE, it is generally
possible to install such heat recovery
at a later date. The installation
effort depends on whether system
technolo gy has already been preequipped
for this – respective existing
data centre for connecting waste
heat users.
ENGIE has already provided proof
of feasibility: At the German Climate
Computing Centre in Hamburg, the
ENGIE Deutschland team has retrofitted
a waste heat recovery system
to preheat the outside air in a neighbouring
university building.
About ENGIE Deuschland and
the ENGIE Group
ENGIE’s mission is the transition to
climate neutrality. In Germany, the
companies of the ENGIE Group plan,
build, operate and market wind,
photovoltaic and hydropower plants
as well as pumped storage and battery
storage systems. The company
supports industrial customers, local
authorities and the housing industry
in implementing their sustainability
goals by optimising consumption
and implementing and operating
highly efficient building and energy
technology systems. With concepts
for climate-friendly heat supply,
mobility and digitalisation, ENGIE
supports the development of sustainable
neighbourhoods. The Group
trades in electricity and gas, supplies
end customers with energy, offers
multidisciplinary engineering solutions
in the fields of energy, water
and infrastructure and is one of the
leading storage operators in Germany.
In 2023, the ENGIE companies
in Germany generated sales of
2.75 billion euros with around 5,900
employees.
The French parent company ENGIE
SA is a global reference in low-carbon
energy and services and is committed
to accelerating the transition
to a carbon-neutral world by reducing
energy consumption and offering
greener solutions. In 2023, the
listed company generated sales of
around 82.6 billion euros with 97,000
employees.
ENGIE Deutschland GmbH
Aachener Straße 1044
50858 Köln, Germany
Tel.: +49 (0)2 21 4 69 05-0
info-deutschland@engie.com
www.engie-deutschland.de
14 GREEN EFFICIENT TECHNOLOGIES 2024

Industrial heat storage
Thermal storage: building block for the
decarbonisation of industrial process heat
Dr Christian Thiel, Chief Executive Officer, Energynest
Uncovered ThermalBattery made of carbon steel and the special concrete “Heatcrete”
All pictures: Energynest
in the public debate surrounding
the energy transition. Yet energyintensive
industrial sectors such as
steel, chemicals, textiles, food and
the paper industry in Europe consume
almost 2,000 terawatt hours
of energy per year for the production
of process heat. At present, however,
a substantial proportion of this
industrial heat still comes from fossil
energy sources such as natural gas.
As a result, the production of industrial
process heat is responsible for
more than 20 per cent of European
CO 2 emissions, in Germany even 25
per cent.
In Germany, around half of final
energy consumption is accounted for
by the generation of heat, with the
generation of process heat accounting
for around 23 per cent across
all sectors according to the Federal
Environ mental Agency (UBA). However,
according to German Energy
Agency (dena), the share of green
heat is only around 15 per cent.
Accordingly, process heat and process
steam still offer enormous
potential for savings and therefore
also a significant lever for reducing
CO 2 emissions.
New technologies are now
needed to achieve net-zero electricity
generation as quickly as possible
without disproportionately
increasing production costs and,
ideally, reducing overall consumption.
This is where thermal storage
solutions come in, as they can make
a significant contribution to reducing
dependence on fossil fuels and
decisively advance the integration of
renewable energies in industry.
The future of industry is characterised
by decarbonisation. In this
respect, process heat and process
steam are still being neglected in the
public debate. Yet they offer enormous
savings potential for companies.
Thermal storage solutions
can be an important building block
for sustainable, reliable and costefficient
steam and heat production
in industry.
The challenge of industrial process
heat has often been overlooked
Enormous potential for the
decarbonisation of industrial heat
Energy storage is a key aspect of the
energy transition. The reality remains
that biomass is finite, geothermal
energy is only economically available
GREEN EFFICIENT TECHNOLOGIES 2024
15

Industrial heat storage
Fig. 1: View of part of the CST system to which Energynest's ThermalBattery in Turnhout, Belgium, is connected
in small parts of Europe and the efficiency
of hydrogen from electricity
for heat generation is currently 50 per
cent at best. In addition, green hydrogen
is unlikely to be available nationwide
until it is too late and will remain
too expensive to burn in base load for
the foreseeable future. Sustainable
green solutions for energy storage,
on the other hand, are already available
today.
Thermal storage solutions should
not only be considered in the context
of achieving climate protection
targets. They also offer great
potential from a business perspective.
Decarbonisation can make
German industry as a whole more
resilient and competitive by reducing
its dependence on fossil fuels and
thus minimising geopolitical risks.
By implementing storage solutions,
comparatively inexpensive and
decentralised renewable energies
can be integrated and supply and
cost security can be guaranteed in
the long term.
Our ThermalBattery is made of
carbon steel and Heatcrete, a special
concrete developed in collaboration
with Heidelberg Materials. The thermal
storage units can be expanded on
a modular basis, depending on how
much storage is required. No moving
parts were used in the design, which
is why the storage unit has a long service
life and is relatively low-maintenance.
The service life is 30 years or
more.
The heat battery is charged by the
direct flow of hot heat transfer fluid
through embedded steel pipes from
top to bottom, whereby heat energy
is transferred to the core storage
material. In discharge mode, the flow
is reversed: Cold heat transfer fluid is
fed in at the bottom and then leaves
the battery heated to release energy
from the top side of the ThermalBattery.
This principle works just as efficiently
with water and vapour. The
thermal accumulator therefore acts
as a vapour cooler and condenser
during charging, while it functions as
a boiler and superheater during discharging.
The optimum operating range of
the ThermalBattery is between 120°
and 400°. The storage unit can be
customised for different applications,
opening up a wide range of uses in an
industrial context. For example, heat
storage units can be used for waste
heat recovery or the generation of
heat from renewable energies for
drying processes.
Full integration of renewable
energies
In view of the limited availability and
low efficiency of other renewable
energies such as biomass or hydrogen,
the expansion of solar energy
and wind power is rightly a priority.
However, it is precisely the muchcited
“dark doldrums” that make storage
systems an absolute necessity for
the energy transition. This is where
solutions such as our ThermalBattery
come into play, which already represent
a sustainable and practicable
option today.
The natural fluctuation in the
availability of renewable energy is
bridged by the ThermalBattery’s storage
options. Energy that is not immediately
required can be stored for
heat or steam generation at night or
during other peaks in demand, allowing
renewable energy to be fully integrated
into a wide range of industrial
processes. This eliminates the need
16 GREEN EFFICIENT TECHNOLOGIES 2024

Industrial heat storage
for fossil fuels completely or at least
in some processes with the help of
thermal storage.
In this context, for example, concentrated
solar thermal (CST) is a
promising technology for carbon-free
industrial process heat generation.
Parabolic mirrors heat thermal oil,
which is stored in the ThermalBattery
with minimal losses. If required, the
stored energy can be fed into a steam
generator to produce steam on
demand, which can be used in drying
processes, for example. Ideally,
the electrification of heat and steam
production can eliminate the need
for fossil fuels for sub-processes
altogether. However, without storage,
production is only limited to daytime
periods, even if steam is required
throughout the day. Thermal storage
can store excess energy for steam
production at night, enabling true
decarbonisation.
Energynest has implemented this
application in Belgium with its partner
Avery Dennison, a leading manufacturer
of self-adhesive materials.
The project comprises a concentrated
solar thermal platform with 2,240
surface mirrors and a peak solar field
yield of 2.7 GWh of thermal energy, as
well as six thermal storage modules
with a capacity of 5 MWh of thermal
energy. Solar energy is used there
to operate some of the drying ovens
in production, which are used in the
coating process for the pressure-sensitive
adhesive products manufactured
at the site. Thermal energy that
is not generated as required is stored
in the ThermalBattery and released
at night or during other peaks in
demand, thus avoiding the use of fossil
fuels and contributing to a further
reduction in emissions.
The use of thermal storage systems
at a paper manufacturer, for
example, can lead to significant
savings with an assumed storage size
of 8 MWth in combination with an
electrode steam boiler of 5 MWe. In
this scenario, Energynest calculates
that consumption could be reduced
by an average of around 11 GWh
of natural gas and 2,300 tonnes of
CO 2 per year. The total savings per
year could thus amount to up to 1.3
million euros per year, which would
lead to amortisation of the system
after four years of operation.
Significant improvement in energy
efficiency
In addition to electrification, thermal
storage systems can also realise previously
untapped potential in waste
heat. The recovery of excess heat
and its storage for later reuse as primary
energy in a type of process heat
recycling also reduces dependence
on fossil energy sources and saves
energy costs and emissions. Many
companies are already working with
heat recovery systems. Thermal storage
systems can supplement these
and enable flexible control of heat
recycling.
This process is used, for example,
by one of the world's largest fertiliser
manufacturers Yara in Porsgrunn,
Norway. The steam-based thermal
storage units – the first of their kind
in industrial use – enable Yara to
recover energy that is not generated
on demand in the form of steam and
RECIPROCATING
PUMPS TO API 674
- Liquid ammonia pumps
- Reactor feed pumps
- Methanol pumps
- Produced water injection pumps
- Wash water pumps
Pressure:
Flow rate:
50 – 4000 bar
0,1 – 200 m³/h
HAMPRO® HIGH-PRESSURE
PROCESS TECHNOLOGY
Hammelmann GmbH
Carl-Zeiss-Straße 6-8
D-59302 Oelde
+49 (0) 25 22 / 76 - 0
pp@hammelmann.de
www.hammelmann-process.com

Industrial heat storage
feed it back into the steam network
for various plant processes, according
to requirements. This form of
steam grid balancing ensures that
fewer fossil fuels have to be used to
generate additional steam and that
fluctuations in production and energy
feed-in can be balanced out.
Huge demand, speed required
A large number of different storage
solutions are now needed to realise
the industry’s ambitious climate
protection targets. Thermal storage
systems are already commercially
mature and are playing their part in
the energy transition in the process
heat sector. Storage projects with
Energynest can be realised in less
than twelve months from the initial
consultation to commissioning. The
storage systems are then in operation
for 30 years without any loss of
performance, in some cases even significantly
longer. On the road to a climate-neutral
industry, the need for
such and comparable storage technologies
is gigantic.
Many fields of application for
thermal storage no longer require
new political measures or special
subsidies – especially not with high
energy prices and the prospect of
further increases in CO 2 prices. The
pressure on the industry to act is
enormous: rapid implementation
and scaling of climate-friendly technologies
are now crucial. To achieve
this, German industry must abandon
its caution, turn energy procurement
from a pain point into a solution and
combine various technologies into a
sustainable supply portfolio.
Thermal storage systems can play
a central role in securing the industrial
heat supply and at the same
time become a core component of climate-neutral
production processes.
They are both sustainable and economical,
quick to implement and
scalable. This makes thermal storage
systems not only a sustainability
project, but also a real business case
from a management point of view.
About Energynest
Energynest offers a flexible and
cost-effective thermal energy storage
(TES) system for customers in
the power generation, energy-intensive
manufacturing and renewable
energy sectors. The thermal battery
solutions decarbonise the energy
supply by electrifying industrial
heat and by recovering and reusing
waste heat into energy on demand.
Energynest also offers large-scale
energy storage for solar thermal
and other zero-emission power
plants. Founded in 2011 and headquartered
in Billingstad with offices
in Hamburg, Seville and Rotterdam,
the company was ranked 3rd in the
Global TOP100 Carbon Reducing
Innovations by Mission Innovation.
Fig. 2: Heat storage in use at the Yara plant in Porsgrunn, Norway
ENERGYNEST AS
Billingstadsletta 13
1396 Billingstad
Norway
post@energy-nest.com
www.energy-nest.com
18 GREEN EFFICIENT TECHNOLOGIES 2024

