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With the amendment to the German Climate Change Act in 2021, the Federal Government of Germany has set the target to become greenhouse gas neutral by 2045. Reaching this ambitious target requires multisectoral efforts, which in turn calls for interdisciplinary collaboration: the Net-Zero-2050 project of the Helmholtz Climate Initiative serves as an example of successful, interdisciplinary collaboration with the aim of producing valuable recommendations for action to achieve net-zero CO2 emissions in Germany. To this end, we applied an interdisciplinary approach to combining comprehensive research results from ten German national research centers in the context of carbon neutrality in Germany. In this paper, we present our approach and the method behind the interdisciplinary storylines development, which enabled us to create a common framework between different carbon dioxide removal and avoidance methods and the bigger carbon neutrality context. Thus, the research findings are aggregated into narratives: the two complementary storylines focus on technologies for net-zero CO2 emissions and on different framing conditions for implementing net-zero CO2 measures. Moreover, we outline the Net-Zero-2050 results emerging from the two storylines by presenting the resulting narratives in the context of carbon neutrality in Germany. Aiming at creating insights into how complementary and related expertise can be combined in teams across disciplines, we conclude with the project’s lessons learned. This paper sheds light on how to facilitate cooperation between different science disciplines with the purpose of preparing joint research results that can be communicated to a specific audience. Additionally, it provides further evidence that interdisciplinary and diverse research teams are an essential factor for defining solution spaces for complex, interdisciplinary problems.

Abstract To reach their net‐zero targets, countries will have to compensate hard‐to‐abate CO2 emissions through carbon dioxide removal (CDR). Yet, current assessments rarely include socio‐cultural or institutional aspects or fail to contextualize CDR options for implementation. Here we present a context‐specific feasibility assessment of CDR options for the example of Germany. We assess 14 CDR options, including three chemical carbon capture options, six options for bioenergy combined with carbon capture and storage (BECCS), and five options that aim to increase ecosystem carbon uptake. The assessment addresses technological, economic, environmental, institutional, social‐cultural and systemic considerations using a traffic‐light system to evaluate implementation opportunities and hurdles. We find that in Germany CDR options like cover crops or seagrass restoration currently face comparably low implementation hurdles in terms of technological, economic, or environmental feasibility and low institutional or social opposition but show comparably small CO2 removal potentials. In contrast, some BECCS options that show high CDR potentials face significant techno‐economic, societal and institutional hurdles when it comes to the geological storage of CO2. While a combination of CDR options is likely required to meet the net‐zero target in Germany, the current climate protection law includes a limited set of options. Our analysis aims to provide comprehensive information on CDR hurdles and possibilities for Germany for use in further research on CDR options, climate, and energy scenario development, as well as an effective decision support basis for various actors.

Equipment integrity is an essential aspect of process engineering. Design guidelines facilitate the design and production of safe-to-operate and economic devices. Thin-walled, slit-shaped modules form a subgroup of process engineering devices made via additive manufacturing (AM). Being subject to internal pressure, they have lacked design guidelines until now. We derived a user-centered calculation model for such modules with regular internal structures. It was validated with Finite Element Analysis (FEA) and practical pressure tests for which the modules were manufactured additively. The performance of the calculation could be confirmed, and a design graph was derived. Slit-shaped modules with appropriate internal structures can withstand high pressure at a minimum wall thickness, and they are efficiently fabricated. These structures, being pins, fins, lattice, or heat transfer enhancing fluid-guiding elements (FGEs), occupied approximately 10% of the modules’ internal volume.

