Covestro will modernize its Dormagen plant to enhance the sustainability and competitiveness of TDI production

To further strengthen the sustainability and competitiveness of TDI (toluene diisocyanate) for flexible foam production in Europe, Covestro will invest mid- to high double-digit million euros by 2025 , modernizing its production plant in Dormagen, Germany. The plant opened in early 2015 and is considered one of the most advanced TDI production facilities in the world thanks to its use of gas phase technology developed by Covestro. The work will include the installation of a modern reactor so that the reaction energy can be used for energy-efficient steam power generation in the future.

The modernization will significantly increase the energy efficiency of the plant and thereby reduce CO2 emissions. After modernization, the plant’s energy consumption will be 80% lower than traditional TDI production processes, and greenhouse gas emissions will be further reduced by 22,000 tons per year. This not only makes a significant contribution to the company’s climate goals and safeguards European TDI production in the face of sharply rising energy costs, but also improves the sustainability performance of customer industries. At present, with the equipment being hoisted into the factory, the first phase of the project has been successfully completed. All further measures will be implemented gradually until spring 2025. This will ensure continued supply of TDI to customers.

Thorsten, Member of the Management Board and Chief Technology Officer of Covestro
Dr. Dreier said: “We want to continue growing in Germany and drive the transition to climate-neutral production. However, the overall situation, and especially high energy prices, make it increasingly difficult for us to make such investments. Policymakers must ultimately take Effective measures to restore Germany’s competitiveness in energy prices and ensure a reliable basis for the climate-neutral transition of industry.”

TheDormagenfactory serves asTDI’shub in Europe

The TDI plant in Dormagen has an annual production capacity of 300,000 tons. It uses gas-phase technology developed by Covestro, which, even before modernization, uses 60% less energy and 80% less solvent than traditional processes. The current investment will significantly increase the efficiency of the plant, thereby further improving its sustainability. TDI is an important raw material for soft foam, which provides comfort for mattresses, upholstered furniture and car seats. The material will continue to play an important role for Covestro and the process industry in the future.

Christine, Head of Sales Performance Materials EMEA and Latin America at Covestro
Dr. Mendoza-Frohn said: “In Dormagen we have Europe’s largest TDI production facility, which means this location plays a central role in providing reliable supply to our customers in the region. We now continue to consistently meet their needs. The investment not only underlines our commitment to the European market, but also enables our customers to further reduce indirect CO2 emissions and develop climate-neutral and circular products for the consumer market. At the same time, this investment also highlights our cooperation with the value chain partners to play a leading role in climate protection and the circular economy.”

Covestro is actively promoting circular economy. In the process, the company has set itself the goal of making its operations climate neutral by 2035. Improving the efficiency of existing production processes is an important lever to achieve this goal. From 2005 to 2020, Covestro was able to reduce its specific energy consumption (i.e. energy consumption per ton of product produced) by approximately 35%. By 2035, through targeted energy management, the specific demand for primary energy at the three sites in North Rhine-Westphalia, Germany, will be further reduced by approximately 25% compared to 2020. Covestro aims to save approximately 1,100 RMB per year from 2035 onwards
GWh of primary energy. This is equivalent to the annual consumption of more than 50,000 average German households. Within the next five years, nearly half of this potential will be realized.

The modernization of the TDI plant in Dormagen is partly funded by the German Federal Ministry for Economic Affairs and Climate Action as part of the Federal Energy and Resource Efficiency Fund.