CONSENS: Objectives

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 important areas 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 neighbouring sectors of the European processing industry

Coordinator: Manuel Pereira Remelhe
Bayer AG - Engineering & Technology - Process Design & Optimization
Leverkusen, Germany



Project partner

  1. Arkema France, Colombes, France
  2. Atlan-Tec Systems GmbH, Willich, Germany
  3. BASF SE, Ludwigshafen am Rhein, Germany
  4. Bayer AG, Leverkusen, Germany
  5. Bundesanstalt für Materialforschung und –prüfung BAM, Berlin, Germany
  6. Clariant Produkte (Deutschland) GmbH, Frankfurt am Main, Germany
  7. Coatex SAS, Genay, France
  8. Inno TSD SA, Antipolis Valbonne, France
  9. Invite GmbH, Leverkusen, Germany
  10. Krohne Messtechnik GmbH, Duisburg, Germany
  11. Procter & Gamble Services Company NV, Strombeek Bever, Belgium
  12. Solvay, Paris, France
  13. Technische Universität Dortmund, Dortmund, Germany
  14. TNO, Delft, The Netherlands
  15. Universita degli Studi di Cagliari, Cagliari, Italy

Bilateral Talks

  • Participants59
  • Meetings Requested59
  • Meetings Accepted30


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