Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT
Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT

Process Engineering

Rising energy and raw material costs, constantly growing regulatory requirements regarding sustainability and emissions from industrial processes, and vulnerable global supply chains can no longer be viewed as unrelated issues. The transformation of business models into a resilient and sustainable circular economy is therefore not only an ecological goal, but it is increasingly becoming a decisive competitive advantage.

Since 1998, our interdisciplinary team with experts from various fields of engineering and natural sciences has been successfully developing practical process solutions for national and international industrial partners at our Oberhausen location.

Our objectives

  • Maximum product yield increase in the main process
  • Reduction of solid and liquid waste streams, thereby eliminating cost-intensive disposal processes in particular
  • Recovery of recyclable materials that were previously unused

As part of Fraunhofer UMSICHT, which has over 600 employees and more than 4,500 square meters of state-of-the-art laboratory and technical center area, we offer you in-depth process engineering expertise and access to the extensive knowledge of a worldwide leading research network.

Process development and implementation: from your idea to the completed pilot plant

Whether you approach us with a specific idea or a technical challenge, we will be pleased to guide you through all phases of process development and support you along the entire value chain.

  • Design of customized solutions
  • Construction of tailored test and pilot plants
  • Integration into existing production processes

You will not only benefit from our scientific expertise but also from a proven network of experienced specialists, plant manufacturers and research institutions. We are familiar with the current framework conditions, directives and guidelines, and we have established the relevant contacts with public authorities and politics.

© Bild rechts oben: Fraunhofer/Piotr Banczerowski

Fast, location-independent and without disrupting existing processes

Our aim is not only to develop technological solutions but also to make them suitable for practical application. Mobile pilot plants are ideal for testing processes in real production environments.

Successful technology transfer to continuous industrial operation

We combine process engineering expertise with our long-standing experience in industrial environments, especially focusing on interfaces, process stability and quality assurance. This creates a sustainable bridge between research and industrial application.

We can support you with the following topics

Material disintegration and recovery of recyclable materials

Even seemingly exhausted residual waste streams often contain recyclable components that conventional processes cannot access. Using cutting-edge methods, we tap these so far unused resources, selectively separate hard-to-access materials and concentrate them in an economical manner.

Biotechnological process development

With the help of microorganisms and enzymes, a single input material can be used to create completely new molecules – from special-purpose active ingredients to biopolymers. Through targeted strain optimization and well-thought-out reactor strategies, we make sure these novel products are efficient, sustainable and suitable for industrial production.

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Treatment of process water and wastewater

Wastewater can contain both recyclable components and harmful substances. We develop application-specific processes to specifically recover recyclable materials and remove harmful substances. This reduces water consumption and disposal costs and closes water cycles through the reuse of purified process water.

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Bio-based carbon products

High disposal costs can arise from the heterogeneous nature of bio-based residues containing carbon. We develop and combine material-specific methods to convert carbon into high-quality biocarbon products. These can replace fossil-based activated carbon, electrode materials or carbon black, thus closing the material cycle.

Bio- and testing laboratory

Our specialized biotechnology laboratory enables us to secure our research and development activities. Here, we can conduct fermentation tests under realistic conditions, carry out investigations for systematic process optimization and downstream processing, and analytically validate all results: an ideal basis for quickly and reliably transferring your project from laboratory scale to industrial application.

 

© Bild links: Fraunhofer UMSICHT/Christian Deppe

We support our customers and partners with analytical issues by conducting DIN-certified (DIN CERTCO) biodegradability tests on substances (such as plastics) in compost, soil or aqueous media.
Furthermore, we offer:

  • Investigation of the gas formation potential of biogenic substances (fermentation test as per VDI 4630)
  • Determination of residual gas emissions from fermentation residues (fermentation test as per VDI 4630)
  • Substrate optimization to maximize biogas production in scale-up processes
  • Analysis of samples from mechanical-biological waste treatment in accordance with the German Landfill Ordinance (DepV)

Details about our services

Technologies and expertise

Membrane technology and filtration

We develop energy- and resource-efficient membrane processes – from microfiltration, ultrafiltration and nanofiltration to reverse osmosis. Our focus is on the concentration of recyclable products, minimization of by-products and functional scale-up from laboratory to pilot scale.

