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Experimental infrastructure

The Gas- und Wärme-Institut Essen e.V. has extensive test rig facilities equipped with modern measurement technologies for carrying out application-oriented investigations for industrial and R&D projects, which are integrated into the GWI's so-called LivingLab via intelligent communication technology.

The spectrum ranges from test benches for small fuel cells with outputs of less than 1 kW to semi-industrial high-temperature test rigs with firing rates up to 1.3 MW. The test facilities are partly modular and mobile; they can be operated with all types of combustible gases and gas blends, with air (preheated up to 1,200 °C) or pure oxygen. With these flexible test infrastructures, we are able to investigate and optimize both individual technologies and the energy supply for buildings, commerce and industrial applications according to process-specific criteria and also to carry out investigations on site directly at the customer's premises. Through the professional analysis, evaluation of the measurement results and years of experience, we can provide support in solving the problems that arise in practice, in the implementation of measures to increase efficiency, reduce pollutant emissions and mitigate greenhouse gas emissions. 

Issues concerning the entire chain of energy supply in the residential and commercial sectors, as well as their equipment and systems, are covered at the test facilities of the Fuel and Appliance Technology Department. In the laboratory, systems and system combinations are tested and optimized for efficiency, dynamics and emissions. In addition to efficiency measurements, time-dependent load profiles can also be specified and efficiencies can be determined. For special requirements/questions, specially adapted test facilities are designed, built and put into operation. Furthermore, a technology demonstration house offers the possibility to test different appliances and appliance combinations under real conditions. Here, user behavior can be simulated in a controlled setting and the respective data recorded and evaluated in detail with the aid of modern measuring technologies. In addition, training seminars, demonstrations and information events are organized on the systems installed.

The test rigs of the Industrial and Combustion department are used for operators of thermoprocessing plants, but also for furnace and burner manufacturers . These test rigs can be used to investigate the integration of alternative fuels in industrial processes and to prove measures for increasing energy efficiency and reducing pollutant emissions in order to provide solutions for optimum practical settings. These include two high-performance, high-temperature test furnaces with firing rates ranging from 300 kW to 1.3 MW. The test rigs can be operated both with preheated air (up to 1200 °C) and pure oxygen.

Water-cooled probes are used to measure both species concentrations and gas temperatures. UV flame visualization is used to evaluate combustion processes so that flame characteristics such as flame shape, stability or length can be determined. An IR camera can be used to take thermographic images and detect defective zones and damage in the refractory of thermoprocessing equipment earlier, so that the safety and energy efficiency of the equipment can be increased.

Our range of services is rounded off by a mobile unit equipped with measurement technology, with which we provide highly accurate measurements of the most important combustion parameters of the industrial plant at the customer's site and consult and support in optimizing the operation of the plant on-site.