Industrial heat storage
Storing heat directly
Storing waste heat and reusing it
offers great potential for saving
energy in a wide variety of manufacturing
processes. A new storage technology
for process steam has been
developed by the Norwegian company
Energynest. Its CEO Christian
Thiel answered questions from the
GET editorial team.
Your storage system essentially
consists of concrete and steel. In
what time frame does the storage
system recover the CO 2 emitted
during its production? What does
the necessary utilisation profile of
charging and discharging cycles
look like?
Christian Thiel: The thermal battery
is a long-term storage device. We
charge for around three to four hours
and always discharge for the same Christian Thiel, Chief Executive Officer
amount of time. Typically, one to two
charges and discharges per day are planned for most applications. The
projects typically amortise between two and seven years.
What are the strengths of your product in comparison with other
“thermal batteries” such as hot water storage tanks, sand storage
tanks or ice storage tanks? Or in other words – for which temperature
range is your technology particularly suitable?
Christian Thiel: Our ThermalBattery is made of steel and a special concrete
with few moving parts, which makes it economical and durable.
The storage tank works optimally in the temperature range between
120 and 400 degrees Celsius.
Is it only possible to use water/steam as the charging and
discharging medium, or can a user also directly introduce other
media or products (e.g. molten salts or hydrocarbons) directly into
your storage without detours?
Christian Thiel: Our storage system uses either steam, water, or thermal
oil as the charging and discharging mediums. These applications are
most common in the temperature range in which we operate. Therefore,
it makes the most sense to provide these mediums directly for
further heat utilization in production. Direct storage using steam/water
as a heat transfer medium is also our unique selling point compared
to our competitors. However, green electricity can also be converted
into heat using electric heaters or electric boilers. Ultimately, the only
important thing is that in the end heat is needed and consumed again.
Which sectors do you consider to be
your direct target group?
Christian Thiel: Our core target group
can be found in energy-intensive
industries such as paper manufacturing,
food production, chemicals and
agriculture. In general, our storage
systems are of interest to all industries
in which process heat or process
steam is used.
Can you name a typical cluster
size for a medium-sized factory
production?
Christian Thiel: This depends entirely
on the production location and the
respective production conditions
as well as input/output variables.
The storage tank, its size, peripherals,
additional systems and the heat
transfer medium are then configured
accordingly. As our system is easily
scalable and can be expanded at any time, it can also be upgraded at
any time. In a classic SME production facility, the capacity can therefore
vary from 8MWh to 100MWh.
Name three features of your product that you consider to be
particularly important.
Christian Thiel: Firstly, our ThermalBattery is very versatile, meaning
that it can be used in various configurations and industrial contexts. It
is also very durable, with a service life of at least 30 years without any
loss of performance. Finally, there is the cost-effectiveness, which can
be attributed to low product costs and great savings potential on the
part of the companies.
What is the typical service life of a storage module? Can a company
simply take the storage solution with it if it relocates?
Christian Thiel: No moving parts were used in the design, which is why
the storage tank has a long service life and is relatively low-maintenance.
The service life is 30 years or more.
GREEN EFFICIENT TECHNOLOGIES 2024
19

Energy storage
Sustainable, well-cooled energy storage
systems for commerce and industry
Arthur Brinkmann
Individual housing solutions from CTX
Photo: CTX Thermal Solutions GmbH
Commercial energy storage systems
from STABL Energy make an active
contribution to climate protection.
Housings with a cooling function
made in Nettetal ensure long-term
reliable operation of the storage
modules.
An increasing percentage of our electricity
comes from renewable energies.
Not only homeowners, but also
more and more skilled trade and
industrial enterprises, are installing
photovoltaic systems on the roofs
of their houses or production halls.
Electricity generated in this way that
cannot be used immediately is either
sold to grid operators or stored in
solar batteries. However, typical photovoltaic
storage systems are often
designed to store only the amount of
energy needed to operate electrical
devices during the evening or night.
For companies that work only two
shifts, such a model generally is not
worthwhile.
But there is a highly sustainable
storage solution for industrial
enterprises: High-quality automotive
batteries that no longer provide
enough power for use in a vehicle
are by no means worthless. STABL
Energy gives these batteries a se cond
life. The Munich-based company
was established in 2019 based on
research projects by the Technical
University of Munich, the University
of the Bundeswehr Munich, and the
Osnabrück University of Applied
Sciences. The goal of the fast-growing
international team of experts in
battery technology and power electronics
was to increase the use of
renewable energies with the help of
energy storage systems.
Special business model
The energy storage systems from
Munich fulfill the highest stand-
Fig. 1: Each module consists of a battery and the power electronics of the multi-level inverter
Photo: STABL
20 GREEN EFFICIENT TECHNOLOGIES 2024

Energy storage
ards and are especially attractive for
enterprises that operate a photovoltaic
system, or would like to limit peak
loads or avoid high grid costs.
The Munich-based company
relies on a special business model:
The energy storage systems are
leased to enterprises on a subscription
basis that includes operation,
maintenance and other services.
Use of the sustainable energy storage
systems not only reduces the
consumption of electrical energy by
storing excess energy and using it
to optimize electricity costs. It also
makes the enterprises less dependent
on external energy sources, while
actively contributing to climate protection.
Efficient and sustainable
For its storage system, which received
the 2022 ees Award, STABL uses
automotive batteries. “By doing this,
we give the retired batteries a second
life and reduce CO 2 emissions by up
to 70 percent compared to the use
of new batteries,” explains Dr. Arthur
Singer, CEO and one of the four
founders of STABL Energy.
STABL’s modular technology can
be used to connect large numbers
of batteries with different health
statuses to the public electricity
grid without the need for a central
inverter. The advantages of this innovative
technology are numerous: The
STABL technology, which is based
About CTX
For more than 25 years, CTX Thermal
Solutions GmbH has been developing
and manufacturing tailor-made cooling
solutions for electronic components
used in virtually all industries.
Comprehensive technical expertise in
thermal management, state-of-theart
production technologies, and its
unique product diversity have made
CTX the European leader of the industry.
In addition to the development of
new custom cooling solutions, CTX
also implements heat sinks according
to drawings, as well as complete
logistics services for the transport of
products.
Established in 1997, CTX has
more than 35 employees. In terms
of revenue, the company is among
the major suppliers of cooling systems,
especially when it comes to
application-specific cooling solutions.
The certified quality and environmental
management system
meets the requirements of DIN
EN ISO 9001:2015 and DIN EN ISO
14001:2015.
on patented solutions, achieves outstanding
peak round-trip efficiency.
Its modular structure allows flexible
adaptation to different requirements.
Continuous monitoring of operation
is ensured by a web-based software
that enables efficient remote monitoring
and maintenance. Furthermore,
the system sets new standards
About STABL Energy
STABL Energy GmbH, located in
Munich, specializes in scalable commercial
battery storage systems and
is known for improving energy management
in enterprises. STABL uses
patented technologies that optimize
the use of renewable energies
for peak shaving and autonomous
demand to increase the operating
efficiency of enterprises. The company’s
modular multi-level inverters
ensure the reliable and safe supply
of power.
As an advocate for recycling
economy, STABL Energy is committed
to reusing batteries. This increases
their service life and greatly reduces
carbon emissions.
for low-noise operating processes,
which results in a user-friendly
environ ment.
CTX provided support from the
start
Like all power electronics, the electronic
components of the energy
Fig. 2: Their unique comprehensive product line makes CTX a leading supplier of cooling solutions in Europe
Photo: CTX Thermal Solutions GmbH
GREEN EFFICIENT TECHNOLOGIES 2024
21

Energy storage
storage modules have to be cooled
for long-term reliable operation. That
is why STABL consulted CTX Thermal
Solutions GmbH during initial development
of the system. The Nettetalbased
specialists for custom cooling
and housing solutions supported the
start-up in the project development
of housings with a cooling function
for use in the sustainable energy storage
systems.
Every year, STABL now purchases
several thousend anodized cooling
housings made in Nettetal. One
housing is needed for each storage
module, consisting of two parts: an
extruded aluminium profile heat sink
with long cooling fins and a sheet aluminium
cover. The passive cooling
effect of the profile heat sink is sufficient
to ensure a continuous flow of
current through the modules. Since
both components are visible elements
of the energy storage systems,
STABL insists on a flawless black anodized
coating for the heat sinks and
covers, as well as premium-quality
silk screen printing.
“CTX also supported us in procuring
specific screws with springs,
quality control, organizing air freight
deliveries, and producing the housing
components, in addition to customs
and import issues,” says Dr. Arthur
Singer, emphasizing the advantages
of Nettetal as the location of the
heat sink specialists, which is crucial
especially in times of battered supply
chains.
More than custom-tailored cooling
solutions
In addition to application-specific
heat sinks and ready-to-install cooling
systems, the thermal management
experts also offer their
customers custom-tailored service
bundles including engineering, heat
sink machining, and individual logistics
services. Like STABL, they offer
customer support as early as the project
stage. Support includes the thermal
solution of a potential heat sink,
creation of the required CAD data
and 3D models, and a consultation
relating to the heat sink design and
production optimization. On request,
CTX also performs CNC machining
and surface treatment of the heat
sinks using diverse processes.
STABL Outdoor Storage
405 kVA ISO 20’
Outer dimensions:
Length:
Width:
Height:
Inner dimensions:
Length:
Width:
Height:
6058 mm
2438 mm
2896 mm
5786 mm
2344 mm
2622 mm
• Comprehensive 10-year guarantee,
including maintenance and
servicing
• 24/7 system monitoring
• Fast module replacement in less
than 15 minutes
• Made in Germany: High-quality
automotive industry batteries, processed
in Germany
• Lowest CO 2 emissions and resource
consumption
• Tested according to CE, IEC 62619,
IEC 63056, VDE-AR 4105, VDE-AR
4110
• Available as a 20’ container
Reliable delivery guaranteed
Fig. 3: The electronics housing consists of a
black anodized aluminum profile heat sink
and a likewise black anodized sheet aluminum
cover with printing (covered)
Photo: STABL
One service offered by CTX is especially
important in times of battered
supply chains: complete logistics services
for the delivery of heat sinks and
housings, as a guarantee for reliable
delivery. For this purpose, the heat
sink specialist operates a reserve
warehouse in Nettetal, delivers to
consignment and buffer warehouses
around the world, and uses all available
means of transport – land, sea
and air – for delivery of its products.
STABL likewise benefits from the optimized
supply chains and the uninterrupted
flow of goods. On request, CTX
can also maintain the logistics portals
of their customers, including integration
in their customers’ Kanban systems,
if required.
The Author:
Arthur Brinkmann
Sales Manager
CTX Thermal Solutions GmbH
Lötscher Weg 104, 41334 Nettetal,
Germany
Tel: +49 2153 7374-0
Fax: +49 2153 7374-10
info@ctx.eu
www.ctx.eu
22 GREEN EFFICIENT TECHNOLOGIES 2024