Ultrasound application

We specifically use ultrasound to optimize processes such as cell disruption, extraction, and emulsification. By applying sound waves, we shorten process times, increase yields and thus enable a significant increase in efficiency – flexible in use from laboratory to pilot scale.

Process development

Our core strength lies in our comprehensive understanding of processes. We combine interdisciplinary expertise and long-standing experience to develop customized, innovative solutions for complex challenges. From the initial idea to the design and subsequent implementation, we accompany the entire development process and ensure practical, sustainable and economical results – tailored to your specific requirements and existing production environments.

Electrodialysis

Electrodialysis is used to efficiently separate ions and dissolved salts from process streams. This technology enables selective concentration or desalination – with low energy consumption and without using chemicals. We thus offer sustainable solutions for resource recovery and process water treatment that are flexibly scalable from laboratory scale to pilot scale.

Fermentation

We use fermentation to convert raw materials with the help of microorganisms into high-quality products such as biopolymers, platform chemicals and active substances for special purposes. Through targeted process control, strain selection and reactor design, we enable efficient and scalable production that is both economically and ecologically convincing.

Thermochemical processes

We develop and optimize thermochemical processes such as pyrolysis, gasification and hydrothermal carbonization to convert residues into reusable materials. By precisely adjusting the process parameters, we obtain high-quality biocarbons, synthesis gases and platform chemicals – our processes are resource-efficient and can be adapted to different feedstocks and production scales.

Reference Projects

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FutureProteins – Proteins from plants, insects, fungi and microalgae for the food industry

Proteins are among the key nutrients in the human diet and have traditionally been sourced primarily from animal products such as meat, milk and eggs. However, producing these foods is resource-intensive and associated with high greenhouse gas emissions. Alternative protein sources such as legumes, insects, algae and fungal mycelia offer significantly broader potential – not only for meat substitutes but also for baked goods, desserts and functional foods.

The »FutureProteins« project (Fraunhofer flagship project, from 2021 to 2025) has developed climate-independent, closed production systems that provide proteins from plants, insects, fungi and microalgae in a resource-efficient manner. Using technologies such as vertical farming (OrbiPlant®), insect farming and photobioreactors, high-quality proteins were produced year-round and processed into food-grade prototypes such as burger patties, gluten-free bread and desserts. Closed material cycles – such as the use of residual materials as substrate or fertilizer – resulted in a significant reduction in waste.

Life cycle assessments show that the environmental balance of »FutureProteins« depends heavily on the energy mix used but improves significantly with renewable energies. We thus offer an approach to sustainably meet the growing demand for proteins while reducing the ecological footprint of food production.

Learn more

Bio-Phy-FR – Bio-based flame retardant with added value through side stream utilization and waste reduction

Phytin, the salt of phytic acid, is found primarily in oilseeds and cereal grains and serves as a storage compound of phosphorus and cations for seedlings. For the most part, it is chemically extracted from rice bran and used in cosmetics. However, due to its structure, phytic acid has much greater potential, for example in medicine (prevention of diabetes, kidney stones, Parkinson's disease, and cancer), in the Chemical Industry (plastics, paints) or in metal and mining applications (corrosion protection, chelation).

In the project "Natural flame retardants based on phytic acid for the textile and plastics processing industry," we extracted phytin from rapeseed press cake and successfully used it as a flame retardant in PLA (biodegradable plastic). The test specimens achieved fire protection class UL-94 V-0. We were also able to coat functional wear accordingly, extracting a protein as a by-product in addition to phytin. The main waste products were only the rapeseed hulls.

BIORICE

Rice starch is a versatile raw material that is used, for example, in the food, pharmaceutical and cosmetics industries. Rice starch is mainly obtained through chemical extraction from broken rice, with the resulting rice protein being used as inexpensive animal feed.

In the BIORICE project, we broke down the protein using enzymes and microorganisms. After separation by means of cross-flow filtration, the fractions obtained were tested for their antioxidant, blood pressure-lowering, tyrosinase-inhibiting and anti-aging properties. The fractions obtained all exhibited one of the above-mentioned properties without being cytotoxic or irritating.

The project has shown that waste materials from the food industry can indeed be used as food supplements and for cosmetic applications. However, further in-depth research is necessary in this field.

