Fraunhofer UMSICHT Institute Branch Sulzbach-Rosenberg
Fraunhofer UMSICHT Institute Branch Sulzbach-Rosenberg

Pyrolysis Pilot, Research and Demonstration Plants

We develop, engineer and manufacture customized pyrolysis plants

At Fraunhofer UMSICHT, we develop, design, and construct pyrolysis research plants for universities, research institutions, and corporate clients.

30 kg/h pyrolysis unit for a Canadian university with an integrated post-reformer (based on the Fraunhofer TCR principle) to enhance the quality of pyrolysis products.
An experienced team of mechanical engineers, designers, process engineers, stainless steel specialists, and technicians.

We combine our scientific work in thermochemical carbon conversion technologies and clean combusiton technologies with specialized engineering and manufacturing of process equipment. 

Whether you require a prototype unit, a pilot plant, or a demonstration-scale installation, our specialties lie in thermochemical and thermal process engineering, focusing on pyrolysis reactors.

To deliver cost efficiency, we combine tailored manufacturing of specialized components in our own workshop with seamless integration of pre-fabricated modules.

Assembly, test runs, and commissioning are handled by our experienced team of technicians and engineers.

Reference-Projects of pyrolysis research plants

Pyrolysis research plants that we have engineered, manufactured and commissioned worldwide for industrial partners and research institutions.

Workflow: from Idea to Industrial Plant

Services from feasibility check through Engineering, Manufacturing, Commissioning, and Scale Up

Our services cover the full workflow from concept and feasibility through detailed design, fabrication, commissioning, and, where required, scale‑up toward industrial scales.

Mechanical models- such as screw‑conveyor rigs - are used to investigate feed conveyance and mixing behavior prior to full‑scale fabrication.
Customer-site installation and commissioning of a pyrolysis research plant
Installation of a 500 kg/h pyrolysis demonstration plant using a gantry crane

Ahead of reactor development, we recommend feedstock test campaigns with the intended materials, whether biomass, mixed plastics waste or composite materials or mineral waste.

At the Fraunhofer Institute we operate more than 20 pyrolysis and combustion test stands across multiple scales and reactor designs. Insights from these tests directly inform the design basics, sizing, heating concept, and control strategy of a pilot or demonstration plant.

Knowledge generated in testing and pilot operation is transferred into subsequent design iterations and industrial‑scale concepts.

Our mechanical engineering capabilities are centered on reactor design, feedstock input, and temperature control. We implement a range of reactor designs and conveying concepts, including custom feed and product withdrawal systems with dedicated transport and input mechanisms for challenging feedstocks. In‑house developments include reactor heating (electrical or tail‑gas), heat transfer into the feedstock, and temperature control. 

Key engineering competencies include:

  • Development of novel reactor geometries
  • Stainless‑steel design and fabrication
  • Corrosion mitigation and materials selection
  • Gas‑tight operation via lock‑hopper and other sealing systems

All research plants are equipped with extensive analytical instrumentation and, as required, integrated gas analysis. Control is typically implemented with SIMATIC S7 PLCs according to industrial standards, offering open interfaces to common analytics and data systems (e.g., databases, visualization), up to virtualization of the entire plant. Larger systems support automated operating modes.

Auxiliary systems for product conditioning and emissions control

Gas train and condensation unit for large pyrolysis plant

 In addition to the reactor, we integrate components for processing and upgrading pyrolysis products - particularly the vapor phase - using cyclones, filters, and electrostatic precipitators to achieve target gas compositions and reduce tar formation.

Condensation trains for the separation of pyrolysis oils can be included. Gas trains, off‑gas utilization, combined heat and power (CHP), hydrogen separation, and emissions control are integrated as required by the research objectives and regulatory context.

Optional modules include:

  • In‑situ upgrading of the pyrolysis vapor phase (including patented solutions such as TCR technology and PyroMat technology)
  • Adjustment of product distributions (e.g., minimizing solids/char, increasing gas yield)
  • Integrated utilization of biochar
  • Utilization of pyrolysis gases via oxy‑fuel combustion to produce a high‑purity CO2 stream
  • Hydrogen separation from pyrolysis gas, e.g., via PSA systems