The new compressor operates on the principle of a heat pump. Water vapor is generated during production processes for TDI, a component of flexible foam. Covestro uses steam in many production processes, but the steam produced during TDI manufacturing is not hot enough for those applications. The compressor raises the steam to a higher temperature and pressure level so it can be reused in production.

“Energy efficiency is a key lever for transforming our production towards climate neutrality and a circular economy. The principle is: the less energy we need, the better,” said Thorsten Dreier, CTO of Covestro. “That’s why we’re using every opportunity to make our production even more energy-efficient with modern, innovative process technologies.”

From 2005 to 2022, Covestro reduced its energy consumption by about 40%. By 2030, the company aims to consume 20% less energy per ton of product produced than in 2020.

The project is part of Covestro’s energy efficiency strategy to support its transition toward climate-neutral production. The company said it is continuing to identify additional measures for using waste heat generated in its processes.

“With these projects, we are not only reducing our CO₂ emissions, but also saving on energy costs,” said Andreas Doerfer, global energy excellence manager. “To achieve our energy efficiency target, we must utilize all available options for using the waste heat generated in our processes to manufacture our products.”

Following the installation of an energy-efficient reactor at the TDI plant last year, the new compressor is Covestro’s next major project at the Dormagen site. Construction is scheduled to begin at the end of this year, with the compressor expected to begin operation in mid-2027.