Learn more

Biolectid – Innovative approach to utilizing CO₂ in a novel bioelectrochemical fermentation process for the production of succinic acid

Succinic acid is a key platform chemical that has so far been produced mainly from fossil raw materials. The “Biolectid” project is therefore developing a new bioelectrochemical fermentation process that uses glucose and CO₂ from biogas plants as sustainable raw materials. The yield of bio-based succinic acid is significantly increased by supplying electrons via an electrochemical cell. The process is being transferred to pilot scale and integrated into a group of biogas plants. Work packages include the development of the bioelectrochemical system, process optimization, the construction of a pilot plant, substrate preparation, and an overall ecological and economic assessment. Key issues concern electron transfer, the choice of materials for the electrolyzer and the effects on the microorganisms that produce succinic acid.

The project is funded by the Federal Ministry of Research, Technology and Space (BMFTR) as part of the "CO2BioTech" announcement.

H₂Mem – Production and processing of biomethane using innovative membrane-based H₂ feed and separation

Biomethane can make a significant contribution to the defossilization and security of energy supply of industry and society. In theory, up to 40% of our gas consumption could be replaced by biomethane by 2030. However, only around 220 biogas plants in Germany currently feed biomethane into the natural gas grid. Biological methanization can significantly increase the CH4 content of biogas through reaction of CO2 and H2, but the injection of H2 into the reactor system is limited by its low hydrogen solubility.

In “H2Mem”, a functional, diffusive gasification system based on microstructures (sub-µ range) was therefore developed and applied to optimize biological methanation. The efficiency gains in terms of methane concentration and methane formation rate are being investigated and implemented in practical concepts, especially for small and medium-sized biogas plants.

UltraSep – Innovative process for material and energy recovery from sewage sludge

Germany produces around 1.8 million tons of sewage sludge every year. Previous methods of utilization (agricultural use, co-incineration) are coming under pressure as a result of the amendment to the Sewage Sludge Ordinance (2017). Technical solutions are needed that combine nutrient recovery, particularly that of phosphorus, with safe and cost-effective sewage sludge disposal.

“UltraSep” therefore developed a combined thermal-alkaline ultrasonic disintegration process followed by mechanical separation, which separates the sludge into an organic-rich liquid phase and a fibrous solid fraction. The process was implemented in a pilot plant (1–2 m³/h) at the Hückeswagen wastewater treatment plant (Wupperverband) and iteratively optimized. The results show that targeted recovery of recyclable materials and energy is possible through the treatment and utilization of sewage sludge. The liquid phase was successfully converted into biogas in a high-load digestion process. The fiber fraction is suitable for use as a bio-based fuel or raw material for material utilization processes such as pyrolysis. This increases the resource efficiency of the wastewater treatment plant and at the same time creates recovery options instead of simply disposing of the sewage sludge.

The joint research project "UltraSep" was funded by Federal Ministry of Research, Technology and Space (BMFTR) as part of the SME Innovation Program "Resource Efficiency and Climate Protection" (grant number 02WQ1398).

DISCOVERY

Plant-based beverages and products made from soy, oats and other plant-based raw materials are a healthy and sustainable alternative to animal products. Their popularity and market demand are growing steadily in both Europe and worldwide. Conventional production of plant-based beverages requires soaking, grinding, and pressing the raw materials in water. The separated liquid phase is the basis for beverages and other products such as tofu. The solid phase is a press cake that is considered waste or used as animal feed. However, these press cakes still contain a considerable amount of valuable ingredients such as proteins.

The aim of DISCOVERY was therefore to tap into this potential and thus improve the yield of food from plant-based raw materials. Ultimately, both the European food industry and consumers shall benefit from the economic and sustainability effects associated with increased efficiency in food production.

To this end, promising techniques such as ultrasound and enzyme treatment were investigated as part of the project in order to disaggregate press cakes from soy, oats, rice, almonds, and coconut and then separate a further protein-rich liquid phase. In addition, the liquid fraction was post-treated by concentration and the separated fibers were utilized in meat analog products and baked goods. Furthermore, the influence of the treatments on the nutritional quality and safety of the food was investigated.

Overall, DISCOVERY demonstrated that the disintegration, treatment, and utilization of press cakes from soy, oats, almonds, and coconut has broad and promising potential for the food industry. Individual treatments were selected for each specific product and process line in order to cover both the technological product properties and economic requirements.

