Greater process efficiency for lower CO₂ emissions

New technologies, sustainable materials, renewable energies, and process efficiency are the four levers of the time‑bound action plan with which Röhm aims to reduce CO2e emissions by 30% per ton of product manufactured by 2030.

The conscious and economical use of raw materials and energy resources reduces the burden on the environment. Savings can be reinvested to secure the future. With innovative ideas and technologies, we make our processes more efficient and save energy and water.

Successfully completed process‑efficiency projects from 2025 are already having an impact. They also demonstrate the workforce’s strong sense of responsibility and innovative spirit.

As part of the reconstruction of the sulfuric acid recovery plant – an important unit for the integrated site in Worms, Germany – the fourth and final reactor was converted from heavy fuel oil to natural gas last year. This saves as much CO2e as 3,800 passenger cars emit annually.

In the production of methacrylamide in Worms, Germany, vapor condensates (evaporated liquids that are recondensed) are generated, most of which can be reintegrated into the process. Until now, condensate that could not be kept in the loop was discharged and incinerated. The natural gas required for incineration releases emissions and adds to cost. In this publicly funded project, the excess vapor condensate is reused at the integrated site by mixing it into one dedicated process water stream. This saves energy in the incineration unit and reduces the amount of demineralized water required in the methacrylic acid plant.

Altogether, the measure reduces natural gas consumption by approximately 4,000 MWh per year. This corresponds to the annual heating demand of 200 single‑family homes. CO2e emissions decrease by 750 tons per year.

During product changes or the process start-up phase in Röhm’s molding compound production, off-spec materials are produced that are still valuable – some can be reprocessed, while others are sold for further use. There are also waste streams that must be disposed of at a cost. These include polymer residues contaminated with packaging materials, glass fragments, metal parts, and dust. With the goal of reducing both total waste at Röhm and waste per ton of product produced worldwide by 30% by 2030 compared to 2020, operations, logistics, and sales succeeded in reducing the waste volume from 600 tons to 150 tons.

Production losses cost money and squander valuable resources. At the MMA plant in Shanghai, China, improved control technology and process‑engineering measures significantly increased product yield and reduced the amount of residual waste requiring disposal. The Glacial Methacrylic Acid-producing GMAA plant, in Worms achieved similar results. Changes in operating conditions and technical improvements reduced undesirable side reactions, resulting in lower specific raw material consumption.

The conversion of the off-gas treatment of our resins production in Wesseling, Germany, by replacing the external combustion unit with highly efficient regenerative thermal oxidation (RTO) not only reduced Röhm’s overall power consumption but also CO2e emissions during the external incineration.

As part of a comprehensive, subsidy‑eligible plan for energy‑efficient use of the Innovation Center and other buildings, four photovoltaic systems were installed and have been in operation at the Worms site in Germany since early 2025. The estimated yield of the installed capacity is 350 MWh annually – enough to supply about 100 households with electricity for a year. This is expected to reduce CO2e emissions by around 100 tons annually.

In 2026, additional energy‑efficiency projects are planned – for example, a more efficient combustion‑air supply at Röhm’s site in Wesseling, Germany, which is expected to save 750 MWh annually.