Sonderforschungsbereich (SFB) Smarte Reaktoren für die Verfahrenstechnik der Zukunft Hamburg

The transition towards sustainable and flexible chemical production demands a deeper understanding of the dynamic processes inside complex reactors. Conventional measurement techniques, typically fixed in space, fail to capture the transient and spatially distributed phenomena that govern real process behavior. Project A08 within the CRC1615 compound introduces a radically different approach: the development of miniaturized, freely moving sensor spheres that operate as Lagrangian probes, travelling with the flow to record physical and chemical parameters directly within the reactor volume.

These millimeter-scale sensors combine integrated electronics, optical communication, and autonomous energy supply into a compact platform designed for in-situ process monitoring. By following the motion of individual sensor spheres, A08 aims to reveal how local flow structures, temperature gradients, and chemical transformations interact in real time, even under highly dynamic and opaque conditions.

Scientifically, the project investigates how to correlate sensor trajectories with flow field dynamics, how to realize ultra-low-power communication and energy harvesting within closed reactor environments, and how to reconstruct spatially resolved process states from distributed sensor data using advanced filtering and modeling methods.

First results, presented at the Microsystem Technology Conference (MST Kongress), demonstrate the feasibility of this vision. A working prototype of a Lagrangian sensor sphere with integrated inertial sensors, LED-based optical data transmission, and photodiode receivers has been successfully tested in water-filled reactor models. Complementary optical and acoustic coupling simulations further validate the system design and guide the next steps towards robust operation under realistic process conditions. In parallel, a scalable light-based energy harvesting concept has been realized, enabling autonomous power supply for sensor prototypes in the laboratory.

In the long term, A08 seeks to open a new window into the interior of chemical reactors, enabling adaptive process control, improved material efficiency, and a more sustainable use of resources. Beyond its immediate scientific goals, the project offers a fertile environment for interdisciplinary research — connecting microelectronics, fluid dynamics, photonics, and systems engineering — and providing young researchers with an opportunity to shape the next generation of intelligent reactor technologies.

Further Contact: Anton Geläschus