# Isopropanol: Production route

Three ways to make it, from propylene or spare acetone

Source page: https://www.materialinsights.org/chemicals/isopropanol/routes/

What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.

Three routes make IPA. Indirect hydration with sulphuric acid is the oldest and is used by some US producers. Direct hydration of propylene over acid catalysts, gas or liquid phase, is cleaner. Acetone hydrogenation uses surplus acetone from cumene-phenol plants and is common in Asia, including China, Taiwan, Japan and India (Deepak Phenolics). The route mix depends on whether a producer is long propylene or long acetone.

#### Routes compared

| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| **Direct hydration of propylene** | about 45% of global capacity (indicative) | about 0.75 t propylene per t IPA (indicative) | 50-200 kt/yr | about 93-95% on propylene (indicative) | small diisopropyl ether | propylene about 60-70% of cash cost (indicative) |
| **Indirect hydration (sulphuric acid)** | about 20% (indicative) | about 0.75 t propylene; refinery-grade propylene acceptable (indicative) | 100-300 kt/yr (US Gulf) | about 90% (indicative) | spent acid, diisopropyl ether | lower feed cost (refinery-grade propylene), higher energy and corrosion costs |
| **Acetone hydrogenation** | about 35% and rising in Asia (indicative) | about 0.98 t acetone and 0.035 t hydrogen per t IPA (indicative) | 30-150 kt/yr; Deepak Phenolics Dahej about 30 kt (indicative) | above 99% (indicative) | minimal | acetone about 75-85% of cost; viable when acetone is cheap |

#### How each route works
**Direct hydration of propylene**

Propylene and water react over strong acid ion-exchange resin, zeolite or supported phosphoric acid catalysts. Conversion per pass is low, so propylene is recycled.

Cleaner than indirect route; needs high-purity propylene.
 indicative **Indirect hydration (sulphuric acid)**

Propylene is absorbed in concentrated sulphuric acid to form isopropyl sulphates, which are hydrolysed. Acid is reconcentrated and recycled.

Can use cheaper propylene; corrosive and energy-intensive.
 indicative **Acetone hydrogenation**

Acetone from cumene-phenol plants is hydrogenated over copper-chromite, nickel or copper catalysts. Used where acetone is in surplus, since every tonne of phenol makes about 0.6 t acetone.

Simple and flexible; ties IPA to the phenol cycle.
 indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.

## Other sections

- [Summary](https://www.materialinsights.org/chemicals/isopropanol/index.md)
- [Overview](https://www.materialinsights.org/chemicals/isopropanol/overview/index.md)
- [Correlation](https://www.materialinsights.org/chemicals/isopropanol/correlation/index.md)
- [Production](https://www.materialinsights.org/chemicals/isopropanol/production/index.md)
- [Feedstocks](https://www.materialinsights.org/chemicals/isopropanol/feedstocks/index.md)
- [Cycles](https://www.materialinsights.org/chemicals/isopropanol/cycles/index.md)
- [Trading](https://www.materialinsights.org/chemicals/isopropanol/trading/index.md)
- [Movement](https://www.materialinsights.org/chemicals/isopropanol/movement/index.md)
- [Regulation](https://www.materialinsights.org/chemicals/isopropanol/regulation/index.md)
- [Characteristics](https://www.materialinsights.org/chemicals/isopropanol/characteristics/index.md)
- [Emissions](https://www.materialinsights.org/chemicals/isopropanol/emissions/index.md)
- [Relationships](https://www.materialinsights.org/chemicals/isopropanol/links/index.md)