Hydrogen sensor technology
Putting the pressure on hydrogen
Measurement challenges linked to H 2
refuelling station operation
Christian Wirl
In hydrogen filling stations, many sensors ensure a safe refuelling process.
Bild: Adobe Stock/scharfsinn86
In the public debate on hydrogen
mobility, the focus is usually on the
various propulsion systems available.
Yet to help H 2 breakthrough
in a big way as an alternative fuel,
it will take more than an attractive
range of vehicles. A comprehensive
network of refuelling stations has
to be high on the list of priorities.
The development of suitable infrastructure
will create a significant
demand for measurement technology,
mainly to ensure the safety of
the refuelling process. Manufacturers
will need to address some very
specific challenges here.
Climate change cannot be halted
without a radical change in mobility
patterns. This inevitably means
“game over” for the traditional internal
combustion engine. Its demise
will be accelerated as demand for
vehicles with zero-emission powertrains
gathers momentum. Hydrogen
is increasingly moving into the
spotlight here because H 2 fuel cells
offer similar performance data to
“petrol” and “diesel”. Ambitious
goals are being formulated worldwide
for hydrogen mobility in road
transport, especially where commercial
vehicles are concerned.
Transport and logistics companies
have started to convert their fleets,
and hydrogen-powered cars can
nowadays be observed on the roads
more and more frequently.
Expanded network of refuelling
stations
Further advances in hydrogen
mobility will hinge on our success
in expanding the network of refuelling
stations, so that no detours
are necessary to refill the hydrogen
tank. There are currently around 700
such “Hydrogen Refuelling Stations”
GREEN EFFICIENT TECHNOLOGIES 2024
23

Hydrogen sensor technology
(HRS) worldwide, and this number
is expected to rise to 6000 by 2030.
In January 2023, 95 H 2 refuelling stations
were in opera tion in Germany,
giving the Federal Republic the densest
network anywhere in Europe.
Parallel to expanding the HRS
network, it will also be vital to step up
the production of “green” hydrogen,
in other words the production of H 2
by electrolysis using renewable energies.
This is considered to be the only
truly climate-neutral method. According
to energy company EnBW, there
are 40 plants in Germany currently
producing “green” hydrogen. These
electrolysers are ideally located in the
vicinity of large wind farms or solar
parks.
Their product is delivered to the
refuelling stations in so-called tube
trailers, which consist of semi-trailers
with a cluster of seven steel tube
tanks. In the future, these tanks will
progressively make way for Type
IV carbon fibre tanks, which are
designed for a higher tank pressure –
500 bar rather than 200 – and have a
lower dead weight, enabling a higher
payload. This represents an important
step in efforts to increase HRS
storage capacity to more than a ton
of fuel in the medium term. The tank
in a passenger holds about 4 to 5 kg
of hydrogen as compared to around
40 kg in a truck, and this is likely to
increase in the future.
Standards for measurement
technology still in transition
The hydrogen industry is working to
establish a normative framework to
keep pace with the expanded infrastructure.
New guidelines are being
formulated and existing specifications
adapted in the light of new
developments. The sector is pushing
for the comprehensive standardisation
of processes and components,
to put hydrogen's usability as a fuel
on a broad, international footing. This
needs to be achieved without compromising
safety in any way.
The changing landscape of
standards makes it difficult for
manufac turers of the measurement
technology that is used to monitor
and control the refuelling process to
get a clear picture of which guidelines
should be defined for their H 2 products.
This applies to new solutions
as well as to modifications of existing
products. Durable specifications for
hydrogen refuelling stations can be
found, for example, in the ISO 19880
series of standards.
Three basic challenges of H 2
Irrespective of the specific requirements
of refuelling stations, the
physical and chemical properties of
hydrogen alone place substantial
demands on the measurement technology,
which cannot be met using
standard equipment:
• Hydrogen is highly flammable,
which is why the equipment
usually has to meet explosion protection
requirements in stationary
applications. Due to its small particle
size, H 2 penetrates materials
and forms an explosive mixture in
the air in concentrations as low as
four percent. Welded connections
or ones with metal seals are therefore
generally considered when it
comes to adapting the instrument
processes.
• The extremely small H 2 molecules
also penetrate metal structures,
where they can lead to material
embrittlement and become a
safety risk. Austenitic steels such
as 316L are preferred for this
reason for measuring instruments
in H 2 applications.
Fig. 1: A gold coating prevents the diffusion of
H 2 through conventional membrane materials.
• Furthermore, hydrogen can impair
the desired long-term stability
of a sensor's measurement signal.
If it adheres to the resistor
and/or penetrates into sensitive
structures of the electronic measuring
instrument, this can ultimately
result in signal offset and
hence measurement errors. One
possible countermeasure is to
use separating layers to prevent
hydrogen penetration. Gold is only
one suitable material for this kind
of solution.
Pressures up to 900 bar and
temperatures from -40°C to +85°C
Beyond these generally applicable
requirements for H 2 applications,
there are also specific challenges
to be addressed in connection with
hydrogen refuelling stations. Owing
to the design of both these stations
and the refuelling process itself, the
measurement and control technology
must be rated for pressures of
up to 900 bar and temperatures from
-40°C to +85°C.
The hydrogen is currently delivered
in the tube trailers at a pressure
of 200 bar and then further
compressed to 900 bar in high-pressure
tanks by means of compressors.
This happens in several stages.
The compression corresponds to the
700 bar pressure in the tank of a passenger
car. Trucks presently have a
tank pressure of 350 bar; however,
this will also be increased to 700 bar
in the future to achieve more range.
The pressure and flow rate required
in each case are controlled by communication
between the sensor systems
of the fuel pump, referred to as
the dispenser, and the vehicle tank.
Customers are keen for the
refuelling process to be completed in
the shortest possible time. Pressure
and temperature play an important
role here: the larger the pressure difference
between the refuelling station
and the vehicle, the faster the
hydrogen will flow. It goes without
saying that the specified vehicle tank
pressure must not be exceeded.
The temperature profile over the
refuelling line means the time factor
is relevant too: hydrogen heats up
24 GREEN EFFICIENT TECHNOLOGIES 2024

Hydrogen sensor technology
Summary and outlook:
Fig. 2: Pressure sensor IS-3
when it expands. The gas is accordingly
cooled down beforehand to
-40°C by means of a heat exchanger,
so that a temperature below 85°C can
subsequently be maintained. This is
necessary because the vehicle tanks
are only specified up to this value.
The closer the temperature gets to
85°C, the more the refuelling process
must be slowed down and regulated
by cooling.
Complex instrumentation
In view of the potentially critical situation,
the refuelling line of an H 2 station
ships with complex instrumentation –
including sensors for pressure, temperature
and flow as well as shut-off
and vent valves. Coriolis flow meters
are particularly suitable for monitoring
the flow rate due to the high pressures
involved.
The temperature and pressure
measuring points are crucial for
operational safety. The thermometers
must work with short response
Fig. 3: The measuring solutions in the H 2
refuelling process must work reliably over
a long period at pressures of up to 900 bar
and temperatures from -40°C to +85°C.
WIKA’s IS-3 pressure sensor and the TC90
high-pressure thermocouple are just two
appropriately specified devices.
times and be pressure-tight: the
need for a rapid response means it
is not a good idea to use a thermowell.
The probe tip must thus be ca-
pable of withstanding pressures of up
to 875 bar unprotected. At the same
time, it must have a compact design
in order to restrict the influence on
the media flow to a minimum. A conical
threaded connection, for instance,
gives the thermometer the requisite
strength and keeps the measuring
point reliably sealed.
The pressure sensors installed in
the dispenser usually have a nominal
pressure of 1000 bar or 1050 bar.
This value is based on the nominal
tank pressure in the vehicle – 700 bar
in the case of passenger cars – plus a
temperature-related safety factor. The
sensors must also operate to specification
in the typical HRS temperature
range from -40°C to +85°C. Last but
not least, the task at hand necessitates
devices with explosion protection – or
even SIL certification at certain measuring
points in the system.
The construction of a comprehensive
network of refuelling stations opens
up new opportunities for manufacturers
of measurement technology
in the promising hydrogen mobility
segment. Both the hydrogen refuelling
stations themselves and the
electrolysers that are essential for
climate-neutral production of green
hydrogen must be built in large numbers
and simultaneously made more
efficient. It could even make more
financial sense for large HRSs with
a correspondingly large footprint,
for example at service stations, to
produce their own hydrogen using
green electricity. By the same token,
as more pipelines purely for hydrogen
are constructed and expanded,
refuel ling stations could conceivably
be connected directly to the supply
network of tomorrow.
It will become much easier to
satis fy the instrumentation needs
of the infrastructure once ongoing
standardisation activities are nearing
completion. Parallel to this, the
hydrogen industry is endeavouring
to reduce the cost of building
and operating refuelling stations
through standardisation, cheaper
components and optimised processes,
in order to make H 2 refuelling
also attractive price-wise. The
additional requirements which the
measure ment and control technology
is expected to meet as a result
of this will pave the way for improved
efficiency.
The Author:
Christian Wirl
Portfolio Manager Hydrogen
WIKA Alexander Wiegand SE & Co. KG
Alexander-Wiegand-Str. 30
63911 Klingenberg/Germany
Tel. +49 9372 132-0
info@wika.de
www.wika.com
GREEN EFFICIENT TECHNOLOGIES 2024
25

Hydrogen infrastructure
Ex-enclosures from ROSE protect the
hydrogen infrastructure
Katharina Lange
ROSE has equipped the first LNG terminals in Germany with explosion-proof enclosures. Enclosures from Porta Westfalica are also installed
in hydrogen plants.
All pictures: ROSE Systemtechnik GmbH
Green hydrogen plays a central role
in establishing a CO 2 -neutral industry.
However, special precautions
are necessary for the safe operation
of control electronics in electro lysers
and pipelines. ROSE Systemtechnik
GmbH equips hydrogen facilities
worldwide with explosion-proof
enclosures and sees significant
re venue potential in the market.
the development of a hydrogen infrastructure,
with over ten billion euros
allocated for this purpose.
Hydrogen sector becomes ROSE's
new target industry
“The hydrogen market is still in its
early stages, and a lot is happening
right now,” reports Heiko Felsmann,
Sales Director at ROSE Systemtechnik
GmbH. The company, specializing in
the production of high-quality industrial
enclosures, has identified the
hydrogen sector as a new target market.
“The decision for us is obvious:
we have been producing the explosion-proof
enclosure systems needed
Not long ago, discussions about the
energy carrier hydrogen were confined
to specialist circles. Nowadays,
the topic is encountered almost daily
in the media. The hype around this
colorless and odorless gas is justified,
as both the European Commission
and the German government
have declared hydrogen the key element
of the energy transition. In the
European Union, electrolysers for
hydrogen production with a capacity
of at least 40 gigawatts are expected
to be established by 2030. Germany,
too, has ambitious plans regarding
hydrogen: with the “Climate Protection
Agreements Support Program,”
the federal and state governments
aim to provide targeted incentives for
Fig. 1: The flameproof enclosures of the EJB series by ROSE are ideally suited for use in applications
involving gas groups IIB and H 2 .
26 GREEN EFFICIENT TECHNOLOGIES 2024