In this study, we investigated the catalytic properties of mono- and bimetallic palladium (Pd) and platinum (Pt) nanoparticles deposited via supercritical fluid reactive deposition (SFRD) on titanium dioxide (TiO2) powder. Transmission electron microscopy analyses verified that SFRD experiments performed at 353 K and 15.6 MPa enabled the deposition of uniform mono- and bimetallic nanoparticles smaller than 3 nm on TiO2. Electron-dispersive X-ray spectroscopy demonstrated the formation of alloy-type structures for the bimetallic PdPt nanoparticles. H2O2 is an excellent oxidizing reagent for the production of fine and bulk chemicals. However, until today, the design and preparation of catalysts with high H2O2 selectivity and productivity remain a great challenge. The focus of this study was on answering the questions of (a) whether the catalysts produced are suitable for the direct synthesis of hydrogen peroxide (H2O2) in the liquid phase and (b) how the metal type affects the catalytic properties. It was found that the metal type (Pd or Pt) influenced the catalytic performance strongly; the mean productivity of the mono- and bimetallic catalysts decreased in the following order: Pd > PdPt > Pt. Furthermore, all catalysts prepared by SFRD showed a significantly higher mean productivity compared to the catalyst prepared by incipient wetness impregnation.

A microstructured cover flow mixer equipped with two cyclone structures was used for stable continuous hydrothermal synthesis of ZnO nanoparticles from Zn(NO3)2 and NaOH aqueous solutions in supercritical water. The effects of the NaOH/Zn(NO3)2 ratio, Zn(NO3)2 molality, and flow rate on Zn conversion, crystal structure, particle size, particle morphology, and mixer clogging were examined. The advantages of this mixer were identified by comparing with the results obtained using the same chemical conditions with tee-type, cross-type, and central collision-type mixers.

The industrial adoption of additive manufacturing (AM) technologies increased due to more applications and use cases demonstrating significant functional benefits. Additive manufacturing of thin-walled gas-tight structures with complex shapes can fulfil requirements for a wide range of applications, such as process equipment for the chemical industry. The requirement to be gas-tight makes the manufacturing process very fault-sensitive as even a single open pore in the submicron range can lead to an impermissible leak of hazardous gases. Further, it has always been a challenge to make thin walls using Laser Powder Bed Fusion of Metals (PBF-LB/M). We explore the key design limit of inclined overhanging gas-tight thin walls made from 316l. A double pass scan strategy is presented to realize these structures along with guidelines to be followed when attempting to print these structures. The paper reports the common failure modes where leaks occur and lessons learned to successful design and printing of gas-tight walls. The results show that fabrication of gas-tight walls is feasible even for a 30° inclination angle to the horizontal and wall thicknesses in the range of 200–300 µm. A case study shows the successful the application of the findings to the production of modular distillation devices.

In its latest assessment report the IPCC stresses the need for carbon dioxide removal (CDR) to counterbalance residual emissions to achieve net zero carbon dioxide or greenhouse gas emissions. There are currently a wide variety of CDR measures available. Their potential and feasibility, however, depends on context specific conditions, as among others biophysical site characteristics, or availability of infrastructure and resources. In our study, we selected 13 CDR concepts which we present in the form of exemplary CDR units described in dedicated fact sheets. They cover technical CO2 removal (two concepts of direct air carbon capture), hybrid solutions (six bioenergy with carbon capture technologies) and five options for natural sink enhancement. Our estimates for their CO2 removal potentials in 2050 range from 0.06 to 30 million tons of CO2, depending on the option. Ten of the 13 CDR concepts provide technical removal potentials higher than 1 million tons of CO2 per year. To better understand the potential contribution of analyzed CDR options to reaching net-zero CO2 emissions, we compare our results with the current CO2 emissions and potential residual CO2 emissions in 2050 in Germany. To complement the necessary information on technology-based and hybrid options, we also provide an overview on possible solutions for CO2 storage for Germany. Taking biophysical conditions and infrastructure into account, northern Germany seems a preferable area for deployment of many concepts. However, for their successful implementation further socio-economic analysis, clear regulations, and policy incentives are necessary.

