Covestro wants to put CO pipeline into operation

With the connecting pipeline between Dormagen and Krefeld-Uerdingen, we aim to supplement the existing production system between our sites in North Rhine-Westphalia. This will create a secure, efficient, cross-site raw material network for plastics production. The connecting pipeline will significantly increase the availability of CO for production in Krefeld-Uerdingen and improve the competitiveness of the Rhineland site. This also benefits the downstream industry in North Rhine-Westphalia. At the same time, greenhouse gas emissions from CO production will be reduced by at least 50 percent.

The connecting pipeline is laid on the right bank of the Rhine. The route was subject to the regional planning scheme of the state of North Rhine-Westphalia and thus subject to an intensive assessment of all circumstances and safety aspects. As a result, the pipeline runs as far as possible along existing infrastructure routes such as railways and highways or other pipelines. A large part of the route runs through agricultural land. In some municipalities, the pipeline partly runs near residential areas.

In a complex infrastructure project, adjustments to the plans are generally unavoidable. Most of the changes only arose during construction work. The majority of the requested changes relate to route shifts of a few meters. For example, construction companies had to account for the location of existing power, water, gas, or oil lines or avoid other unexpected obstacles in the ground, and consequently adjust the actual route of the CO pipeline. Ecological considerations, such as the protection of tree stands, also led to changes. Despite prior evaluation of all available plans, their exact locations were not always known. It is standard practice to summarize these minor deviations in a subsequent application.

Long-distance pipelines are the safest and most environmentally friendly means of transport for most liquid and gaseous substances. Carbon monoxide is transported safely via long-distance pipelines worldwide. Covestro uses materials and designs in the construction of the supply pipeline that exceed existing safety standards. For example, the walls of the plastic-coated steel pipes are particularly thick yet still flexible. This protects the pipes from impacts and earthquakes, among other things. The pipes are laid at a depth of 1.40 meters, and in some places even significantly deeper. The legal requirement is only 1.00 meter. The pipeline operates at a maximum pressure of 13.5 bar, though it is designed to withstand up to 100 bar.

Continuous monitoring relies primarily on the following systems: The pressure in the CO pipeline is continuously monitored — any changes would be detected immediately. Multiple leak detection and localization systems are installed along the entire length of the route. A sensor hose system would detect even the smallest amounts of CO via diffusion at an early stage, before any hazard could arise. In addition, both the CO fed into the system and the output volume at the end of the pipeline, as well as temperature and pressure along the pipeline route, are constantly monitored using the model-based mass balance method. The pressure wave method complements the mass balance method and is used for computer analysis to locate the leak based on the pressure wave pattern. Additional measuring devices will be installed, for example, to monitor temperature and pressure along the pipeline.

Even though Covestro does not expect any irregularities in the operation of the CO pipeline, the company has taken extensive precautions to alert and protect residents in the event of malfunction. In fact, several independent safety systems are activated even in the event of the slightest irregularity. If the monitoring equipment reported a malfunction, the pipeline would be immediately shut off via several valves. It can be vented in both directions — toward Dormagen and toward Uerdingen — where the carbon monoxide is safely disposed of. This depressurizes the pipeline. At the same time, a comprehensive alarm and emergency response plan is activated.

The safety concept for the connecting pipeline provides fundamental protection against external influences. The pipeline was laid at a depth of at least 1.40 meters and is monitored technically around the clock. Modern control and leak detection systems continuously monitor the CO flow in real time. In addition, the pipeline is regularly flown over and inspected on foot to detect any irregularities at an early stage.

Carbon monoxide (CO) is not a harmless gas — it can be fatal because it prevents the body from absorbing oxygen. Carbon monoxide is subject to the Hazardous Substances Ordinance. On the other hand, CO is a gas that people live with daily in low concentrations: it is produced when fuel is burned in cars and airplanes, as well as when smoking cigarettes. The key is the safe handling of CO. Covestro has decades of experience with this; carbon monoxide has been used at Covestro sites for just as long. Through this extensive operational experience, with employees specially trained in handling CO, and highly advanced plant technology, Covestro ensures the highest level of safety.

Covestro has always emphasized that the pipeline will only go into operation once all legal and construction requirements for its safe operation have been met. With the decision of the Higher Administrative Court of Münster in January 2025, the planning approval decision for the construction and operation of the pipeline has now become final and legally binding. The remaining work to be performed is clearly defined. However, due to the lengthy duration of the proceedings, these tasks must be tendered again. For environmental protection reasons, the construction work itself can only be carried out within narrow time frames. Finally, the pipeline must undergo final technical acceptance. Covestro is now planning all these steps in detail and will use this as a basis to develop a schedule for the final steps leading up to the pipeline’s commissioning.