Covestro Invests Millions of Dollars to Transform TDI Factory!

In order to further strengthen the sustainability and competitiveness of TDI (toluene diisocyanate) production in European flexible foam production, Covestro will invest millions of dollars in the modernization of its Dormagen production plant until 2025.

The plant was commissioned in early 2015 and is considered one of the most modern TDI production facilities in the world thanks to its use of gas phase technology developed by Covestro. As part of the works, a modern reactor will be installed, allowing the energy produced by the reaction to be used to produce energy-saving steam.

The modernization will significantly increase the energy efficiency of the plant, thereby reducing CO2 emissions. After modernization, the plant will use 80% less energy to produce TDI than conventional processes, reducing greenhouse gas emissions by a further 22,000 tonnes per year. This not only makes a significant contribution to safeguarding TDI production in Europe and achieving the company's climate targets in the face of sharply rising energy costs, but also improves the sustainability balance in a declining industry.

With the equipment installed at the factory, the first phase of the project is now successfully completed. All further measures will be phased in until spring 2025 to ensure continued supply of TDI to customers.

"We want to continue growing in Germany and drive the transition to climate-neutral production. However, material conditions, especially high energy prices, make it increasingly difficult to make such investments," Dr. Thorsten Dreier, Chief Technology Officer at Covestro explain. "Politicians must finally take effective measures to restore Germany's competitiveness in energy prices and ensure a reliable basis for the transition of industrial production to climate protection.

The TDI plant in Dormagen has an annual output of 300,000 tons. The plant uses gas-phase technology developed by Covestro, which, prior to the modernization, already used up to 60% less energy and up to 80% less solvent than conventional processes. The current investment will significantly increase the efficiency of the plant, thereby once again enhancing its sustainability. TDI is an important raw material for flexible foams that provide comfort in mattresses, upholstered furniture, car seats and more. In the future, this material will continue to play an important role in Covestro and the downstream processing industry.

"In Dormagen we have Europe's largest TDI production plant, which means that it plays a central role in reliable supply to our customers in the region. We will now continue to focus on their needs."In Dormagen, we have the largest TDI production plant in Europe, which means that the plant plays a central role in reliable supply to customers in the region. We will now continue to focus on their needs.

This investment not only demonstrates our commitment to the European market, but also enables our customers to further reduce indirect CO2 emissions while developing climate-neutral and circular products for end consumer markets," said Dr. Christine Mendoza-Frohn, Head of Sales, Performance Materials, Europe, Middle East, Africa and Latin America. "At the same time, this investment also demonstrates our ambition to play a leading role in climate protection and circular economy together with partners along the industry chain."