Sustainable aviation fuels (SAF) are needed in large quantities to reduce the negative impact of flying on the climate. So-called power-to-liquid (PtL) plants can produce SAF from renewable electricity, water, and carbon dioxide. Reactors for these processes that are suitable for flexible operation are difficult to manufacture. Metal 3D printing, also known as additive manufacturing (AM), enables the fabrication of process equipment, such as chemical reactors, with highly optimized functions. In this publication, we present an AM reactor design and conduct experiments for Fischer-Tropsch synthesis (FTS) under challenging conditions. The design includes heating, cooling, and sensing, among others, and can be easily fabricated without welding. We confirm that our reactor has excellent temperature control and high productivity of FTS products up to 800 kgC5+ mcat−3 h−1 (mass flow rate of hydrocarbons, liquid or solid at ambient conditions, per catalyst volume). The typical space-time yield for conventional multi-tubular Fischer-Tropsch reactors is ~100 kgC5+ mcat−3 h−1. The increased productivity is achieved by designing reactor structures in which the channels for catalyst and cooling/heating fluid are in the millimeter range. With the effective control of heat release, we observe neither the formation of hot spots nor catalyst deactivation.

Abstract Germany 2050: For the first time Germany reached a balance between its sources of anthropogenic CO2 to the atmosphere and newly created anthropogenic sinks. This backcasting study presents a fictional future in which this goal was achieved by avoiding (∼645 Mt CO2), reducing (∼50 Mt CO2) and removing (∼60 Mt CO2) carbon emissions. This meant substantial transformation of the energy system, increasing energy efficiency, sector coupling, and electrification, energy storage solutions including synthetic energy carriers, sector‐specific solutions for industry, transport, and agriculture, as well as natural‐sink enhancement and technological carbon dioxide options. All of the above was necessary to achieve a net‐zero CO2 system for Germany by 2050.

The polycondensation reaction to produce polydextrose can be intensified by using micro-process engineering. Fluid Guiding Elements are additively manufactured internal inserts that have already shown their potential to intensify heat transfer in double-pipe heat exchangers. This study investigated the intensification of the polydextrose yield when these internal inserts were used. Different reactor lengths and internal inserts geometries, as well as different operating conditions, were analyzed. The experiments showed that the reactant concentration had no effect on the product yield. Furthermore, it was shown that the process could be intensified at higher temperatures, with relatively low residence times and lower pressures. It was confirmed that the good heat transfer characteristics of the internal inserts allow them to continuously evaporate water during the reaction and to further reach the required reaction temperature, thus shifting the equilibrium towards the desired product. These findings are of special significance for the optimization of the polycondensation reaction of polydextrose.

Climate change represents an existential, global threat to humanity, yet its delocalized nature complicates climate action. Here, the authors propose retrofitting air conditioning units as integrated, scalable, and renewable-powered devices capable of decentralized CO2 conversion and energy democratization.

A higher density of large-angle grain boundaries in palladium membranes promotes hydrogen diffusion whereas small-angle grain boundaries suppress it. In this paper, the microstructure formation in 10 µm thick palladium membranes is tuned to achieve a submicronic grain size above 100 nm with a high density of large-angle grain boundaries. Moreover, changes in the grain boundaries’ structure is investigated after exposure to hydrogen at 300 and 500 °C. To attain large-angle grain boundaries in Pd, the coating was performed on yttria-stabilized zirconia/porous Crofer 22 APU substrates (intended for use later in an ultracompact membrane reactor). Two techniques of plasma sprayings were used: suspension plasma spraying using liquid nano-sized powder suspension and vacuum plasma spraying using microsized powder as feedstock. By controlling the process parameters in these two techniques, membranes with a comparable density of large-angle grain boundaries could be developed despite the differences in the fabrication methods and feedstocks. Analyses showed that a randomly oriented submicronic structure could be attained with a very similar grain sizes between 100 and 500 nm which could enhance hydrogen permeation. Exposure to hydrogen for 72 h at high temperatures revealed that the samples maintained their large-angle grain boundaries despite the increase in average grain size to around 536 and 720 nm for vacuum plasma spraying and suspension plasma spraying, respectively.

