More time for exchange

Mr. Moodley, how well did you know the HZB before the fellowship program?

We've been in close contact for two years now, so I haven't entered new territory, if that's what you mean. The main thing that's different for me is that I now have more truly focused time for discussions and regular exchanges. So our relationship is building on a more solid foundation.

What do you hope to gain from your time as a fellow?

Let me elaborate further: For me as an industrial researcher, the collaboration with the numerous different partners on the CARE-O-SENE project is a fascinating experience. These many multidisciplinary perspectives. Our goal at Sasol is to develop a catalyst for the Fischer -Tropsch process that can be used to produce synthetic fuel very efficiently. And our colleagues at the Karlsruhe Institute of Technology are developing, for example, X-ray methods that allow us to observe this catalyst during operation – and at HZB, many technologies have been developed to enable high-end analysis of the catalyst at BESSY II.

Now, the Fischer -Tropsch process, which is intended to produce sustainable kerosene, is nothing new to you.

That's true. But in traditional industrial research, we usually use a catalyst, let the reaction take place, and then analyze the catalyst - " post mortem," as we call it. Here, thanks to the synchrotron, we have the opportunity to observe the catalyst during the reaction. That is a fundamental difference. In addition, we pursue an integrated approach , which includes theoretical modeling , working with different model catalysts, detailed characterization, but also various types of testing and life cycle analyses . The HZB is involved in most of these areas .

What do you think is the greatest benefit of the fellowship program?

Personally, I enjoy spending a lot of time with the doctoral students and postdocs involved . For example, if one of them conducts an experiment with a model catalyst, we discuss how close the experiment is to the realistic conditions that will later be required in production. The young people have a precisely defined area of ​​responsibility within the project. I then help them put together the bigger picture—understand where their piece of the puzzle plays an important role. And I explain to them how our industrial processes work. For me personally, it is an additional advantage that, beyond CARE-O-SENE, I now come into contact with researchers at HZB who are experts in the fields of ( electro )chemical energy conversion and storage, solar fuels and thin-film catalysis .

In the In the CARE-O-SENE project , you lead the team tasked with scaling the processes—that is, the step from a lab-scale catalyst to a catalyst capable of producing thousands of liters of sustainable kerosene . What are the key issues here?

If you look at the catalyst under a microscope, you'll see that the active particles are tiny—we're talking about six to ten nanometers. Working with them in a test tube in the lab is completely different than working with them in an industrial facility, where reactors are suddenly 20 or even 50 meters high. So how do these tiny particles behave in an environment where tons of material are reacting with each other and where the pressure conditions alone are completely different? When scaling up, questions of hydrodynamics —the flow patterns of liquids —and heat dissipation become very important, because Fischer- Tropsch is a highly exothermic reaction that generates heat. These conditions change whether the reaction takes place in a laboratory environment or in a large reactor.

How do you approach scaling to larger quantities ?

We're gradually shifting the scale. Put simply: In each step, we use equipment and catalyst quantities that increasingly resemble those of an industrial reactor. Each of these steps carries a different risk, because it's not always a linear process. And so we're moving toward larger scales.

The ultimate goal for CARE-O-SENE is to produce on a semi-commercial scale. How difficult is the final step— transfer to full-scale industrial production?

We also call the semi-commercial scale demonstration level . The reactor is almost identical in terms of hydrodynamics and heat dissipation, and the equipment for preparing the catalyst is also similar. Of course, there's still a risk that something might go wrong when taking the final step toward industrial production—but it's much smaller than now, when we're dramatically scaling up the scale from a few grams in the lab.

How far are you currently?

At CARE-O-SENE, we're looking at four catalysts. Some are already usable, while others promise even greater efficiency but still require further development. For one of these catalysts, we've just completed the path to semi-commercial-scale production. We've produced a product that meets our target of 80 percent yield, paving the way for commercial application next year. So, things are progressing well.

Let's get back to your fellowship. Will there be another exchange afterward?

Well, for now, the CARE-O-SENE project will run until the end of 2026. But I'm convinced that after that, we'll look for opportunities to extend the partnership. There are a number of topics where I can imagine both sides benefiting from a similar fellowship program.

Is there anything that surprised you about the role change?

Absolutely: the teamwork and camaraderie at HZB, this pulling together. I had no previous experience with program-oriented funding, which requires even huge projects to be planned down to the smallest detail. The way people from very different backgrounds come together for this and the coordinated way in which this planning takes place – that really impressed me.

Denzil Moodley holds a doctorate in chemistry and has worked in the research and technology department of the South African chemical giant Sasol for almost 25 years . He specializes in the Fischer -Tropsch process and is one of the lead scientists in the international collaborative project CARE-O-SENE. He is currently working closely with HZB as an Industrial Research Fellow.

The CARE-O-SENE project aims to produce a catalyst that can be used to produce synthetic aviation fuel. This process requires catalysts that are significantly more efficient than currently available materials. The development of such a catalyst is therefore one of the project's key tasks; a subsequent step will involve scaling up production to a semi-industrial scale. CARE-O-SENE is funded by the BMBF. Seven companies and research institutions from Germany and South Africa are involved under the leadership of Sasol and HZB: Sasol South Africa , Sasol Germany, HZB, KIT, Fraunhofer IKTS, UCT, and INERATEC . The project runs until the end of 2026.