High-performance plastics
for climate neutral
H 2 technologies.
Hydrogen: A climate neutral energy source
for the future. Produced through electrolysis
with renewable resources. As a
development partner for high-performance
plastics we support you from production
of hydrogen to multiple hydrogen applications.
Customized sealing solutions even
for parts used in mobility applications.
Dimensions up to 3 meters for large-scale
electrolysis and beyond.
Visit us:
Hydrogen Technology Expo Europe
Hamburg
Oct. 23-24, 2024
Fig. 2: GUB series enclosures by ROSE have been designed to protect control-related components in
environments with atmospheres of gas group IIC.
there for decades and possess extensive
expertise in the field,” says Felsmann.
Industry has long sourced
Ex-enclosures from East Westphalia
In addition to serving the chemical and
petrochemical industries, ROSE also
supplies the oil and gas industry with
Ex-certified enclosure systems. The
requirements for explosion protection in
these industries are similar to those for
components used in hydrogen facilities.
All ROSE’s Ex-certified enclosures comply
with the ATEX and IECEx directives for
Zones 1 and 2 in gas explosion protection
and Zones 21 and 22 in dust explosion
protection. Moreover, the Ex-enclosures
are approved for use in countries such
as the United Kingdom (UKCA), Brazil
(INMETRO), South Africa (Explolabs), and
China (CCC).
Customers can choose between
explosion-proof enclosure systems made
of aluminium, polyester, and stainless
steel at ROSE. Depending on the application
and area of use, the enclosures are
also available with different protection
concepts (ignition protection types). The
range includes intrinsically safe designs
(Ex i) as well as the pressure-encapsulated
variants of the EJB, IJB, GUB, and
TBE series.
It all starts with climate-neutral
electricity
However, the hydrogen infrastructure
is not only about areas where explosion-proof
enclosures are mandatory.
In the case of green hydrogen, the process
chain begins with the generation of
electricity required for electrolysis using
wind, hydropower, or sunlight. Manufacturers
of both wind energy and photovoltaic
systems use robust enclosures from
ROSE to protect their control electronics.
Renowned manufacturers of wind energy
systems (WES), for example, house frequency
converters at the generator using
enclosure systems from Porta Westfalica.
The electronics of the wind sensor, pitch
system, brake system, and various sensors
are also protected from weather
www.ek-kt.de/electrolysis
ekt.hydrogen@elringklinger.com
Fon +49 7142 583-0
GREEN EFFICIENT TECHNOLOGIES 2024

Hydrogen infrastructure
Fig. 3: All enclosures at ROSE are custom machined and equipped according to individual preferences upon request.
influences by enclosures from Porta
Westfalica. These are mostly aluminium
enclosures, as they are highly
robust thanks to the high-quality aluminium
casting alloy AC-AlSi 12 (Fe)
and can withstand strong corrosive
loads without further coating.
Many photovoltaic systems also
use aluminium enclosures to keep
wind and moisture away from the
control system of the tracking unit.
The Aluform enclosures were specifically
designed for easy installation of
boards and circuit boards, making
them particularly suitable for applications
in measurement and control
technology.
Control technology in electrolysers
must be secure
After electricity generation, electrolysis
is the next step in the production
process of green hydrogen. In the
electrolyser, water is split into hydrogen
and oxygen molecules using electricity.
Pumps that transport water
into the electrolysis cell, water treatment
systems, gas purifiers, transformers,
and rectifiers ensure the
smooth operation of the plants. But
also, gas coolers, gas compressors,
and sensors are components of electrolysers.
The required control technology
must be protected from environmental
influences. Conventional
industrial enclosures are not suitable
for this purpose, as hydrogen is
easily flammable, and the enclosures
do not provide sufficient protection
against, for example, sparking. The
reactivity of hydrogen is evident from
two figures: The lower explosive limit
(LEL) of hydrogen is only 4 vol. % in
an air-gas mixture, and the minimum
ignition energy is only 0.02 mJ.
Hydrogen is extremely reactive
Fig. 4: Flameproof enclosures from ROSE prevent the propagation of an explosion from the
inside to the outside.
Due to these properties, hydrogen
belongs to explosion group IIC –
including explosive mixtures requiring
an ignition energy of

Hydrogen infrastructure
A gas mixture is introduced and
ignited while the enclosure is in an
explosive environment. If the ignition
transfers to the outer atmosphere,
the ATEX/IECEx requirements are not
met.
Growing demand for Ex-enclosures
for hydrogen facilities
Fig. 5: ROSE Systemtechnik already offers suitable enclosure solutions for protecting the control
technology of electrolysers, gas compressors, pipelines and caverns.
the enclosure into the surrounding
atmosphere.
Pressure-tight encapsulation
contains the explosion in the
enclosure
Even more robust are ROSE’s Ex d
enclosures: they feature a pressure
encapsulation that ensures an
explosion inside the enclosure cannot
propagate outward. In addition,
sparks, flames, and hot gases are
cooled through an ignition protection
gap, preventing them from igniting a
potentially explosive atmosphere in
the surroundings.
The Ex d enclosures have another
advantage for operators of hydrogen
infrastructure facilities: since the
enclosures already provide very high
explosion protection, the use of normal
components without Ex certification
is allowed inside. Therefore,
users can choose from the entire
range of automation components
available on the market.
Comprehensive service saves users
time and money
ROSE not only manufactures a wide
selection of Ex-enclosures but also
takes care of their assembly with customer-specific
components such as
switches, pushbuttons, terminals,
or cable glands upon request. Some
parts, such as explosion-proof pushbuttons,
are even produced by ROSE
itself.
“Almost all customers in the Ex
sector have their enclosures assembled
by us,” says Sales Director Heiko
Felsmann. But the service goes even
further: “If needed, we also take care
of sourcing the electrical and electronic
components – so the user gets
everything from us in one place.”
In addition to assembly and
sourcing, ROSE also offers the
mechanical processing and surface
finishing of the enclosures. If customers
want to certify enclosures or components
themselves, Heiko Felsmann
and his colleagues are happy to support
them, ensuring a fast and efficient
approval process.
Stringent material tests ensure high
quality
Regular quality and stress tests of
the Ex-enclosures in ROSE’s in-house
labo ratory ensure compliance with
the high requirements of the ATEX
and IECEx directives. The conducted
tests include self-heating tests as well
as reference pressure, overpressure,
and spark transmission tests. Permeability
tests are also part of this:
In the coming years, forecasts indicate
a rapid increase in global
demand for hydrogen. Especially
energy-intensive industries such as
the chemical, steel, cement, and glass
industries aim to replace fossil fuels
with climate- neutral hydrogen.
ROSE Systemtechnik already
offers suitable enclosure solutions
for the protection of control technology
in electrolysers, gas compressors,
pipelines, and caverns. The
company not only manufactures at
three European locations but also in
India. The production there supplies
equipment suppliers and operators
of hydrogen facilities worldwide with
Ex-enclosures according to German
standards.
The Author:
Katharina Lange
Head of Marketing
ROSE Systemtechnik GmbH
www.rose-systemtechnik.com
GREEN EFFICIENT TECHNOLOGIES 2024
29

Efficient drives
Reliable pump drives for sustainable fibres
form threads. The exact procedure
is a trade secret closely guarded by
Lenzing.
Highly efficient IE5+ synchronous
motors from NORD
With the aid of spinning pumps, Lenzing produces endless, uniformly strong threads with a
constant denier
Lead image + images 1-3: Lenzing AG
The Austrian fibre manufacturer
Lenzing relies on drives from
NORD DRIVESYSTEMS for its spinning
pumps. Here, IE5+ motors
impress with their operational
safety and energy efficiency
Our bodies come into contact with
them every day, be it with jeans or
outdoor jackets: cellulose-based
fibres. Lenzing AG is a company that
specialises in the production of these
fibres, which are made from wood.
The so-called spinning pumps play
an important role in the production
of these fibres. To drive them reliably
and efficiently, Lenzing AG relies
Fig. 1: In Lenzing, Upper Austria, the
company sustainably produces fibres for
clothing and much more
on drives from the North German
specialist NORD DRIVESYSTEMS.
Technology leader in fibre
production
Over the 85 years since it was established,
Lenzing AG has built up a reputation
as a global market, technology
and sustainability leader in the field
of fibre production. The sustainably
produced high-quality fibres of the
Lenzing brands TENCEL, VEOCEL,
etc. are the raw material for many
textile and non-woven fabric applications.
Being a pioneer of the ecological
movement, the company had
already established their first environmental
department in 1975, and
began restructuring their manufacturing
towards resource-saving production.
Fibres from Lenzing are used for
different textile and non-woven fabric
applications, for protective and
work clothing, and for a wide range of
industrial applications. The fibre production
process converts raw wood
material into a liquid mass. With the
aid of the spinning pumps, the material
is pressed through fine nozzles to
As these threads are endless and
need to have a constant denier, the
pump drives must supply a reliable
and constant performance. When
redesigning its systems in 2022, the
Austrian fibre specialist therefore
decided on IE5+ synchronous motors
from NORD DRIVESYSTEMS.
IE5+ motors from NORD offer
extremely high operational reliability.
Designed as Interior Permanent
Magnet (IPM) motors, the
magnets are incorporated into the
rotor, significantly increasing reliability
and safety. Furthermore, permanent
magnets in IPMs are better
Fig. 2: The fibres from Lenzing are exclusively
produced from natural raw wood
material
protected against current peaks,
which can occur with high currents
that may generate an opposing field.
Excellent energy efficiency
Lenzing AG’s further requirements
for its pump drives include constant
speed without encoder feedback,
temperature resistance up to
60 °C, extensive freedom from maintenance
and – particularly important
for the ecologically committed company
– excellent energy efficiency.
“Our IE5+ permanent magnet synchronous
motors comprehensively
30 GREEN EFFICIENT TECHNOLOGIES 2024

FILTECH
November 12 – 14, 2024
Cologne – Germany
The Filtration Event
www.Filtech.de
Platform
Fig. 3: The Austrian fibre manufacturer Lenzing is known for its TENCEL and VEOCEL fibre brands
for your
fulfil these requirements”, the Head of
Marketing at NORD, points out. They provide
a constant torque over a very wide
speed range and thus achieve efficiencies
of up to 95 percent, surpassing the highest
defined efficiency class IE5.
The IE5+ motor in the smooth-surface
and fanless version also handles
temperatures of 60 °C and is also resistant
to chemicals used during production.
“We always supply the motor with
our specially developed nsd tupH surface
treatment, whose hygienic characteristics
approach those of stainless steel”,
the Head of Marketing explains.
customer solution, the connection cable
is not fed to the motor’s terminal board
via a PG screw connection, but is directly
connected to the terminal box. In case
of a replacement, this allows for a quick
electrical connection and disconnection
of the motor. Potential downtimes will be
reduced, which is an important factor for
the customer.
Lenzing AG has been using the drives
from NORD DRIVESYSTEMS for a good six
months now and is fully satisfied. This is
why the long-term business relationship
between both companies will certainly be
continued.
success
500+ Exhibitors
Individually developed motor plug
Together with Lenzing, NORD specialists
developed a drive solution consisting
of IE5+ motors and ideally matched
two-stage NORDBLOC.1® helical in-line
gear units. The motor plug was specially
designed for Lenzing. In the individual
NORD DRIVESYSTEMS
Bargteheide, Germany
www.nord.com
Filtration
Solutions
for the
Processing
Industry
Fig. 4: The IE5+ synchronous motors from
NORD achieve an outstanding 95% energy
efficiency Images 4-5: NORD DRIVESYSTEMS
Fig. 5: In the smooth-surface and fanless version,
the IE5+ motor from NORD is also resistant
to chemicals used during fibre production
GREEN EFFICIENT TECHNOLOGIES 2024
Your Contact: Suzanne Abetz
E-mail: info@filtech.de
Phone: +49 (0)2132 93 57 60