In the future, hydrogen (H2) will play a significant role in the sustainable supply of energy and raw materials to various sectors. Therefore, the electrolysis of water required for industrial-scale H2 production represents a key component in the generation of renewable electricity. Within the scope of fundamental research work on cell components for polymer electrolyte membrane (PEM) electrolyzers and application-oriented living labs, an MW electrolysis system was used to further improve industrial-scale electrolysis technology in terms of its basic structure and systems-related integration. The planning of this work, as well as the analytical and technical approaches taken, along with the essential results of research and development are presented herein. The focus of this study is the test facility for a megawatt PEM electrolysis stack with the presentation of the design, processing, and assembly of the main components of the facility and stack.

Hydrophobic membranes were characterized at elevated temperatures. Pressure was applied at the feed and permeate side to ensure liquid phase conditions. Within this scope, the applicability of different polymeric and ceramic membranes in terms of liquid entry pressure was studied using water. The Visual Method and the Pressure Step Method were applied for the experimental investigation. The results show the Pressure Step Method to be an early detection method. The tests at higher pressure and temperature conditions using the Pressure Step Method revealed the temperature as being the main factor affecting the liquid entry pressure. Novel LEP data up to 120 °C and 2.5 bar were obtained, which broadens the application range of hydrophobic membranes.

The integration of mixed ionic–electronic conducting separation membranes in catalytic membrane reactors can yield more environmentally safe and economically efficient processes. Concentration polarization effects are observed in these types of membranes when O2 permeating fluxes are significantly high. These undesired effects can be overcome by the development of new membrane reactors where mass transport and heat transfer are enhanced by adopting state-of-the-art microfabrication. In addition, careful control over the fluid dynamics regime by employing compact metallic reactors equipped with microchannels could allow the rapid extraction of the products, minimizing undesired secondary reactions. Moreover, a high membrane surface area to catalyst volume ratio can be achieved. In this work, a compact metallic reactor was developed for the integration of mixed ionic–electronic conducting ceramic membranes. An asymmetric all-La0.6Sr0.4Co0.2Fe0.8O3–δ membrane was sealed to the metallic reactor by the reactive air brazing technique. O2 permeation was evaluated as a proof of concept, and the influence of different parameters, such as temperature, sweep gas flow rates and oxygen partial pressure in the feed gas, were evaluated.

Abstract To achieve substantial reductions in CO2 emissions, catalysts for the photoreduction of CO2 into value‐added chemicals and fuels will most likely be at the heart of key renewable‐energy technologies. Despite tremendous efforts, developing highly active and selective CO2 reduction photocatalysts remains a great challenge. Herein, a metal oxide heterostructure engineering strategy that enables the gas‐phase, photocatalytic, heterogeneous hydrogenation of CO2 to CO with high performance metrics (i.e., the conversion rate of CO2 to CO reached as high as 1400 µmol g cat−1 h−1) is reported. The catalyst is comprised of indium oxide nanocrystals, In2O3−x(OH)y, nucleated and grown on the surface of niobium pentoxide (Nb2O5) nanorods. The heterostructure between In2O3−x(OH)y nanocrystals and the Nb2O5 nanorod support increases the concentration of oxygen vacancies and prolongs excited state (electron and hole) lifetimes. Together, these effects result in a dramatically improved photocatalytic performance compared to the isolated In2O3−x(OH)y material. The defect optimized heterostructure exhibits a 44‐fold higher conversion rate than pristine In2O3−x(OH)y. It also exhibits selective conversion of CO2 to CO as well as long‐term operational stability.

