Infrastructure and expertise for construction and operation of pilot plants

The technologically risky and capital-intensive steps involved in transferring new processes from the laboratory to industrial-scale implementation require pilot and demonstration plants for concept testing and evaluation. Start-ups and small and medium-sized enterprises (SMEs) in the chemical, pharmaceutical, and materials industries, in particular, need an optimally structured infrastructure to bring their concepts and technologies to market and to bridge the “Valley of Death” in the innovation chain – that is, the transition from the laboratory and pilot plant scale to the pilot scale – as quickly as possible while maintaining their competitiveness. 

Bring science2scale: Infrastructure, space, and technical expertise for the construction and operation of your pilot plant

The path to a successful scale-up is complex and requires significant investment. Fraunhofer CBP supports you in transferring your technologies into industrial practice. This helps minimize risks and realize potential more quickly.

7 reasons to partner with Fraunhofer CBP

• Support for the transition from development to industrial implementation 
• Minimizing investment risks through a stable partner with experience in scale-up
• Rapid implementation through brownfield approaches
• Technical and scientific support for ramping up, operating, and/or advancing your demonstration
• Reduction of investment costs through existing facilities
• Flexible use of a chemical plant environment
• Support in improving the entire value chain and process chain

The Fraunhofer Center for Chemical-Biotechnological Processes CBP is located on the chemical plant grounds of InfraLeuna GmbH in Leuna (Saxony-Anhalt, Germany), in the immediate vicinity of companies such as Leuna Polyamid GmbH, Linde, Shell, Total Energies, and UPM.

The center offers customers and partners modular reactor and plant technology, pilot plants, and technical expertise with a focus on processes in the following areas:

• Biomass fractionation (e.g., lignocellulose, oilseeds, plant proteins)
• Industrial biotechnology
• Chemistry
• Separation and Purification

This makes it possible to simulate integrated processes – from the fractionation of renewable raw materials through various biotechnological and/or chemical conversion processes to complex downstream process steps – even in continuous operation, in order to test innovative and sustainable process chains on a pilot scale, produce sample quantities, validate product specifications, and gather important data regarding the design and economic viability of production facilities.

Our expertise for your demonstration projects

Since its inauguration in 2012, Fraunhofer CBP has been continuously working on a wide range of projects with partners from academia and industry. As a branch of Fraunhofer IGB, it is an integral part of complete value and process chains in the field of the bioeconomy. As a pilot center, its research is particularly industry-oriented, which is also reflected in the large number of direct industry contracts.

In addition to projects that utilize existing pilot plants, Fraunhofer CBP has experience with the commissioning and operation of specialized demonstration facilities. As a result, our staff understands the key considerations for subsequent implementation and addresses them accordingly. Furthermore, CBP is integrated into an extensive network at the regional, national, and EU levels and can connect you with relevant stakeholders and experts along your value chain.

• Vacant land for specific pilot and demonstration facilities for a period of 3–5 years
• You are the sole owner of the facility
• Operation and execution of the associated research work by qualified Fraunhofer staff
• Access to process analytics, modeling, scale-down, and process optimization
• Access to extensive additional services from InfraLeuna, e.g., logistics, storage, and utilities that cannot be provided by the CBP
• Indoor space (ATEX-compliant environment possible) currently available: 300 m² + 150 m² of laboratory facilities
• Outdoor space currently available: 600 m²

Fraunhofer CBP facilitates and supports the construction of customer-owned demonstration plants on its premises. The experience and expertise of its staff in commissioning and operating customer-owned plants ensure the safe, rapid, and targeted implementation of demonstration projects, taking into account all aspects relevant to subsequent industrial implementation.

Our range of services is individually tailored to meet specific requirements. As a result, partners benefit from the infrastructure of a fully integrated chemical park as well as access to process analytics, modeling, and process digitization. In addition, the CBP team also provides support for other scale-up issues on the path to implementing commercial plants, such as drafting specifications for engineering contracts or developing concepts for the subsequent use of the demonstration plant.

We would be happy to explore the possibilities in an initial, no-obligation consultation. We look forward to your email or phone call.

One example of a successful technology demonstration at Fraunhofer CBP was the collaboration with Global Bioenergies S.A. on scaling up and optimizing a newly developed fermentation process for producing isobutene – an important petrochemical feedstock – from renewable raw materials. To this end, Global Bioenergies constructed an indoor demonstration plant at Fraunhofer CBP with a nominal capacity of 100 metric tons per year and a fermentation volume of 5,000 liters, in which isobutene was produced by fermentation from sugars rather than petroleum for the first time.

Fraunhofer CBP supported the construction and commissioning of the plant and, on behalf of the company, took over the subsequent four-year operation of the demonstration plant from 2017 to 2021. The scientific evaluation and validation of the process campaigns were carried out in close collaboration between Fraunhofer CBP and Global Bioenergies. Unique in Europe was the directly connected product purification system for liquefying the pure isobutene. Due to the aerobic fermentation process combined with the highly flammable isobutene, special emphasis was placed on safety engineering.

The data obtained during research and development enabled the validation of applications in bio-based fuels and cosmetics and served as the basis for planning an industrial production facility.