During the first 36 months of SIMPLI-DEMO, activities progressed across all work packages as planned (WP4 starting in M36).
WP1 investigated HEUR, HMPE and NIPU chemistry at lab scale. New analytical and spectroscopic tools were developed to support reactive extrusion, particularly for HMPE. A pilot-extrusion guideline using ultrasound-assisted power transfer was created. In the second period, flexible REX systems for HEURs, HMPEs and PHUs were designed, integrating MW/US units, automation, modelling and continuous monitoring. HMPEs and PHUs were produced in an 18 mm pilot extruder, with optimisation and MW/US intensification ongoing.
WP2 focuses on a modular COBR system for zeolite and API synthesis. A high-temperature, high-pressure pilot unit with ultrasound, microwaves and PAT tools was revamped and validated, with first zeolite trials completed. Downstream development (filtration/washing) continues. For APIs, lab work progressed alongside the installation of two process systems, including a commissioned laboratory unit used for training in July 2023.
WP3 performed parametric studies on the effect of ultrasound and microwaves on HEUR/HMPE extrusion, NIPU synthesis and zeolite/API crystallisation. Key process parameters were identified, models developed and monitoring tools applied. Studies continued in batch and continuous modes in the second period, with further analysis of MW/US effects and monitoring techniques still in progress.
WP4, launched in September 2025, builds on WP1–WP3 to expand pilot plants and demonstrate modular reactive extrusion and crystallisation in industrial environments using MW/US as alternative energy sources. Efforts focus on process optimisation, scale-up and validation across all use cases.
WP5 delivered an initial assessment of economic feasibility and potential GHG reductions enabled by SIMPLI-DEMO technologies. Benchmark processes were compared with SIMPLI-DEMO alternatives using plant-wide simulations. Mass and energy balances informed equipment sizing and utility needs, and CAPEX/OPEX evaluations were carried out for both batch and continuous configurations using Aspen Plus and standard economic methods.
WP6 strengthened project visibility through communication, dissemination and exploitation activities, using coordinated tools (website, flyers, posters, social media, presentations) deployed across events and partner networks.
WP7 ensured effective coordination and management by TUDO, supporting smooth implementation and collaboration among partners.
