The KoPPonA 2.0 consortium project, funded under the ENPRO initiative with project code 03EN2004A, was the successor to KoPPonA 1.0 and aimed to transfer a concept for energy‑efficient, accelerated, simultaneous product and process development from aqueous solution polymerisation to a broader range of polymerisation systems. The core objective was to enable a batch‑to‑continuous conversion while reducing time‑to‑market for specialty polymers. The project was divided into two main parts. The first part focused on developing continuous processes for selected specialty polymers and demonstrating their feasibility on a pilot scale. Reaction kinetics were derived for each system, including potential gel‑formation pathways caused by side reactions. The second part investigated fouling phenomena—gel particle and deposit formation—in continuous reactors, analysing how chemistry, formulation, reactor design, geometry and operating parameters influence deposit build‑up. A multidisciplinary approach was adopted, combining chemistry, process engineering, modelling and advanced measurement techniques.

Key technical outcomes include the successful derivation of kinetic models for catalytic oligomerisation and the identification of gel‑formation mechanisms in continuous reactors. Spectroscopic methods, ultrasonic sensor technology, and acoustic (body‑wave) measurements were evaluated for fouling detection and quantification. An ultrasonic sensor developed jointly by KROHNE and RUB‑EST was integrated into the laboratory setup in Leverkusen, while a fouling‑monitoring sensor from Ehrfeld Mirkotechnik was tested but found unsuitable for the intended application. The project established a framework for modelling fouling dynamics, enabling the prediction of operating conditions that avoid deposit formation. Although the pilot plant in Leverkusen was not retrofitted with autonomous measurement systems due to the lack of suitable technology and insufficient test duration, the laboratory‑scale demonstrations confirmed the feasibility of the continuous processes and provided data for model validation. Milestones MS1.1 to MS1.3 and MS2 were achieved on schedule; MS3, which involved kinetic validation and sensor assessment, was completed within the project period, albeit slightly later than initially planned. Milestone 4, concerning simulation‑driven optimisation of reactor internals, was only partially realised because of extended simulation times. Milestone 5, the decision to use the existing pilot plant for test runs, was met on time.

Collaboration was central to the project’s success. Covestro Deutschland AG led the overall coordination and provided the aqueous solution polymerisation examples. Wacker Chemie AG contributed an emulsion polymerisation case study of vinyl ester monomers, representing a widely used industrial system. BASF SE had been a partner in the predecessor project and continued to provide expertise. The consortium also included KROHNE and RUB‑EST, who supplied the ultrasonic sensor technology, and Ehrfeld Mirkotechnik, which supplied a density‑viscosity sensor for fouling monitoring. University partners supplied academic expertise in reaction engineering and modelling. The project ran until 30 September 2022, with the final report submitted on 31 March 2023. The ENPRO programme, a joint initiative of the German Federal Ministry of Education and Research and the German Research Foundation, financed the effort, underscoring the strategic importance of continuous polymerisation technologies for the German chemical industry.