PFAS
Removal of PFAS from drinking water with
granulated activated carbon
Johanna Muthmann and Jan Hojak
Per- and polyfluoroalkyl substances,
PFAS for short, are increasingly
becoming the focus of attention in
water treatment. These chemicals,
which are also known as perpetual
chemicals, are synthetic fluoroorganic
compounds in which several
fluorine atoms are bound to an alkyl
chain. According to the OECD definition,
at least one carbon atom is
fully fluorinated.
They are characterised by high chemical
and thermal stability due to the
strong fluorocarbon bond. The fluorocarbon
chain has a hydrophobic
character and can also have a hydrophilic
character due to a polar head
group. They can therefore be water
and oil repellent and also reject dirt
particles to some extent.
PFAS is present in many places
Due to these properties, they have
been and continue to be used in
many areas. We encounter them in
everyday objects such as functional
textiles, impregnating agents, Teflon
pans and special paper.
In addition to their positive properties,
their negative properties
have increasingly come into focus
in recent years. They accumulate in
the environment and in animal and
human tissue. Some PFAS are toxic,
are suspected to be carcinogenic and
contribute to neurological developmental
disorders. This fact, especially
in conjunction with the fact that many
PFAS do not degrade in the environment
or only degrade over very long
periods of time, has led to them being
increasingly monitored and the use
of certain compounds being increasingly
regulated or banned. The explosive
nature of this is also reflected
in the fact that the European Drinking
Water Directive (Directive (EU)
2020/2184) requires the application
of maximum levels in the sum of
PFAS contents.
Aim of the investigation
Drinking water is our most important
foodstuff and is therefore one of the
best monitored and most strictly controlled
goods in Germany. The use of
activated carbon is common practice
in the treatment of drinking water.
It effectively removes various pollutants
such as pesticides, drug residues
and hydrocarbons from the water
through adsorption. The Drinking
Water Ordinance of 20 June 2023 also
set binding limits for PFAS for the first
time. From 12 January 2026, a limit
value of 0.1 µg/l will apply for substances
in the PFAS 20 group and a
limit value of 0.02 µg/l for substances
in the PFAS 4 group. These new
requirements pose a challenge for
drinking water treatment. Here too,
the use of activated carbon offers
a suitable solution. For this reason,
CarboTech - one of the world’s leading
full-service providers of activated
carbons based in Essen - has had the
adsorption of PFAS on various activated
carbons for drinking water
treatment tested at the Water Technology
Centre in Karlsruhe (TZW).
Experiment description
The tests were carried out in accordance
with the Granular Carbon Selection
Test (GCS test) developed at
TZW. This test allows activated carbons
to be compared and evaluated
in terms of their adsorption properties
within a few weeks, depending
on the concentration and adsorbability
of the pollutants. In the GCS test
rig, four small filter columns were
filled with 1.7 litres of activated carbon
each and run in parallel. Karlsruhe
tap water, to which a mixture
of different PFAS was added, served
as the test matrix. The analysed
substances were perfluorobutanoic
acid (PFBA), perfluoropentanoic
acid PFPeA, perfluorohexanoic acid
(PFHxA), perfluorooctanoic acid
(PFOA), perfluorobutanesulfonic acid
(PFBS), perfluorohexanesulfonic acid
(PFHxS) and perfluorooctanesulfonic
acid (PFOS).
All substances belong to the
PFAS-20 group, PFOA, PFHxS and
PFOS also belong to the particularly
critical PFAS-4 group. During the
tests, the spectral absorption coeffi-
Table 1: Properties of the activated carbons analysed
Activated carbon Iodine number Nitrobenzene number Bulk density Apparent density Ash
[mg/g] [mg/L] [kg/m³] [kg/m³] [% by weight]
DGK 8x30/65 1140 15 490 540 2,3
DGP 8x30/65 1170 22 430 480 6,7
DGF 8x30 GL 1010 19 410 450 9,9
DGF BX 8x30/65 990 24 470 510 11,0
32 GREEN EFFICIENT TECHNOLOGIES 2024

PFAS
cient (SAC) at 254 nm and the concentrations
of PFAS were recorded at
regular intervals in the inlet and outlet
of the small filter columns.
Activated carbons analysed
Various steam-activated activated
carbons with an 8x30 MESH grain size
were tested in the trials. The selected
activated carbons are based on different
raw materials. The DGF 8x30
GL and DGF BX 8x30/65 are based
on mineral origin, like the majority
of activated carbons currently
used in drinking water treatment.
DGK 8x30/65 and DGP 8x30/65 are
based on renewable raw materials
and agricultural by-products, which
re present a more sustainable alternative.
All selected activated carbons
have drinking water certification in
accordance with DIN EN 12915-1. The
properties of the activated carbons
analysed are shown in Table 1.
Overall, the DGF 8x30 GL has
the highest porosity of all the activated
carbons tested, which is also
reflected in the lowest apparent density.
It also has the highest proportion
of mesopores. Based on its raw material
and the significantly lower degree
of activation, the DGK 8x30/65 has
much finer pores and is almost exclusively
microporous.
Results of the tests
The breakthrough curves determined
for the SAC 254 nm and for the total
concentration of PFAS-20 and PFAS- 4
are shown in Figure 1 to 3. The SAC
254 nm and the concentrations in the
filter effluent are plotted against the
specific amount of water permeated
in bed volumes.
Figure 1 shows that all activated
carbons tested were able to further
reduce the already low SAC of 254
nm. This means that the activated
carbons can remove substances
present in the water by adsorption.
In addition to the added PFAS, these
can be hydrocarbons, for example.
The DGF 8x30 GL showed the
best performance, with the lowest
concentrations in the effluent at
all bed volumes. On the one hand,
this is probably due to the fact that
it has the largest pore volume overall
and the largest volume available
for adsorption. On the other hand,
this may also be due to the fact that
it has both micropores and larger
mesopores and therefore has good
adsorption sites for different large
molecules. The weakest performance
is shown by DGK 8x30/65, which is
due to the smallest pore volume and
may be influenced by the fact that
almost exclusively small micropores
are present and therefore larger molecules
cannot adsorb. The adsorption
properties of activated carbons DGF
BX 8x30/65 and DGP 8x30/65 are
comparable with each other, but are
significantly lower compared to activated
carbon DGF 8x30 GL.
With regard to the adsorption of
the sum of all PFAS (Figure 2), DGK
8x30/65 shows the lowest adsorption
performance, analogous to the
SAC value. The other activated carbons
show a comparable adsorption
performance, with the DGF 8x30 GL
showing a slightly better removal performance
for the sum of all PFAS analysed
at low bed volumes. Overall, it
can be seen that the initial concentration
of PFAS was not reached with any
Fig. 1: Breakthrough curves for the SAK 254 nm in the GCS test stand
GREEN EFFICIENT TECHNOLOGIES 2024
33

PFAS
yet been reached for the PFAS-4 substances.
If the apparent density/bulk density
is taken into account when analysing
the adsorption performance
– as is usual when evaluating activated
carbons – the DGF 8x30 GL
shows the best cleaning performance
due to its low density.
Conclusion
Fig. 2: Breakthrough curves for the sum concentration of PFAS in the GCS test stand
activated carbon at around 13500 BV.
This means that the equilibrium load
has not yet been reached and all activated
carbons have further capacities
for adsorbing PFAS. Overall, this also
shows that the mass transfer zones
in the selected test setup are very
broad.
The DGK 8x30/65 showed a significantly
lower adsorption performance
compared to the other activated carbons.
The difference to the other activated
carbons is proportionally more
pronounced than when considering
all PFAS analysed. This is due to
the fact that the PFAS-4 substances
When viewed alone (Figure analysed are molecules with chain
3) of the PFAS-4 substances analysed
lengths ≥ C6. Overall, these can form
(PFOA, PFHxS, PFOS), the stronger interactions with the surface
DGF 8x30 GL shows the best adsorption
performance. In contrast, the
activated carbons DGP 8x30/65 and
DGF BX 8x30/65 showed slightly
higher effluent concentrations of the
individual substances and, as a result,
than short-chain PFAS. Due to the
dimensions of the molecules, they
also adsorb in wider pores, of which
the DGK 8x30/65 has only a small
proportion or none at all. As with all
PFAS analysed, equilibrium has not
higher values for the sum parameter.
The starting point for the tests was
the assessment and comparative
evaluation of the adsorption performance
for PFAS in the drinking water
treatment of various granulated activated
carbons. The tests were carried
out with Karlsruhe tap water on small
filter columns. It was found that all
the activated carbons analysed were
able to reduce the PFAS content in
the water tested, with DGF 8x30 GL
showing the best separation performance.
DGF 8x30 GL was also found
to have the greatest reduction in SAK
254 nm at the same time. The results
show that a sustainable alternative
for the removal of PFAS can be an
activated carbon based on renewable
raw materials (DGP 8x30/65), which
shows a similarly good performance
for the sum parameter of PFAS.
To summarise, all activated carbons
can be used to remove PFAS. If
there is another pollutant problem,
this should be taken into account in
addition to the adsorption performance
for PFAS.
Fig. 3: Breakthrough curves for the total concentration of PFOA, PFHxS and PFOS in the
GCS test stand
CarboTech Group
Elisenstr. 119
45139 Essen, Germany
www.CarboTech.de
34 GREEN EFFICIENT TECHNOLOGIES 2024

Trade fairs and events
hy-fcell with renowned exhibitors and
many new features
Fig. 1: Messe Stuttgart, the organiser of hy-fcell 2024, will offer a mixture of new features and proven highlights during the Conference and
accompanying programme.
Picture credits: Landesmesse Stuttgart GmbH
Keen interest in taking part in the
trade fair, exhibition hall almost
booked up / Extensive programme
for technical discussions, advanced
training and promotion
Planning of hy-fcell – International
Expo and Conference – is well underway.
130 exhibitors have already
registered for the event in order to
present their products and services
to the hydrogen and fuel cell community
in Stuttgart on 8 and 9 October
2024, and hold discussions with
trade visitors. Manufacturers of cutting-edge
technologies will showcase
their latest developments relating to
the generation and use of sustainable
energies. International experts will
meet at the accompanying Conference
in order to obtain information
in plenary talks and workshops about
the latest topics in the industry and
exchange both know-how and experiences.
“One of the focal points of
hy-fcell 2024 will be the extension
of networks for international cooperation
on one of the most promising
markets at present,” said Guido
von Vacano, Executive Vice President
of Messe Stuttgart. “Platforms
such as hy-fcell are important in
order to know what is happening in
this dynamic industry. And to find the
right partners with whom you can
develop new markets.”
Fig. 2: Heavy-goods transport is regarded as a highly promising application area for fuel cells.
Picture credits: Landesmesse Stuttgart GmbH
Fuel cell truck with a range record
Heavy-goods transport is deemed
to be a highly promising application
area for fuel cells. Daimler Truck will
therefore definitely be partici pating
in hy-fcell 2024. Paul Mandaiker,
Manager Technology & Regulations
Communication at Daimler Truck
AG, describes what visitors to the
event can expect: “We will present a
record-breaking vehicle at hy-fcell!
Last year, our Mercedes-Benz GenH
2 truck proved that hydrogen fuel
cell technology can be an ideal solution
for decarbonisation of long-distance
road transport. During the
Daimler Truck #HydrogenRecordRun
it co vered a distance of 1,047 kilometres
with one tank load of liquid
hydrogen. The truck is powered by a
fuel cell system from cellcentric. With
effect from the middle of 2024, the
Mercedes-Benz GenH 2 truck will be
used in the first customer-oriented
test runs.” Paul Mandaiker is looking
forward to the opportunities for discussions
at hy-fcell. “The feedback
from trade visitors regarding fuel cell
drive technology is valuable and very
important for our company.” In addition
to Daimler Trucks, Hyundai and
Refire have already announced that
GREEN EFFICIENT TECHNOLOGIES 2024
35

