R&D, Engineering & Services

Engineering expertise for industrial complexity.

Pilotanlage im Technikum von DWE für Prozessentwicklung und Scale-up

DWE is not only a manufacturing partner, but also an engineering and technology partner for demanding reactor and apparatus systems. From the initial process concept to commissioning, thermal, process-engineering, and mechanical questions are considered holistically. For decades, the pilot-plant center (Technikum), engineering, and manufacturing have worked together at a single site – for solutions that can not only be calculated, but also realized industrially.

Rohrbündelreaktor von DWE für großtechnische chemische Prozesse

Thermal, process-engineering, and mechanical design

The performance of a reactor is largely determined by heat removal, flow control, and mechanical integrity. DWE handles the thermal, process-engineering, and mechanical design of reactors and apparatus – from media distribution in the reaction tubes and heat and mass transfer to the design of the heat-removal systems.

This expertise covers molten-salt reactors as well as water-, boiling-water-, oil-, and gasoperated systems. In addition to the reactor itself, the associated water/steam circuits, heat-transfer-medium systems, and heat exchangers are also considered. On this basis, DWE assumes contractual guarantees for heat removal and thermal plant behavior.

Pressure, temperature, dead weight, and operating and transport situations are evaluated by means of strength and stability analyses in accordance with the relevant international codes. CFD, temperature, and stress analyses complement the classic code-based design for complex questions.

Salzbadreaktor von DWE für exotherme Prozesse oberhalb von 300 °C

Manufacturing-oriented design

From the design emerges a construction that is not only functional, but also economical to manufacture. Already in early project phases, material availability, welding and heattreatment concepts, fabrication sequences, assembly procedures, inspection accessibility, and transport concepts are taken into account.

This expertise ensures that even large and complex apparatus can be completely tested, efficiently manufactured, and delivered on schedule.

Manufacturing

R&D and process development in the Technikum

Joint development with technology partners

When developing new processes or reactor concepts, DWE supports the implementation from the initial idea to industrial application. In doing so, the processengineering know-how of customers, technology partners, and research partners is combined with DWE’s reactor, engineering, and manufacturing expertise. The result is tailored reactor solutions that are designed for their later industrial implementation already during the development phase.

Pilot plants and Technikum

For development and scale-up projects, DWE plans and builds application-specific pilot plants. Depending on the task, reactors operated with molten heat-transfer salts or oil thermostats are used, as well as other specially designed test facilities. The plants are set up on a project basis and tailored to the respective process and research objectives. The focus is not on short-term laboratory trials, but on reliable operating data under industrially relevant conditions. Depending on the application, catalysts, reactor concepts, and operating strategies can also be investigated and validated over long periods. The Technikum is used both for internal development projects and for research and development contracts from customers and technology partners.

Industrially relevant development through numbering-up

A key feature of DWE’s reactor technology is the direct transferability of test results to the later production plant. Already in the Technikum, reaction tubes in commercial geometry and the intended catalysts are used. The operating data obtained can thus be used directly for the design of industrial plants. Accordingly, after initial laboratory investigations at technology partners, DWE transfers new processes into industrial reactor systems by means of numbering-up. The individual reaction tube remains unchanged, while the desired production capacity is achieved by increasing the number of tubes in the multi-tubular fixed-bed reactor. This reduces technical risks and significantly shortens the path from process development to the world-scale reactor.

Reaktionsrohre eines Salzbadreaktors von DWE

Qualität und Nachweisführung

Qualitätssicherung, Dokumentation und Nachweisführung sind integraler Bestandteil jedes Projekts. Von der Werkstoffanlieferung über Fertigung, Wärmebehandlung und Prüfung bis zur Auslieferung werden alle qualitätsrelevanten Schritte nachvollziehbar dokumentiert und entsprechend den projekt- und marktspezifischen Anforderungen nachgewiesen. 

Prüfung und Dokumentation

Prüfkonzepte werden bereits während der Auslegung und Fertigungsplanung berücksichtigt. Werkstoffprüfungen, Maßkontrollen, zerstörungsfreie Prüfungen sowie Druck- und Dichtheitsprüfungen begleiten die Fertigung und stellen die Konformität mit den jeweiligen Spezifikationen sicher. Die vollständige technische Dokumentation bildet die Grundlage für Abnahme, Zulassung und langfristige Nachverfolgbarkeit.

Internationale Regelwerke

DWE entwickelt und fertigt Komponenten für internationale Märkte und unterschiedliche regulatorische Anforderungen. Die Ausführung erfolgt gemäß den jeweils projektspezifisch geforderten Regelwerken, Normen und Kundenspezifikationen. Umfang und Nachweisführung werden dabei auf den jeweiligen Einsatzbereich und Zielmarkt abgestimmt.

Services across the life cycle

DWE’s responsibility does not end with delivery. Reactors and apparatus from Deggendorf are often operated over several decades. As the original equipment manufacturer, DWE supports these plants throughout their entire life cycle – from commissioning and modernizations to performance increases and long-term support during ongoing operation.

Reaktor von DWE in der Fertigung am Standort Deggendorf

Construction site services

DWE supports operators worldwide with the assembly, commissioning, and turnarounds of complex plants. The scope of services includes the assembly of sectional reactors and large-scale apparatus, turnarounds, revamps, and the construction of modular PtX plants. Prefabricated and assembly-optimized components reduce the effort on site and shorten shutdown and assembly times.

Modernization and plant development

Over operating periods of four decades and more, technical requirements, safety standards, and production goals change. DWE supports operators with feasibility and revamp studies, capacity increases, adaptations to current HSE requirements, and technical enhancements of existing reactors and apparatus. Where technically sensible and economically feasible, new findings and improvements are also made available for existing plants.

Großzerspanung eines Reaktorbauteils bei DWE

Mitarbeitende von DWE am Standort Deggendorf

Maintenance and after-sales

As the original equipment manufacturer, DWE has detailed knowledge of the design, materials, manufacturing, and operating limits of its own components. This expertise forms the basis for condition assessments, service-life analyses, spare-parts supply, and technical support during planned plant turnarounds. Experienced site supervisors, welding specialists, and service teams support catalyst changes, inspections, and revamp measures on site worldwide.

Long-term service concepts

For Power-to-X plants in particular, long-term service agreements are gaining importance. For this, DWE develops corresponding life-cycle and long-term service concepts, which can encompass technical support, spare-parts supply, catalyst management, and the continuous optimization of plant operation over the entire service life.

Contact for service, revamps, and plant modernization.