Equipment

© Fraunhofer IKTS
Semiautomatic plugging unit for filter segments.
© Fraunhofer IKTS
Scanning electron microscopic image of a catalytically coated substrate at the polished section.
© Fraunhofer IKTS
Continuous multi-step system for foam coating.

Extrusion of honeycomb and tube geometries

  • Preparation with Eirich mixer and double-Z kneader
  • Ram extruder and various screw extruders
  • Various dies for honeycomb and tube geometries, individual dies are possible

 

Manufacture of open-cell foam ceramics following the Schwartzwalder method

  • Semiautomatic impregnating unit for foam
  • Single- and multi-step rolling unit for foam coating
  • Centrifuges for foam coating

 

Calcination/heat treatment

  • Air sintering furnaces, up to 1700 °C
  • Inert gas furnaces, up to 2500 °C (Ar, N2, vacuum)
  • Fast firing continuous furnace, up to 1100 °C (air)
  • Hydrothermal aging unit, up to 650 °C, 10% H2O

 

Coating

  • Immersion coating for individual segments and fine filter substrates
  • Centrifuges of various sizes

 

Filtration test stands

  • Sooting, back pressure and particle test stand for segments and filter discs (RT)
  • Sooting, back pressure and particle test stand for filters up to 12’’ or industrial hot gas filtration up to 1000 °C (hot gas test stand), also for the endurance testing of filters or cyclical analyses of service life, drop-to-idle
  • Back pressure measurements, up to 12 bar on small sample geometries (porometer)
  • Pressure drop test stand for foam ceramics, up to 20 m/s
  • Determination of cell width for cellular systems

 

Catalysis test stands

  • Fully automatic chemisorption analysis unit (Autochem) for chemical and temperature-programmed reactions on powder samples
  • Syngas test stands for the analysis and aging of honeycombs and core samples, static and highly dynamic heating and gas dosing regimes, synthetic gaseous mixtures (N2, O2, CO, NO/NO2, NH3, HC, H2O, SO2, CH4+C3H6, C3H8)

 

Testing of mechanical properties

  • Compressive strength testing on filters, up to 10 bar
  • Compressive strength testing for foam ceramics
  • Compressive strength testing for honeycomb geometries in A, B or C direction
  • Strength testing for honeycomb geometries according to ASTM C1674-08 at RT and < 1600 °C in air
  • Determination of Young’s modulus
  • Thermal stability and thermal shock resistance

 

Chemical Composition

  • Elemental analysis (EDX)
  • X-ray fluorescent analysis (XRF)
  • Inductively coupled plasma atomic emission spectroscopy (ICP-AES)
  • Qualitative and quantitative phase analysis (XRD) also with grazing incidence, from RT to 1400 °C

 

Characterization of particulate matter and suspensions

  • Particle size distribution, particle shape
  • Specific surface BET (N2/Kr adsorption and desorption)
  • Pore distribution (Hg porosimetry, permeation porosimetry)
  • Surface charge, zeta potential
  • Rheology, viscosity
  • Determination of density (bulk density, true density, pyknometry)
  • Sedimentation stability

 

Microstructure and material characerization

  • Materialographic preparation of samples (mechanical preparation, chemical and physical etching techniques, ion beam preparation)
  • Microscopy (light microscopy, stereo light microscopy, scanning electron microscopy [REM/FESEM], transmission elec-tron microscopy [TEM], etc.)
  • Coat thickness analysis
  • Precious metal crystallites and particle size
  • X-ray computer tomography

 

Thermal analytics and thermal physics

  • Thermogravimetry (TG)
  • Thermomechanical analysis (TMA)
  • Thermodilatometry (TD)
  • Thermal conductivity at RT
  • Heat capacity

 

Modeling and simulation

  • Finite element analysis (FEM), ANSYS (Emag/Mech), COMSOL Multiphysics, FlexPDE, Atila
  • Flow simulation (Fluent)
  • System simulation (Matlab/Simulink, Simulation X, Dymola/Modelica)
  • Thermodynamic simulation (Factsage)

 

Accredited laboratories (DIN EN ISO/EC 1725)

  • Thermal analytics and thermal physics
  • Characterization of particulate matter and suspensions
  • Laboratory for quality assurance and reliability