Trade fairs and events
they will be taking part in the mobility
theme area.
Platform for know-how transfer
and promotion of young people
Messe Stuttgart, the organiser of
hy-fcell 2024, will offer a mixture of
new features and proven highlights
during the Conference and accompanying
programme. For example,
one new aspect is the relocation of
the Conference from the ICS International
Congress Center Stuttgart
to the exhibition hall. This will reduce
distances and further promote networking
in the Business Area. The
exhibitors will be able to participate
in talks and seminars more easily and
more cheaply because an exhibitor
ID will also entitle the holder to automatically
attend the hy-fcell Conference.
While the programme for the
hy-fcell Conference is still being prepared,
the participants can again look
forward to an excellent range of talks
with first-class speakers. Global challenges,
technological advances and
prospects in the energy sector will be
discussed during these talks.
Training and advanced training
will also be the focal points of the
new hy-fcell Academy in which training
institutes will present their portfolios.
Non-experts will also be able
to make use of an introductory offer
that will provide them with insights
into the topic of hydrogen. The
hy-fcell University Area will also celebrate
its première this year. It is being
sponsored by the German Hydrogen
Association (DWV). Eight universities
will use the opportunity there to present
themselves and their research
projects relating to hydrogen and
fuel cell technology. The DWV is also
sponsoring the Innovation Award
which will be presented for outstanding
dissertations during hy-fcell.
hy-fcell Award: Submit innovative
ideas now
The presentation of the hy-fcell
Award is one of the highlights of the
accompanying programme for many
people. The Innovation Award for
hydrogen and fuel cells will also again
be presented in three categories in
2024. Every Award in these categories
is endowed with 10,000 Euros. Anyone
wanting to apply for the Award
can now submit their entry. The
annual hy-fcell Award is supported by
the Baden-Württemberg Ministry for
the Environment, Climate Protection
and the Energy Sector, the Stuttgart
Region Economic Development Corporation
(WRS) (Wirtschaftsförderung
Region Stuttgart GmbH (WRS)) and
Messe Stuttgart.
The Technical Tours will be staged
again as another successful feature
of hy-fcell. These Tours will provide
exclusive glimpses behind the scenes
at companies and research institutes
in Baden-Württemberg. Concentrated
networking will be possible
during the hy-fcell Career Compass,
in which employers and job seekers
will be able to hold discussions, and
the hy-fcell Networking Night which
will represent an informal setting for
people to get to know one another
after the first day of the trade fair and
the Conference.
Tickets for hy-fcell 2024 are now
available. Information about the
exhibitors, the Conference and the
accompanying programme is being
constantly updated. Anyone purchasing
a ticket for hy-fcell can also
use it to attend the concurrent trade
fairs Quantum Effects, VISION and
IN.STAND. Since the exhibition hall is
now almost booked up solid, Messe
Stuttgart advises companies to register
straightaway if they are interested
in taking part in hy-fcell. All the
information about hy-fcell 2024 in
Stuttgart can be found here.
www.messe-stuttgart.de/hy-fcell
Fig. 3: The participants can again look forward to an excellent range of talks with first-class speakers. Global challenges, technological
advances and prospects in the energy sector will be discussed during these talks.
Picture credits: Landesmesse Stuttgart GmbH
36 GREEN EFFICIENT TECHNOLOGIES 2024

Trade fairs and events
Filtration and separation:
trends for the process industry
With constant growth rates, the
global market for industrial filtration
continues to surprise with
innovations – this is also evident at
FILTECH. An overview of promising
trends.
Separation and filtration are becoming
finer and more precise, more digital
and more intelligent. With the
defining trends in mind, industry players
are preparing for the most important
platform in the sector. When
FILTECH invites visitors to the trade
fair and congress in November 2024,
experts from all areas will exchange
ideas, discover new technologies and
shape the future of separation technology.
Which topics will occupy the
industry in the near future? An overview
of application-specific developments.
AI: Boost for soft drinks
Artificial intelligence has enormous
potential for various industries,
including filtration. It enables realtime
monitoring and optimization of
filtration systems, improves efficiency
and minimizes energy consumption.
Adaptive systems automatically
adjust to changing conditions, while
AI-based quality control increases filtration
accuracy and efficiency.
Filtration as a Service
Filtration as a Service (FaaS) is a new
concept for the business use of filtration
technology: instead of filter elements,
operators book throughputs.
Companies can use filtration services
on demand without having to deal
with equipment investments or maintenance.
FaaS enables a focus on core
competencies and always up-to-date
filtration technology with an integration
of monitoring and optimization.
Pharmaceutical production:
Safe products thanks to activated
carbon
In the food and pharmaceutical
industries, filtration requirements
are becoming particularly stringent.
Activated carbon is increasingly being
used to remove unwanted by-products,
discoloration and odours. Two
trends can be identified: products in
powder form and filter sheets with
bonded activated carbon, which offer
even greater safety and purity.
Wine: Filtration problems due to
Botrytis- and Oidium-contaminated
grapes
The 2023 wine year brought various
challenges for producers, such
as oversupply in various regions and
climatic extremes. The filterability of
the wine is impaired by unclear young
wines and clogged filters, especially
in the case of botrytis- or oidium-infested
grapes. Filtration specialists
offer solutions such as enzymes and
laboratory tests. Climatic conditions
could increasingly force such measures,
which is why winegrowing specialists
are already preparing for them.
Food: Stricter regulations through
better testing procedures
Increasing precision in food testing
increases the demands on filtration.
Systems must meet higher standards
and be regularly monitored and
maintained. Fine filtration technologies
such as membrane or nanofiltration
are becoming more popular
because they remove even the smallest
impurities.
Innovative solutions for complex
processes
Separation technology is diverse. In
all areas, the filtration and separation
market is poised for growth and
change. As companies recognize the
importance of filtration in maintaining
product quality and environmental
responsibility, the demand for
advanced filtration solutions will continue
to grow. At FILTECH, attendees
will find solutions that can meet every
need - today and in the future.
www.filtech.de
GREEN EFFICIENT TECHNOLOGIES 2024
37

Companies - Innovations - Products
CCS - A way to reduce greenhouse
gases in the industrial sector
Storing carbon dioxide (CO 2 ) underground in an
environmentally friendly and permanent manner
• How can we stop global warming?
• How can the various climate agreements and climate targets of
countries and governments be adhered to and ultimately achieved?
• How can carbon capture and storage technology contribute to
achieving global climate targets?
Carbon Capture & Storage (CCS) is part of the plan to achieve these
ambitious destinations. An approach that is particularly suitable for
the emissions-intensive process industry.
Separation - Transport – Storage
What is Carbon Capture & Storage?
Carbon Capture and Storage means the capture and storage of carbon.
With high-performance valves from GOETZE
GOETZE safety valves are involved in all steps from capture to injection
of the CO 2 into the underground storage facilities. The processes
required for this take place under overpressure. In the event of failure
of control systems and regulators, which are responsible for filling
levels, temperatures and, in particular, internal overpressure, the containers
and apparatus must be protected by mechanically operating
overpressure protection.
In addition to overpressure
protection for tanks and apparatus,
there are additional
requirements for the valves
and fittings that need to be
taken into account due to the
chemical resistance of the
sealing and housing materials
used.
As industrial CO 2 emissions are largely responsible for increasing the
temperature in the atmosphere, the CO 2 is captured and separated
directly from the industrial processes, i.e. on site at the producer. The
CO 2 is then liquefied under high pressure so that it can be transported
to safe storage sites via existing infrastructures, e.g. the rail network.
This approach is particularly suitable for emission-intensive process
industries such as steel, cement, lime, fertilisers, pulp and paper,
petrochemicals and waste incineration plants.
A three-step approach to greenhouse gas reduction in Industrial:
Separation
CO 2 is captured at source using various technologies:
• Pre-combustion
• Oxyfuel combustion (Oxyfuel combustion)
• Post-combustion
Compression & transport
CO 2 is purified, compressed and transported to the storage facilities via
pipelines or in tanker lorries via the rail network.
Storage
CO 2 is pumped into porous rock formations for permanent storage.
Because not all CO 2 is
the same.
It depends on whether the
CO 2 is present in a pure dry
or moist state, or whether it
contains admixtures of other
substances. GOETZE can support
you with a large selection
of suitable body and sealing
materials.
If the gas is compressed and stored under high pressure, our 492 series
safety valve is used. This high-pressure safety valve can be used to protect
pressures of up to 1500 bar. At the same time, the GOETZE safety
valve is only half the weight and half the size of comparable valves. This
compact design simplifies the integration of the valve where installation
space is limited. The rotatable outlet cover is another convincing
argument in favour of maximum flexibility. This allows the direction
of the outlet to be adjusted even after installation, making it easier to
install the valve in an existing pipework environment. The high-pressure
safety valves are adjusted on the high-pressure test benches specially
produced for the GOETZE Company.
Fig. 2: GOETZE high-pressure safety valve
492 up to 1500 bar
Photo©: Goetze KG Armaturen
CARBON CAPTURE & STORAGE? BUT SAFE!
When selecting the valve, the physical state of the carbon dioxide
(solid/liquid/gaseous) as a function of pressure and temperature must
always be taken into account. For example, CO 2 flocculates when it is
blown off and thus changes its physical state from gaseous to solid.
Goetze KG Armaturen
Robert-Mayer-Str. 21
71636 Ludwigsburg, Germany
Tel +49 (7141) 488 946-0
info@goetze.de
www.goetze-group.com
Fig. 1: Diagram of CCS: capture, compression & transport, storage
Photo: Goetze KG Armaturen
38

