Covestro Completes Modernization of Dormagen TDI Plant with Enhanced Energy Efficiency
Covestro, a global leader in high-performance materials and chemicals, has successfully completed the modernization of its TDI (Toluene Diisocyanate) plant in Dormagen, Germany. The official commissioning of the plant was celebrated At an event attended by about 60 invited guests from politics, business, and Covestro’s staff, including the North Rhine-Westphalia Environmental Minister, Oliver Krischer. During the event, Covestro also unveiled its new energy efficiency targets, marking a significant step toward more sustainable and competitive operations.
Achieving Climate Protection and Competitiveness Together
The modernization of the Dormagen TDI plant marks a major milestone in Covestro’s efforts to balance climate protection with industrial competitiveness. Dr. Philip Bahke, Head of the North Rhine-Westphalia Site Network, highlighted the significance of the project in aligning these two important goals. “The successful completion of this project shows that climate protection and competitiveness can go hand in hand,” he said. “The modernized plant sets new standards in energy efficiency and underlines our path toward climate-neutral production.”
Bahke also emphasized that, given the persistently high energy costs, the modernization strengthens the competitiveness of TDI production in Europe. He extended special thanks to the project team, whose dedication ensured the successful execution of the complex modernization while keeping operations running smoothly.
Energy Efficiency: A Key to Sustainable Production
One of the most notable outcomes of the modernization is the substantial improvement in energy efficiency. The newly modernized plant now consumes 80 percent less energy compared to traditional TDI production processes, resulting in a reduction of 22,000 tons of CO2 emissions annually. This reduction is made possible by the installation of a state-of-the-art reactor that captures reaction energy for steam production.
Weighing over 150 tons (330,700 lbs) and standing nearly 20 meters (65.6 feet) high, the new reactor is a critical component in the plant’s energy optimization efforts. The energy generated during the chemical reaction is now effectively harnessed to produce steam, significantly reducing the plant’s overall energy consumption and its environmental footprint.
Covestro Completes Modernization of Dormagen TDI Plant with Enhanced Energy Efficiency
Comprehensive Modernization and Infrastructure Upgrades
The scale of the modernization was impressive, involving extensive upgrades to the plant’s infrastructure. Over 3.5 kilometers of new pipelines were installed, along with approximately 14 kilometers of cables. Additionally, hundreds of new pieces of equipment, valves, and monitoring instruments were integrated into the plant’s systems. These upgrades ensure that the plant is operating at the highest standards of energy efficiency, enabling Covestro to deliver more sustainable products to its customers.
Dr. Christine Mendoza-Frohn, Head of Sales Performance Materials for the EMEA and LATAM regions, discussed the broader impact of these improvements. “In Dormagen, we operate Europe’s largest TDI production plant. With the successful modernization, we can now offer our customers TDI with an even better carbon footprint,” she explained. “This supports our customers in achieving their own sustainability goals and strengthens our position as a reliable partner for climate-neutral and circular solutions.”
Covestro’s Commitment to Global Energy Efficiency Goals
In addition to the plant’s modernization, Covestro also presented its new global energy efficiency targets at the event. The company has set a bold goal of reducing CO2 emissions from energy use by 20 percent per ton of product by 2030, compared to 2020 levels. This initiative forms a key part of Covestro’s strategy to achieve operational climate neutrality by 2035.
The Dormagen TDI plant, with an annual production capacity of 300,000 tons, serves as a prime example of how Covestro is transforming its existing production facilities to meet these ambitious energy efficiency targets. The modernization highlights the company’s commitment to reducing its carbon footprint while enhancing its competitiveness in the global market.
Support from the Federal Ministry for Economic Affairs and Climate Action
Covestro’s modernization efforts at Dormagen have been supported by the German Federal Ministry for Economic Affairs and Climate Action (BMWK) through its federal funding program for energy and resource efficiency. This support was instrumental in driving the project forward and underscores the government’s commitment to promoting sustainable practices in the industrial sector.
A Step Forward in Sustainable and Climate-Neutral Production
The successful completion of the Dormagen TDI plant modernization is just one of the many steps Covestro is taking to improve its sustainability and reduce its environmental impact. The company is committed to continually enhancing its operations to support the transition to a circular economy and to help its customers achieve their own sustainability objectives.
The plant’s improved energy efficiency and reduced CO2 emissions are a testament to Covestro’s ongoing efforts to set new industry standards in sustainability. As part of its broader strategy, Covestro plans to continue implementing energy-saving technologies, reducing emissions, and advancing circular solutions that benefit both its business and the environment.
In conclusion, Covestro’s successful modernization of its Dormagen TDI plant demonstrates its commitment to creating a more sustainable future. With its focus on energy efficiency, CO2 reduction, and supporting customers in their sustainability efforts, Covestro is positioning itself as a global leader in climate-neutral production and circular solutions.
About Covestro:
Covestro is one of the world’s leading manufacturers of high-quality polymer materials and their components. With its innovative products, processes and methods, the company helps enhance sustainability and the quality of life in many areas. Covestro supplies customers around the world in key industries such as mobility, building and living, as well as the electrical and electronics sector. In addition, polymers from Covestro are also used in sectors such as sports and leisure, telecommunications and health, as well as in the chemical industry itself.
The company is geared completely to the circular economy. In addition, Covestro aims to achieve climate neutrality for its Scope 1 and Scope 2 emissions by 2035, and the Group’s Scope 3 emissions are also set to be climate neutral by 2050. Covestro generated sales of EUR 14.2 billion in fiscal year 2024. At the end of 2024, the company had 46 production sites worldwide and employed approximately 17,500 people (calculated as full-time equivalents).
