Modernisation programme at Covestro’s Dormagen TDI plant set to cut energy usage

Dormagen, Germany – Covestro is investing mid-to-high double digits of euros at its TDI production plant in Dormagen. The plant, first commissioned in 2015, uses the company’s gas-phase technology in the manufacture of TDI. It is the largest TDI plant in Europe, Covestro said.

The modernisation work includes the installation of a new reactor that will allow energy from the reaction to be used to generate steam. Once the work is complete, Covestro said the plant will consume up to 80% less energy than a conventional TDI manufacturing process, with greenhouse gas emissions cut by 22kT/year.

The first phase of the project is now complete, with the new equipment having been lifted into the plant. The remaining steps of the modernisation will be gradually introduced between now and spring 2025, ensuring a continuous supply of TDI to customers.

The Dormagen TDI plant has a capacity of 300kT/year. The gas-phase process, Covestro said, already requires 60% less energy and 80% less solvent than a conventional process. The new investment will further increase its efficiency and sustainability.

“The location plays a central role in the reliable supply of our customers in the region,” said Christine Mendoza-Frohn, the company’s head of performance materials sales for EMEA and LATAM. “The investment not only underlines our commitment to the European market, but also enables our customers to further reduce their indirect CO₂ emissions on the way to developing climate-neutral and circular products for the consumer markets.”

The modernisation programme is being partly funded by the German Federal Ministry for Economic Affairs and Climate Action, as part of its federal funding programme for energy and resource efficiency.