Publications

D’Adduzio, L., Fanzaga, M., Capriotti, A. L., Taglioni, E., Boschin G., Laganà, A., Rueller, L.,  Robert, J., van Gemmern, A., Bollati, C., Lammi, C., (2024) Ultrasonication coupled to enzymatic hydrolysis of soybean okara proteins for producing bioactive and bioavailable peptides, Current Research in Food Science, Vol. 9, S. 2665-9271, DOI: 10.1016/j.crfs.2024.100919

Aiello, G.; Xu, R.; Pugliese, R.; Bartolomei, M.; Li, J.; Bollati, C.; Rueller, L.; Robert, J.; Arnoldi, A.; Lammi, C. (2022) Quality Assessment of the Protein Ingredients Recovered by Ultrasound-Assisted Extraction from the Press Cakes of Coconut and Almond Beverage Preparation. Foods 2022, 11, 3693. DOI: 10.3390/foods11223693

Babini, E; Taneyo-Saa, D. L.; Tassoni, A.; Ferri, M.; Kraft, A.; Grän-Heedfeld, J.; Bretz, K.; Roda, A.; Michelini, E.; Calabretta, M. M.; Guillon, F.; Tagliazucchi, D.; Martini, S.; Nissen, L.; Gianotti, A. (2020): Microbial Fermentation of Industrial Rice-Starch Byproduct as Valuable Source of Peptide Fractions with Health-Related Activity. Microorganisms 8 (7), S. 986. DOI: 10.3390/microorganisms8070986

Bechthold, I.; Bretz, K.; Kabasci, S.; Kopitzky, R.; Springer, A. (2008): Succinic Acid: A New Platform Chemical for Biobased Polymers from Renewable Resources. Chem. Eng. Technol. 31 (5), S. 647–654. DOI: 10.1002/ceat.200800063 

Bretz, K.; Kabasci, S. (2012): Feed-control development for succinic acid production with Anaerobiospirillum succiniciproducens. Biotechnology and Bioengineering 109 (5), S. 1187–1192. DOI: 10.1002/bit.24387.

Bretz, K.; Kabasci, S. (2012): Influence of Salt Concentration and Nitrogen Source on Growth and Productivity of Anaerobiosprillum succiniciproducens. Chem. Eng. Technol. 35 (10), S. 1797–1802. DOI: 10.1002/ceat.201200101.

Bretz, K. (2015): Succinic Acid Production in Fed-Batch Fermentation of Anaerobiospirillum succiniciproducens Using Glycerol as Carbon Source. In: Chem. Eng. Technol. 38 (9), S. 1659–1664. DOI: 10.1002/ceat.201500015

Ferri, M.; Graen-Heedfeld, J.; Bretz, K.; Guillon, F.; Michelini, E.; Calabretta, M. M.; Lamborghini, M.; Gruarin, N.; Roda, A.; Kraft, A.; Tassoni, A. (2017): Peptide Fractions Obtained from Rice By-Products by Means of an Environment-Friendly Process Show In Vitro Health-Related Bioactivities. PloS one 12 (1), e0170954. DOI: 10.1371/journal.pone.0170954 

Ferri, M.; Tedeschi, T.; Prandi, B.; Michelini, E.; Calabretta, M. M.; Babini, E.; Graen-Heedfeld, J.; Bretz, K.; Raddadi, N.; Gianotti, A.; Lamborghini, M.; Tassoni, A. (2022): Looking for peptides from rice starch processing by-product: Bioreactor production, anti-tyrosinase and anti-inflammatory activity, and in silico putative taste assessment. Frontiers in Plant Science 13. DOI: 10.3389/fpls.2022.929918

Huft, A., Engel, P., van Gemmern, A., Rueller, L., Robert (2023), J. Optimizing protein recovery from plant substrate using ultrafiltration: A case study on wheatgrass, Journal of Agriculture and Food Research, Vol. 13, p. 2666-1543, DOI: 10.1016/j.jafr.2023.100653

Schöwe, N.; Bretz, K.; Hennig, T.; Schlüter, S.; Deerberg, G. (2015): Succinic Acid Removal and Recovery from Aqueous Solution Using Hydrotalcite Granules: Experiments and Modeling. Ind. Eng. Chem. Res. 54 (3), S. 1123–1130. DOI: 10.1021/ie504306p

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