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LEVERKUSEN, Germany

Grant
Agency: Cordis | Branch: H2020 | Program: RIA | Phase: SPIRE-01-2014 | Award Amount: 6.00M | Year: 2015

Intensified continuous processes are a key innovation of the last decade for the production of high quality, high value and customer-specific products at competitive prices in a sustainable fashion. To realize the potential of this technology, key steps must be made towards long-term stable, tightly controlled and fully automated production. The goal of the CONSENS project is to advance the continuous production of high-value products meeting high quality demands in flexible intensified continuous plants by introducing novel online sensing equipment and closed-loop control of the key product parameters. CONSENS will focus on flexible continuous plants but the results will be transferable also to large-scale continuous processes. The research and development is driven by industrial case studies from three different areas, spanning the complete value chain of chemical production: complex organic synthesis, speciality polymers, and formulation of complex liquids. Innovative PAT technology will be developed for online concentration measurements (mid-resolution process NMR), for the online non-invasive measurement of rheological properties of complex fluids, and for continuous measurements of fouling in tubular reactors. New model-based adaptive control schemes based on innovative PAT technology will be developed. The project results will be validated in industrial pilot plants for all three types of processes, including validation in production containers that have been developed in the F3 Factory project. Further, methods for sensor failure monitoring, control performance monitoring and engineering support for PAT-based solutions will be developed. The exploitation of the new technologies will be facilitated by a tool for technology evaluation and economic impact assessment. A Cross-sectorial Advisory Board supports the transfer of PAT technologies and adaptive control to neighboring sectors of the European processing industry.


Grant
Agency: Cordis | Branch: FP7 | Program: CP-IP | Phase: NMP-2008-3.2-1 | Award Amount: 29.36M | Year: 2009

The F3 consortiums vision is that the EUs chemical industrys competitive position would be strongly enhanced if it could operate modular continuous plant (F3 plant) which combines world scale continuous plant efficiency, consistency and scalability with the versatility of batch operation. Our project will deliver such a radically new production mode based on: a) Plugandplay modular chemical production technology, capable of widespread implementation throughout the chemical industry. This technology uses generic backbone facilities designed for rapid interfacing with standardized process equipment containers (PEC). The PEC house process equipment assemblies (PEA) composed of intensified process equipment for fast, flexible future chemical production b) Holistic process design methodology applying process intensification concepts and innovative decision tools. This will accelerate process development and provides a substantial reduction in energy consumption, raw material usage and plant volumes. Our consortium of leading academic & research institutions and 7 major synthetic chemical producing industrial companies has 3 main goals: 1. To prove the technical feasibility of the F3 mode of manufacturing by building and operating a 0.1 to 30 kg/hr demonstration facility, 2. To demonstrate that operation of F3 plant will be more economical, ecoefficient and more sustainable than conventional production modes like large scale continuous or small to medium scale batch processing. 3. To drive a step change in the technology available to EU chemical production and engineering companies by designing intensified equipment for reaction and down stream processing, dissemination of standards for plug and play modular plant and providing open access to the backbone facility Our estimates indicate that the F3 concept will generate additional new business and will save 3.75 billion euro when existing products change to the F3 mode of manufacture.


Grant
Agency: Cordis | Branch: FP7 | Program: CP-IP | Phase: NMP-2009-3.2-1 | Award Amount: 15.99M | Year: 2010

The SYNFLOW vision is the paradigm shift from batch-wise large volume processes in pharmaceuticals, fine chemicals and intermediates production comprising many separate unit operations towards highly integrated but yet flexible catalytic continuous flow processing. For this purpose, SYNFLOW develops a unique integrative approach combining molecular understanding of synthesis and catalysis with engineering science in process design and plant concepts, aiming at an efficiency breakthrough in process development and operation. The SYNFLOW mission is to overcome the traditional way of linear process development providing individual solutions for specific products, and to demonstrate the technological, economic and ecological superiority of truly designing processes by application of advanced chemical and engineering knowledge. The SYNFLOW concept is based on the definition of generic challenges with industrial relevance, represented by Case Studies provided by the industrial consortium members. Catalyst development, studies of the underlying chemical target transformations (synthetic methodology), tailored reaction engineering, conceptual process design and process evaluation interact closely in order to substantiate the SYNFLOW vision. Its success will be demonstrated on a relevant production scale as a reference for the entire European Chemical Industry. The SYNFLOW consortium brings together major industrial producers from the Pharmaceuticals, Fine Chemicals and Intermediates sectors, providers of process technology and technical catalyst supply. A number of high-ranked academic partners ensures the availability of comprehensive expertise for the suggested Case Studies. Dissemination of the results is guaranteed by the participation of DECHEMA and Britest. SYNFLOW presents a holistic approach to central challenges of the European Chemical Industries and therefore a highly promising candidate to fulfill the crucial issues of the NMP-2009-3.2-1 call.

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