Covestro modernising TDI plant in Germany

Leverkusen, Germany – Covestro AG is investing a ‘double-digit-million euro’ amount in modernising its TDI (toluene diisocyanate) production facility in Dormagen, Germany.

The investment will strengthen the sustainability and competitiveness of TDI production for the manufacture of flexible foams in Europe, Covestro announced 5 Dec.

With phase I already completed and more measures set for completion in 2025, the modernisation aims to “significantly improve” the plant's energy-efficiency and cut CO2 emissions.

Once the project is fully completed, the plant is expected to consume up to 80% less energy than conventional processes for the production of TDI.

Greenhouse gas emissions, the German manufacturer added, will be reduced by 22 kilotonnes per annum (ktpa).

The move, it said, will further Covestro’s climate achievements, safeguard Europe TDI production amid rising energy costs and improve sustainability performance of customers.

With an annual capacity of 300ktpa, the Dormagen facility is claimed to be the largest TDI production plant in Europe.

Operational since 2015, the facility is also considered “one of the most advanced" TDI plants in the world” due to its use of Covestro's gas-phase technology.

The process involves reacting toluene diamine and phosgene  “as early as the gaseous state phase”, rather than in later process steps as liquids.

This, according to Covestro, can save up to 60% in energy-consumption and 80% in use of solvents, compared to conventional processes.

Dormagen plays “a central role” in the reliable supply to customers in the region, according to Dr Christine Mendoza-Frohn, head of performance materials sales EMEA and LATAM.

The investment, she added, underlines Covestro’s commitment to the European market and enables customers to further reduce their indirect CO2 emissions.

"We want to continue to grow in Germany and drive forward the transformation to climate-neutral production,” said Thorsten Dreier, chief technology officer.

Nevertheless, he added, the general conditions, especially high energy prices, are making it increasingly difficult for Covestro to make such investments.

Dreier called on policy-makers to take effective measures to restore Germany's competitiveness in terms of energy prices and ensure a reliable basis for the climate-neutral transformation of industry."