Companies - Innovations - Products
Leifeld presents new machine for the
production of robust hydrogen tanks
Maximum safety and flexibility in shaping in terms of sophisticated
neck geometries and wall thickness gradients for very high
operating pressures are the key issues when it comes to the production
of aluminum hydrogen tanks. Leifeld Metal Spinning GmbH
is launching an innovative forming machine on the market that
meets these requirements and helps to reduce CO 2 emissions.
Manufacturers of hydrogen-powered vehicles have clear requirements
for hydrogen tanks: absolute safety, maximum filling volume and maximum
flexibility in the design of the tank shape. All three requirements
are met by hydrogen tanks manufactured with the necking-in machine
AFC from Leifeld Metal Spinning GmbH.
the forming forces even with very thin wall thicknesses. The cylinder is
held stably in a precise position, ensuring tight tolerances and surface
accuracy even at high forming forces and forming speeds. The innovative
support system can be used for parts up to 6 meters in length.
Even stepped tanks can be manufactured for use in cars
There are no limits to the design of aluminum cylinders. Thanks to the
flow-forming and necking-in technology, even stepped dimensions can
be realized. “Some of today's hydrogen tanks have to be integrated
into existing vehicle architectures with limited installation space. For
example, a tank could be stepped in such a way that it takes up as little
space as possible and has the maximum filling volume. With this innovation,
we aim to contribute to electromobility with hydrogen,” says
Benedikt Nillies.
AFC stands for Aluminium Forming Center. The machine forms the
ends of the aluminum cylinders for hydrogen storage using a special
necking-in process. As hydrogen tanks underlie high operating pressures
in their application, the entire neck area is optimized in its wall
thickness profile during the forming process for long-term durability.
In addition to the standard necking-in machine, the German machine
manufacturer also offers a machine type that combines the necking-in
and flow forming technology to form both, the entire pressure vessel
body and the necks.
Customers can choose between two equipment options for preheating
the material: gas burner or induction system. Once the pipe ends have
been heated, the material is necked in. The process is completed by
controlled loading and unloading as well as automated programming.
“With our necking-in machine LEIFELD AFC, we are setting new standards
in the forming technology for hydrogen tanks. Maximum safety,
increased flexibility and a contribution to CO 2 reduction combined with
the famous LEIFELD technology promise - these are the innovations
the automotive industry needs,” says Oliver Reimann, CEO of Leifeld
Metal Spinning GmbH.
Safety ensured through intact surface
Hydrogen tanks operate under immense pressure. Scratches or other
defects on the surface would be catastrophic. To prevent damage to
the material, the R&D team, led by Benedikt Nillies, Technical Director
at Leifeld, has come up with several solutions. For example, the
heating of tube ends in the machine: “Normally, the tube ends are
heated by a gas oven or an induction system outside the machine,”
says Benedikt Nillies. However, during subsequent loading, the component
cools down. “We want to prevent this,” Nillies continues. “With
the AFC machine, the tube ends are either heated by an integrated
heating device with a gas burner or electrical induction to processing
temperature uniformly. We can precisely adjust the temperatures to
the desired level. This avoids coarse grain formation and preserves the
material's strength.” Valid forming tests for aluminum tanks confirm
the success of this innovation.
To keep the surface intact, Leifeld offers various spinning rollers - from
simple necking-in rollers to actively driven forming rollers. The rollers,
developed and manufactured by Leifeld, rotate upon contact with the
part, preventing surface defects by avoiding material buildup on the
roll. The support device was specially designed so that it can absorb
Pioneering forming technology: The new necking-in machine LEIFELD AFC
is shaping the future of hydrogen tank production.
Use of hydrogen tanks interesting for other sectors in the future
Hydrogen tanks are currently primarily used in cars, trucks and buses.
However, Benedikt Nillies also sees the possibility of using hydrogen
tanks manufactured on LEIFELD machines to power rail vehicles and
aircraft as feasible: “We are continuously developing the process and
have received initial inquiries from other industries. Additionally, we
are currently working on automating loading and unloading systems
in order to adapt the machine even more efficiently to the customer’s
material flow.”
Leifeld Metal Spinning GmbH emphasizes its clear focus on innovation
and progress, as well as quality leadership as a solution provider,
deeply rooted in the corporate culture. The company has its own application
center in Germany and Japan, along with in-house research and
development capabilities, driving the continuous development of new
technologies.
Leifeld Metal Spinning GmbH
Feldstr. 2-20
59229 Ahlen, Germany
www.leifeldms.com
39

Companies - Innovations - Products
Innovative, high performance
electric infrared heater for industry
and commerce
• eSchwank S-18000 is the most powerful electric infrared heater
of its kind
• with 3-stage modulation, 6, 12 and 18 kilowatts
• long service life due to reliable infraGlow heating elements
• service-friendly design
• climate neutral heating with green electricity possible
• specially developed for industrial applications
The heating specialist Schwank has added another climate-neutral
product to its portfolio, by launching an innovative, powerful, electric
infrared heater. The new device has been specially developed to meet
the demanding requirements of industrial and commercial buildings
with regard to the Net-Zero Emission goals. With a heating output of
18 kW, the electric infrared heater eSchwank S-18000 is so powerful
that even very high buildings can be heated comfortably, economically
and, if PV electricity is available, 100% environmentally friendly.
gration into a Building Management System (BMS) and Schwank offers
special mounting brackets for the installation on walls. The 3-step version
of the eSchwank S-18000 is controlled via the SchwankControl or
via a higher-level Building Management System (BMS). On the electrical
side, each device has its own relay box including electrical contactors.
Overall, the decades of experience in the field of infrared heating are
reflected in the design. The fire-aluminised and therefore corrosionresistant
and sturdy housing of the new eSchwank S-18000 has a
double-shell design extending far over the heating elements. In this
way, Schwank achieves to produce a heat cushion on the underside
of the appliance that is important for a high infrared yield. The threestep
modulating control can realise 6, 12 and, at full power, 18 kW.
This means that the eSchwank S-18000 can also economically cover
the heat demand that is actually required during
transitional periods. The device's dimensions and low weight take into
account typical building features such as sprinkler spacing or ceiling
loads. This means that the eSchwank S-18000 can usually replace existing
gas-fired appliances on a one-for-one refurbishment.
Schwank GmbH
Bremerhavener Str. 43
50735 Köln, Germany
Tel +49 221-71760
info@schwank.de
www.schwank.de
AERZEN and HH2E agree
on cooperation
Production of green hydrogen in Lubmin
The fire-aluminised, corrosion-resistant and dimensionally stable housing of the
new electric radiant heater from Schwank has a double-shell design and is very
light at 30 kilograms.
In contrast to commercially available electric infrared heaters with
quartz or halogen heating element, the electric infrared heater from
Schwank has robust, efficient heating elements named infraGlow,
which operate at high surface temperatures of approx. 800 degrees
Celsius. According to the manufacturer, their service life is around
ten times longer than that of the quartz elements that are often
used. At the same time, the eSchwank S-18000 does not generate
any potentially harmful light source for the eyes, which could occur
with quartz or halogen heating elements. This is a significant product
advantage, especially in spots where employees work stationary, for
long periods of time.
The new German green energy company HH2E is among the first
companies in the country to produce hydrogen from renewable
energies on a large scale. The hydrogen specialist is currently planning
the construction of a large-scale electrolysis plant at the Lubmin
energy site in Mecklenburg-Vorpommern and intends to start
producing green hydrogen there from 2026. HH2E also relies on the
technologies and expertise of AERZEN. An agreement was reached
for the delivery of three VRW 536M packages for the plant on the
Baltic coast. The aim is to intensify the partnership in the long-term.
As a strong partner to the process gas industry AERZEN is known for
its high level of technology and solution expertise and is recognised
as one of the most competent providers of technical solutions with
maximum efficiency, reliability and cost-effectiveness. The hydrogen
industry also relies on AERZEN’s expertise and experience - as does the
Hamburg-based company HH2E. AERZEN and HH2E have now agreed
to work together to advance the energy transition.
Proof that the eSchwank S-18000 is designed for a long service life
is its ease of maintenance. For instance, the heating elements can
be replaced in just a few minutes if necessary. The water spray protected
device can also be complemented with other useful features.
For example, a protective grille is available for applications in sports
facilities, a ModBus-compatible control system can be used for inte-
HH2E drives the hydrogen transition forward
HH2E produces green hydrogen on an industrial scale using surplus
electricity from wind and solar energy and plans to install production
plants in Germany with a total capacity of at least 4 GW by 2030. One
plant is currently under construction in Lubmin. It utilises the extensive
energy infrastructure of the largest energy and industrial site in Meck-
40

Companies - Innovations - Products
AERZEN and HH2E are planning a long-term cooperation
“HH2E’s projects are leading the way in green hydrogen production.
We are delighted to be working with HH2E to contribute to the hydrogen
transition and decarbonisation of industry. The VRW 536M enables
the compression of saturated electrolysis hydrogen with unrivalled
efficiency and differential pressure, making it an important building
block for the hydrogen transition,” emphasises Christian Meyer from
AERZEN.
Fig. 1: AERZEN and HH2E have decided to work together at ACHEMA 2024
All images: AERZEN
lenburg-Vorpommern and is rated for an initial capacity of 100 MW by
2026. This enables it to produce around 6,000 tonnes (over 200,000
MWh) of green hydrogen per year. By 2030, the capacity is to be scaled
to over 1 GW, which complies with an annual production of more than
60,000 tonnes of green hydrogen.
Karsten Kinzig, Head of Procurement at HH2E, adds: “HH2E stands for
a flexible mix of complementary technologies. This makes it possible to
utilise renewable energies on a large scale. Our aim is to offer hydrogen
at fair prices. Innovative technology partners such as AERZEN support
us in this endeavour. We look forward to building a long-term
cooperation with AERZEN.”
Aerzener Maschinenfabrik GmbH
Reherweg 28
31855 Aerzen, Germany
Tel +49 5154/81-9970
Fax +49 5154/81-709970
info@aerzen.com
www.aerzen.com
AERZEN delivers three VRW 536M for the hydrogen factory
in Lubmin
For the hydrogen factory in Lubmin HH2E and AERZEN have agreed to
supply three VRW 536M packages, each with a volume flow of approx.
4,700 m³/h and a final pressure of 8.0 bar (a), for an order value in
the upper seven-figure range. The AERZEN VRW 536M was specially
designed for efficient and safe compression of hydrogen and combines
the advantages of an oil-free compressor (no contamination of the
medium) with a high compression ratio (max. 10 bar (a)) and high efficiency,
even with light gases (hydrogen/helium). The explosion-proof
package offers a large turndown and can therefore optimally handle
the fluctuations that typically occur when using renewable energies.
As a screw compressor, the VRW 536M can also handle larger volume
flows of up to 6,000 Nm³/h, making it the perfect link between electrolysers
and high-pressure compressors. By pre-compressing (boosting)
the large H 2 volume flows to higher intermediate pressures, the
main compressors (reciprocating compressors) can be designed much
smaller and more favourably. This enables significant cost savings.
Product innovation: Intuitive control
for hose pumps
AxFlow combines the efficiency of dosing pumps with
high-performance hose pumps
AxFlow presents the display control for realAx hose pumps as an exclusive
innovation on the market. With the intuitive display operation, the
user can quickly and easily set a time and quantity-activated dosing
for batch operation. In continuous pumping mode, the flow rate can
be intuitively adjusted with a value in liters per hour. Additional flow
meters or weighing systems are no longer required in the systems.
Even large containers can be filled in precise quantities or additives can
be dosed into the process. With the display controller for realAx hose
pumps, AxFlow simplifies all high-volume processes up to 36 m 3 /h, in
which fast switching during dosing and efficient pumping are required.
These functions can also be controlled remotely via network interfaces
such as ProfiBus or CanBus and via the 4-20 mA input.
The hose change assistant for quick and safe maintenance without
extensive preparation: All realAx series with display control remind
you to change the hose in good time before it is due. Additionally, the
peris taltic pumps in the realAx ISI series have an assistent. This provides
step-by-step instructions for changing the hose using illustrated
symbols on the display and the rotor is automatically moved into the
correct position with each step.
Fig. 2: AERZEN has developed the VRW package especially for the efficient and safe
compression of hydrogen
Automatic pump stop in the event of a hose failure: All new reaAx
peris taltic pumps with display control contain a sensor integrated as
standard, which detects a possible leak. The pump stops automatically
in the event of a hose failure and signals this to the user via the display
and network. In this way, expensive batch losses can be avoided and
system safety increased without additional safety systems.
41

