Fortlaufprozess

Fortlaufprozess is a term used in production, process engineering and information systems to describe a process where materials or information flow continuously through a sequence of operations, from input to output, without discrete, separable batches or interruptions. It contrasts with batch processing, where production occurs in discrete lots.

Key features include a continuous flow of inputs, steady or controlled production rates, ongoing operation with minimal downtime between units, and a reliance on automated control systems to maintain process variables such as temperature, pressure, flow, and composition. Continuous processes often employ integrated instrumentation, sensors, actuators, and supervisory control systems (SCADA, DCS) and may utilize advanced process control and process analytical technology (PAT) to ensure product quality.

Advantages of a Fortlaufprozess include higher throughput, lower unit costs, reduced downtime for changeovers, smoother inventory management, and more uniform product quality. Challenges encompass high capital costs, complexity in start-up and shutdown, sensitivity to disturbances, safety and environmental risks, regulatory compliance in certain industries, and difficulties in changing product specifications.

Applications span chemical and petrochemical production, paper and pulp, steel and metal production (such as continuous casting), food and beverage processing, water and wastewater treatment, and pharmaceutical manufacturing where continuous manufacturing is increasingly adopted. Examples include distillation columns in oil refineries operating in a continuous state, steel continuous casting, and polymerization in loop reactors.

Variants in reactor and plant design may use plug-flow or well-mixed configurations, with control strategies ranging from PID to model predictive control (MPC). See also batch process and continuous manufacturing.