Ludwigshafen, Germany – October 2025 – BASF SE, the world’s largest chemical producer, has announced a 40% reduction in communication-related downtime and 25% lower maintenance costs after deploying the ABB CI858K01 3BSE018135R1 communication module across its Ludwigshafen integrated chemical site. The upgrade, completed in Q3 2025, addressed critical interoperability issues between legacy control systems and new smart sensors in the plant’s ethylene oxide production unit—where real-time data exchange is mission-critical for safety and efficiency.
The Challenge: Fragmented Communication in Hazardous Chemical Processes
Prior to adopting the CI858K01, BASF’s ethylene oxide unit faced three major pain points:
- Protocol Incompatibility: The plant’s existing ABB AC 800M controllers struggled to communicate with new PROFIBUS DP-enabled flow sensors and EtherNet/IP-connected valves, creating data silos. Operators relied on manual data logging for 30% of process parameters, increasing human error risk.
- Harsh Environment Failures: Temperatures in the reactor area reached 75°C, and electromagnetic interference (EMI) from nearby pumps caused frequent module resets—leading to 12 unplanned downtime events in 2024, each costing €80,000 in lost production.
- Complex Maintenance: Legacy modules required shutdowns to replace, forcing the plant to schedule maintenance during peak demand periods, further reducing output.
“Our ethylene oxide process operates 24/7, and even 1 hour of downtime impacts global supply chains,” said Dr. Markus Weber, BASF’s Process Control Manager. “We needed a communication module that could bridge our old and new systems while surviving our harsh operating conditions.”
ABB CI858K01: The Multi-Protocol Solution for Hazardous Environments
After testing two competitor modules, BASF selected the ABB CI858K01 3BSE018135R1 for its unique combination of protocol flexibility, rugged design, and seamless integration:
- Universal Protocol Support: The module natively handles EtherNet/IP, PROFIBUS DP, Modbus TCP/RTU, and CANopen—eliminating the need for protocol converters. It connects the AC 800M controller to 64+ field devices simultaneously, enabling real-time data flow between sensors, valves, and the control room .
- Extreme Environment Durability: With an operating temperature range of -40°C to +85°C and 2.5kV galvanic isolation, the CI858K01 withstands high heat, EMI, and voltage spikes common in chemical plants . Its compact DIN-rail design (12.4cm x 7.4cm x 4.4cm) fits in space-constrained explosion-proof cabinets .
- Hot-Swappable Redundancy: The module supports redundant configuration, allowing technicians to replace units without shutting down the process. Built-in self-diagnostics alert operators to wiring faults or sensor disconnections before they cause downtime .
- Plug-and-Play Integration: The CI858K01 seamlessly integrates with BASF’s existing AC 800M system, requiring no custom software development. Configuration was completed in 3 days using ABB’s Control Builder M software.
Results: Safer Operations, Higher Output, Lower Costs
Six months post-deployment, BASF’s ethylene oxide unit achieved transformative results:
- Downtime Cut by 40%: Communication-related failures dropped from 12 to 5 events annually, saving €560,000 in avoided production losses.
- Data Accuracy Improved by 99%: Manual data logging was eliminated, reducing process parameter errors from 2.3% to 0.1%, enhancing compliance with REACH and OSHA safety standards.
- Maintenance Time Reduced by 60%: Hot-swappable modules and remote diagnostics cut maintenance hours from 120 to 48 annually. Technicians now resolve issues in 30 minutes vs. 4 hours previously .
- Energy Efficiency Gained: Real-time data from connected sensors optimized steam usage, reducing energy consumption by 8%—equivalent to 300 MWh annually, or €24,000 in cost savings.
“The CI858K01 has become the backbone of our smart factory initiative,” Weber said. “It’s not just a communication module—it’s a safety net. We can trust the data we’re getting, and that allows us to optimize processes without compromising on safety.”
Stefanie Becker, ABB’s Global Product Manager for Industrial Communication, emphasized the module’s role in chemical industry digitalization. “Chemical plants need to modernize incrementally, and the CI858K01 enables that by bridging legacy and new systems,” she said. “Its multi-protocol support and rugged design make it uniquely suited for the most challenging process environments.”
BASF plans to deploy the CI858K01 across 10 more production units in Ludwigshafen by 2026, with the goal of reducing overall plant downtime by 30%.
