18. Jun 2026
Covestro launches EU-backed project to scale bio-based aniline production
Covestro has launched an EU-funded project aimed at developing what it describes as the world's first continuous production process for bio-based aniline, a key precursor used in the manufacture of MDI and polyurethane materials.
The Bio4PURConti (Bio-Based Continuous Production for Sustainable Polyurethane Industry) project brings together a consortium of ten partners from seven countries and will focus on scaling up the production of bio-based aniline to semi-industrial level. Pilot activities are planned at the Bio Base Europe Pilot Plant in Ghent, Belgium, and at Covestro's site in Leverkusen, Germany.
Aniline is an important raw material for the plastics and chemical industries, particularly for MDI, one of the principal building blocks used in polyurethane production. According to Covestro, conventional fossil-based aniline production generates around 20 million tonnes of CO₂ emissions worldwide each year.
The company said it already uses a specially developed microorganism that converts industrial sugars derived from plant biomass into an intermediate product through fermentation. A subsequent catalytic step converts the intermediate into aniline containing 100% plant-based carbon.
The Bio4PURConti project aims to advance this process further by replacing batch production with continuous fermentation technology.
“Continuous fermentation represents a major leap forward – not just for our bio-based aniline process, but for industrial biotechnology as a whole,” said Dr Markus Dugal, head of process technology at Covestro.
“By demonstrating this at semi-industrial scale for a high-volume chemical, we are setting the stage for a new generation of sustainable chemical manufacturing. As one of the world's largest aniline producers, we are uniquely positioned to bring this technology to market and support the industry's transition to more circular and climate-neutral solutions.”
Unlike the fed-batch process currently employed, continuous fermentation would allow raw materials to be supplied and products removed continuously. Covestro said the approach is expected to increase productivity and improve space-time yields while reducing the carbon footprint of production.
The process uses plant-derived sugars, including those obtained from hardwood biomass, as renewable feedstocks. The resulting bio-based aniline is designed to be fully drop-in compatible with existing polyurethane value chains and to meet MDI specifications without requiring modifications to downstream processing.
The project will scale the technology from laboratory level to a 1.5m³ semi-industrial demonstration system and will integrate cell recycling, real-time analytics and downstream processing technologies.
The consortium includes industrial and academic partners and has received support through the European Union's Circular Bio-based Europe Joint Undertaking programme.
“Bio4PURConti is a perfect example of how European collaboration can accelerate innovation and strengthen the competitiveness of the bio-based industry,” said Dr Markus Steilemann, chief executive officer of Covestro.
“By bringing together leading experts from industry and academia, we are creating a powerful ecosystem to scale breakthrough technologies and drive the transition towards a circular economy.”
Photo: Covestro has launched Bio4PURConti targeting to develop the first continuous production process for bio-based aniline. © Covestro