Companies - Innovations - Products
With a diverse offering of around 2,700 exhibitors from all over the
globe, ACHEMA is the world’s leading trade fair for the process industry.
This makes it the global hub for chemical and pharmaceutical engineering,
biotechnology, and industrial environmental technologies.
“As a partner for the energy transition to new energy sources as well
as a process and emission measurement specialist with more than
70 years of experience, SICK is making a significant contribution to a
range of innovation areas currently at the forefront of process engineering
globally,” says Stephan Convent, Head of Sales Cleaner Industries.
“ACHEMA is therefore a trend-setting industry get-together and
the ideal event to showcase our products, solutions and LifeTime Services
in these areas.”
Batches can be easily dosed and the flow rate regulated in l/h via the display control
unit, pictured left: realAx RP series up to 36 m 3 /h.
AxFlow is currently the only supplier on the German market that sells
both precise dosing pumps and powerful high-pressure peristaltic
pumps with the realAx display control. All realAx hose pumps with
roller and shoe technology can now be equipped with the display control
as an option. Dosing and delivery rates of up to 36 m 3 /h and 15 bar
are possible. AxFlow also offers retrofitting of existing realAx peristaltic
pumps with the display control in its own workshops or during on-site
installation work. All standard replacement hoses and a large selection
of peristaltic pumps are always available from stock at AxFlow.
AxFlow GmbH
Theodorstr. 105
40472 Düsseldorf, Germany
Tel +49 211 23806-0
Fax +49 211 23806-20
info@axflow.de
www.axflow.de
FLOWSIC900: Leading ultrasonic technology for the custody transfer
measurement of liquefied natural gas (LNG)
Liquefied natural gas (LNG) drives energy diversification in energy supply
and reduces emissions in the mobility and energy sector. Whether
used in onshore or offshore applications, or for the liquefaction, transport,
transshipment, storage, or custody transfer measurement of liquefied
natural gas – the new FLOWSIC900 ultrasonic flow meter meets
the technical, operational, and commercial challenges of the LNG
industry. The measurement instrument offers the highest possible
measurement accuracy and transparency at all times in LNG transfers
thanks to the dynamic volume and quality monitoring. This ensures
measurement certainty at every billing point. The FLOWSIC900 is also
characterized by its fast commissioning, largely maintenance-free
operation, and excellent serviceability.
High precision at low volume flows:
the FLOWSIC550 ultrasonic gas flow meter
The new calibratable FLOWSIC550 ultrasonic gas flow meter from SICK
has been designed for highly accurate billing of small volume flows
in high pressure networks. It can operate off mains power or energy
self-sufficiently and is also easy to integrate into existing transfer and
measurement stations. Thanks to the absence of mechanical moving
parts, the flow measurement instrument is rugged, reliable, and low
maintenance.
SICK at ACHEMA 2024:
Partner for the energy transition
as well as process and emission
measurement technology
SICK as solution specialist for process and emission measurement
Reducing emissions and optimizing processes begins with reliable
recording and analysis of the emissions. The new data created in this
Under the central theme “When every thing counts the world takes
measurements with SICK,” the sensor specialist SICK presented itself
as an innovative partner for the energy transition and a competent
full-service supplier for industrial process and emission measurement
technology at ACHEMA 2024 from June 10–14 in Frankfurt (Hall
11.1, Booth C61). The exhibit highlights included the custody transfer
approved FLOWSIC900 LNG meter as well as the new calibratable
FLOWSIC550 ultrasonic gas flow meter. SICK has decades of experience
in continuous emission monitoring. The company combines
customized solution packages for extractive gas analysis, for dust
and flow measurement technology. and for emissions data management
with a wide portfolio of sustainable services. In this way SICK
is also ensuring long-term compliance with statutory requirements.
“When every thing counts the world takes measurements with SICK” – the sensor
specialist SICK will be presenting itself at ACHEMA 2024 as an innovative partner
for the energy transition and a competent full-service supplier for industrial process
and emission measurement technology. Photo © : SICK
42

Companies - Innovations - Products
way reveals opportunities for optimizing existing processes. This makes
it possible to avoid emissions in a targeted manner and to advance
health and environmental protection. As a full-service supplier, SICK
has decades of experience in the field of continuous emission measurement
technology. Customized solution packages ensure ongoing
compliance with the statutory requirements. Whether it be extractive
gas analysis, dust and volume flow measurement technology, or the
emission measurement calculator – high precision and reliability are
paramount. The product portfolio is rounded off by comprehensive
service offerings in conjunction with the capabilities of Smart Services.
This creates tailored complete solutions throughout the life cycle of
plants.
SICK presentation at the ACHEMA Conference:
Custody transfer gas volume measurement of hydrogen/
natural gas mixtures and pure hydrogen
As part of the congress session Safety for hydrogen applications/
#hydrogen: Transport and storage, SICK gave a presentation on "Fiscal
gas flow measurement of hydrogen-natural gas mixtures and pure
hydrogen". The physical and metrological characteristics of ultrasonic
flow measurement of natural gas with added hydrogen and pure H 2
were explained. Results from European laboratory tests and field data
were used to show why adapted ultrasonic gas meters are well suited
for both media and what additional advantages they offer.
SICK Vertriebs-GmbH
Willstätterstr. 30
40549 Düsseldorf, Germany
Tel +49 211 5301-0
info@sick.de
www.sick.de
Busch Vacuum Solutions ACHEMA 2024 trade show booth
Versatile and environmentally friendly vacuum technologies
One product that was presented was the COBRA NC 0100 B ATEX screw
vacuum pump, which can be used in a variety of ways to convey sensitive
and explosive gases or vapors. With an ultimate pressure of 0.01
hPa (mbar) and oil- and contact-free operation, it offers an environmentally
friendly and energy-efficient solution for a wide range of vacuum
applications in process engineering.
Another highlight of the trade show booth was the DOLPHIN LX 0430
liquid ring vacuum pump. Its efficiency and reliability make it ideal
for demanding applications such as evacuating saturated gases and
vapors. Thanks to its optimized sealing concept, it is especially well
suited for use in chemical and pharmaceutical process technology.
Busch Vacuum Solutions at ACHEMA
2024: Focus on sustainable vacuum
solutions
ACHEMA 2024, which took place June 10-14, 2024 in Frankfurt am
Main, Germany, was once again a significant event for the international
process industry. Busch Vacuum Solutions, one of the world’s
leading suppliers of vacuum pumps and vacuum systems, presented
innovative and environmentally friendly vacuum solutions at the
trade show.
The MINK MV 0080 D dry claw vacuum pump is a particularly powerful
solution for various industrial applications in the pharmaceutical
packaging sector. Thanks to its high efficiency, it enables companies
to reduce their environmental footprint while simultaneously lowering
operating costs.
Focus on sustainability and efficiency
Another important topic at the trade show booth of Busch Vacuum
Solutions was the importance of service. The company has an extensive
service network and intelligent IoT solutions that can help minimize
downtime in manufacturing. Specially qualified and certified
service technicians also offer comprehensive ATEX checks to ensure
operational reliability in hazardous areas.
Under the motto “Save CO 2 and protect the environment – with efficient
vacuum solutions from Busch,” the company presented its latest
technologies and underscored its commitment to sustainable processes
and environmental protection. There was a great deal of interest
from the customers, who were able to find out more about the
products presented at the company’s trade show booth.
Busch Vacuum Solutions
Schauinslandstrasse 1
79689 Maulburg, Germany
Tel +49 7622 681–9980
info-de@busch.de
www.buschvacuum.com
43

Brand name register
Maschinenfabrik
Gustav Eirich GmbH & Co KG
Walldürner Str. 50
74736 Hardheim/Germany
Phone: +49 6283 51-0
Fax: +49 6283 51-325
E-mail: eirich@eirich.de
Website: www.eirich.de
Delivery program:
As a leading manufacturer of machines and systems,
Eirich has been pioneering advanced technologies
for mixing, granulating, dispersing and more since
1863. “Eirich digital” also offers numerous services,
from smart spare parts systems to AI-based process
analysis.
Dry Coating Forum
10.09. – 11.09.2024
Fraunhofer
Battery Show North America
07.10. – 10.10.24
Stand 4239
ElringKlinger Kunststofftechnik GmbH
Etzelstr. 10
74321 Bietigheim-Bissingen/Germany
Phone: +49(0)7321-9641-750
E-mail:
ekt.hydrogen@elringklinger.com
Website:
www.elringklinger-engineeredplastics.com
www.ek-kt.de/elektrolysis
The product portfolio contains a wide range of
materials and components for PtX applications –
from electrolysis to mobile use. Innovative H 2-
Enginering-Solutions, such as large-scale gaskets up
to 3 m Ø, bellows, pipes and tubes, spring energized
seals, guide rings, ElroSeal Rotary Shaft Seal etc.
Hydrogen Technology Expo Europe
Hamburg, Germany
23.10. - 24.10. 2024
Hall A3, Booth C25
Hammelmann GmbH
Carl-Zeiss-Str. 6-8
59302 Oelde/Germany
Phone: +49 (0)2522 76-0
Fax: +49 (0)2522 76-140
E-mail: mail@hammelmann.de
Website: www.hammelmann.de
High-pressure plunger pumps
Process pumps
Sewer cleaning pumps
Mining pumps (deep mining industry)
Hot water appliances
Operating pressure up to 4000 bar
Flow rate up to 3000 l/min
Applications systems for cleaning, removing,
cutting, coating removal, decorning, deburring
with high pressure water
Worldwide participations in trade
fairs,for current trade fairs, please
visit our homepage:
www.hammelmann.com
We are looking forward to your visit!
KAMAT GmbH & Co. KG
Salinger Feld 10
58454 Witten/Germany
Phone: +49 (0)2302 8903-0
Fax: +49 (0)2302 801917
E-mail: info@KAMAT.de
Website: www.KAMAT.de
High pressure plunger pumps + systems
Mining pumps + systems
Process pumps + systems
Water hydraulic pumps + systems
Operating pressures up to 4000 bar
Flow rates up to 10,000 l/min
Systems in mobile and stationary design
KAMAT valve technology and water tools
For KAMAT‘S current global trade fair
partipcipations, visit
www.KAMAT.de/en/news-en/tradefairs/
We are looking forward to your visit!
KLINGER GmbH
Richard-Klinger-Str. 37
65510 Idstein/Germany
Phone: +49 (0)6126 4016-0
E-mail: mail@klinger.de
Website: www.klinger.de
Gasket sheets based on PTFE: KLINGERtop-chem,
KLINGERsoft-chem
Sheets based on graphite and mica:
KLINGERgraphit, KLINGERgraphit-Folie,
KLINGERgraphit-Laminat, KLINGERmilam
Gasket sheets based on fibers: KLINGER Quantum,
KLINGERSIL, KLINGERtop-sil, KLINGERtop-graph
Sealing tapes: KLINGERtop-flon multi,
KLINGERsealex, KLINGERflon-sealing tape,
KLINGERgraphit sealing tape
Spray: KLINGERflon-Spray
Rubber products: Rubber-Steel Gaskets
KLINGER-KGS GII, KLINGER Wall Seal Ring, moulded
and extruded parts
Special products on request
Current trade fair dates:
www.klinger.de/de/unternehmen/
news/events
We are looking forward to your visit!
Index of Advertisers
EIRICH Maschinenfabrik Gustav Eirich GmbH & Co KG
Cover page
KLINGER GmbH Page 44
ElringKlinger Kunststofftechnik GmbH Page 27
Landesmesse Stuttgart GmbH
2. Cover page
Filtech Exhibitions Germany GmbH Page 31
MT – Messe & Event GmbH Page 5
Hammelmann GmbH Page 17
KAMAT GmbH & Co. KG Page 44
44

PROCESS TECHNOLOGY&COMPONENTS
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Dr. Harnisch Verlags GmbH
Eschenstraße 25
90441 Nuremberg, Germany
Phone + 49 (0) 911 2018-0
Fax + 49 (0) 911 2018-100
E-Mail GET@harnisch.com
Internet www.harnisch.com
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