Immobilized multi-enzyme cascades are increasingly used in microfluidic devices. In particular, their application in continuous flow reactors shows great potential, utilizing the benefits of reusability and control of the reaction conditions. However, capitalizing on this potential is challenging and requires detailed knowledge of the investigated system. Here, we show the application of computational methods for optimization with multi-level reactor design (MLRD) methodology based on the underlying physical and chemical processes. We optimize a stereoselective reduction of a diketone catalyzed by ketoreductase (Gre2) and Nicotinamidadenindinukleotidphosphat (NADPH) cofactor regeneration with glucose dehydrogenase (GDH). Both enzymes are separately immobilized on magnetic beads forming a packed bed within the microreactor. We derive optimal reactor feed concentrations and enzyme ratios for enhanced performance and a basic economic model in order to maximize the techno-economic performance (TEP) for the first reduction of 5-nitrononane-2,8-dione.

Determination of local heat transfer coefficient at the interface of channel wall and fluid was the main goal of this experimental study in microchannel flow boiling domain. Flow boiling heat transfer to DI-water in a single microchannel with a rectangular cross section was experimentally investigated. The rectangular cross section dimensions of the experimented microchannel were 1050 μm × 500 μm and 1500 μm × 500 μm. Experiments under conditions of boiling were performed in a test setup, which allows the optical and local impedance measurements of the fluids by mass fluxes of 22.1 kg·m−2·s−1 to 118.8 kg·m−2·s−1 and heat fluxes in the range of 14.7 kW·m−2 to 116.54 kW·m−2. The effect of the mass flux, heat flux, and flow pattern on flow boiling local heat transfer coefficient and pressure drop were investigated. Experimental data compared to existing correlations indicated no single correlation of good predictive value. This was concluded to be the case due to the instability of flow conditions on one hand and the variation of the flow regimes over the experimental conditions on the other hand. The results from the local impedance measurements in correlation to the optical measurements shows the flow regime variation at the experimental conditions. From these measurements, useful parameters for use in models on boiling like the 3-zone model were shown. It was shown that the sensing method can shed a precise light on unknown features locally in slug flow such as residence time of each phases, bubble frequency, and duty cycle.

The gas/liquid phase separation of CO2 from a water-methanol solution at the anode side of a µDirect-Methanol-Fuel-Cell (µDMFC) plays a key role in the overall performance of fuel cells. This point is of particular importance if the µDMFC is based on a “Lab-on-a-Chip„ design with transient working behaviour, as well as with a recycling and a recovery system for unused fuel. By integrating a membrane-based micro contactor downstream into the µDMFC, the efficient removal of CO2 from a water-methanol solution is possible. In this work, a systematic study of the separation process regarding gas permeability with and without two-phase flow is presented. By considering the µDMFC working behaviour, an improvement of the overall separation performance is pursued. In general, the gas/liquid phase separation is achieved by (1) using a combination of the pressure gradient as a driving force, and (2) capillary forces in the pores of the membrane acting as a transport barrier depending on the nature of it (hydrophilic/hydrophobic). Additionally, the separation efficiency, pressure gradient, orientation, liquid loss, and active membrane area for different feed inlet temperatures and methanol concentrations are investigated to obtain an insight into the separation process at transient working conditions of the µDMFC.

Hydrogen production and storage in small and medium scale, and chemical heat storage from renewable energy, are of great interest nowadays. Micro-membrane reactors for reforming of methane, as well as for the dehydrogenation of liquid organic hydrogen carriers (LOHCs), have been developed. The systems consist of stacked plates with integrated palladium (Pd) membranes. As an alternative to rolled and electroless plated (Pd) membranes, the development of a cost-effective method for the fabrication of Pd membranes by suspension plasma spraying is presented.

We present an electrochemical sensor system for the detection of hydrogen peroxide inside a direct synthesis microreactor. The setup allows the online, in situ measurement of high reactant concentrations by amperometric detection across the micro channel width and length. The robust integration of the electrochemical cell in the microreactor was demonstrated. Hydrogen peroxide was detected under reaction conditions (pH 3–4, presence of bromide) showing linear behaviour up to 2 mM with high sensitivity and excellent stability. The linear range was increased up to 10 mM by applying a diffusion limiting pHEMA layer to the electrode surface.