The goal of this unit is the power production of 10 kW, using autothermal reforming steam reforming of methanol and utilizing the produced hydrogen in PEM fuel cells. The steam reforming of methanol is considered a superior methodology over the other two alternatives (partial methanol oxidation and methanol reforming), as it is a combination of the other two. The proposed methodology causes less catalyst sintering and does not require additional reactor heating.

A large pilot-scale hydroprocessing unit has been used for a variety of projects including hydrotreatment catalyst evaluation, hydrotreating and hydrocracking of heavy refinery streams, hydrocracking of Fischer-Tropsch wax, etc. It consists of two fixed bed reactors in series (D=2.8cm, L=48 cm), and is fully automated. It has capacity of ~14 lit/day processing feedstock and combines all the sections of an industrial scale hydroprocessing unit.

The synthesis gas production unit was designed and manufactured within PSDI, aiming to convert natural gas, hydrocarbon gases and oxygenated liquids to synthesis gas. The SYNGAS unit consists of a fixed bed and a spouted bed reactor which may operate in parallel or individually. The SYNGAS unit is a fully-automated unit.

This unit is sufficiently equipped in order to study and control the operation of a single or a cluster of PEM fuel cells. Furthermore it is utilized for Monolithic Electrochemically Promoted Reactors (MEPR) in high temperatures or Solid Oxide Fuel Cells (SOFC). The unit includes an integrated flow control system, gas IR analyzers, potentionstat, high temperature furnace and operating control system. The main goal of this unit is the basic study of the electrode yield for the aforementioned fuel cell assemblies.

This unit consists of an integrated system for the operation and study of operating parameters of a regenerative PEM fuel cell (RPEMFC) system. It consists of a of PEM fuel cells’ cluster and an electrolytic assembly of PEM type for the production of hydrogen and oxygen, an integrated flow control and electrical control system of the cluster. The unit is equipped with the necessary automation to allow continuous operation for extended periods of time. The unit is at the final stage of its construction.

This unit enables research studies on single fuel cells and of the materials they incorporate for their SOFC application. It consists of an advanced arrangement (button cell) with the advantage of automated control of the atmosphere of both anode and cathode. It further includes a cylindrical furnace for allowing operations at high temperatures (up to 1200^oC). The operation of this unit is temporarily supported by the SOFCU unit (see above).

This includes two autonomous units. The first one involves production of membrane electrode assemblies for PEM, and it consists of a press which can operate up to 300oC. The second one is a spray printing device for catalyst deposition in the form of electrodes.

This unit enables the study of the aforementioned electro-catalytic processes and the electrochemical characterization of the solid electrolyte catalyst. The unit includes an intergraded flow control system, a gas chromatograph, a potentionstat/galvanostat and a high temperature furnace.

Calibration device for low gas flow measuring instruments. Semi-automatic operation. Digital display of gas temperature.

The system includes a lightweight, ergonomically designed and easy-to-use portable field multifunction calibrator, suitable for the calibration or simulation of sensors, transmitters, converters, and instruments for pressure, temperature, electrical signals, and frequency signals, including pulses.

Standard calibration oven for sensors and temperature instruments. It is accompanied by an external platinum resistance reference thermometer PT-100. Electronic temperature control and digital display of the oven temperature, as well as digital display of the reference thermometer temperature.

High-Bay Laboratories are equipped with advanced systems that contribute to improving working conditions and workplace safety. The technical team of the laboratory is responsible for the daily supervision of the proper functioning of these supporting systems. Additionally, the design and supervision of Cold and Hot rooms for the storage of supplies and samples is an important responsibility of the laboratory.

The existing infrastructure features optimized data management and collection systems to support web presence services and is based on centralized Database systems where the results of experiments and processes are stored. The implementation of the above is carried out using Database and Application development software. The web presence and Pilot Units monitoring software (iClient TS) provides remote access for supervision and control of the Pilot Units using security procedures.

The modern web presence allows for showcasing and presenting to the general public. To implement the related services, a data reliability assurance system (Firewall Server) was developed to protect the computing infrastructure. The architecture of the network applications consists of two dedicated servers: one serves as the Database Server, while the second acts as the platform for implementing applications and websites (Application Server). For network monitoring of the units, a server is used to handle the connection with the infrastructure servers of the units’ system. The web infrastructure is complemented by a special-purpose server that hosts the modeling software.

Data management is carried out by a Laboratory Information Management System (LIMS). Data archiving and retrieval are implemented through the laboratory information system, which is integrated with the automation system of the units and supplies the online services. The information system consists of a main server to which peripheral data collection nodes are connected. The infrastructure of the servers and workstations is networked through the interconnection of appropriate active network equipment and the physical infrastructure of the corresponding space.

The Process Management Information System (PIMS) for Pilot Units is related to the detailed recording of operational data and measurements of the Pilot Units. The use of this system enables the integration and interconnection of the Laboratory Information Management System (LIMS) with the individual automation subsystems of the laboratory (SCADA PP Nodes), providing a unified environment for archiving and managing operations. Additionally, one of its main functions is the capability for Statistical Process Control (SPC) and Statistical Quality Control (SQC) of the measurements.

Taking into account the particularities of the experimental process and the parameters set due to the nature of the system, the infrastructure related to the automation systems consists of subsystems of the pilot units and instruments. Real-time monitoring is carried out by the process supervisory control software, whose capabilities are combined with each respective pilot unit. The recording system consists of the data collection subsystem and the subsystem for visualization and distribution of the data.

The CPS unit (Cyclic Propylene Steaming Unit), which was constructed by the Environmental Fuels and Hydrocarbons Laboratory (EPERI) of ITHE/ CERTH, is used both for the deposition of metals Ni, V, through the fluidized bed process aiming at its deactivation, as well as for its hydrothermal treatment. Specifically, the metals are deposited onto the catalyst and simultaneously deactivated by exposing the catalyst to successive reaction-regeneration cycles, resulting in gradual deactivation and final aging of the catalyst. Furthermore, the catalyst deactivation service was recently upgraded with the LCDU unit (Large Catalyst Deactivation Unit). The role of the LCDU unit is to deactivate the catalyst for further evaluation both in pilot units and in the laboratory’s experimental units.

The pilot Catalytic Pyrolysis Unit (FCC) operates continuously and aims to test catalysts, feedstocks, or operating conditions on a relatively large scale for the development of new technologies. The unit includes an upward-flow reactor (riser) with an internal diameter of 7 mm, a stripper with an internal diameter of 2.66 cm, and a regenerator with an internal diameter of 7.8 cm. The unit also features a stabilizer for the produced liquid products and a system of chromatographs for online analysis of the composition of pyrolysis products and regeneration off-gases. The pilot unit is fully automated, and its control system is based on a specialized industrial computer (DCS) that executes all control actions of the unit.

This specific unit, provided by the company BP/AMOCO, consists of 4 reactors operating in parallel, thus enabling the simultaneous evaluation of 4 catalysts. The large number of parallel catalyst evaluations is significant because the evaluation of hydrodesulfurization catalysts takes a very long time (approximately two months).

The unit is used for the fluid dynamics simulation of the alkylation process with a solid catalyst.

This unit, which is an exact replica of the FCC pilot unit, was designed by the laboratory’s scientific staff and constructed by the Institute’s technicians. It is used for the fluid dynamic simulation of the catalytic cracking process and fully replicates the FCC pilot unit of CPERI.