Plasticisers: Production route
How one acid-plus-alcohol reaction makes every plasticiser
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.All mainstream plasticisers are made by esterifying an acid with an alcohol, so the main product types differ by building block. Orthophthalates (DEHP or DOP, DINP, DIDP, DPHP) use phthalic anhydride; terephthalates (DOTP, also called DEHT) use PTA or DMT; cyclohexanoates (DINCH) are hydrogenated phthalates; trimellitates (TOTM) use trimellitic anhydride; adipates, citrates and epoxidised soybean oil are specialty and bio-based options. Producers integrated into 2-EH or isononanol and the anhydride have the lowest cost.
Routes compared
| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| Orthophthalates (DOP/DEHP, DINP, DIDP, DPHP) | over 55% of world use (2020), forecast 50-55% | DOP: 0.38 t phthalic anhydride + 0.67 t 2-EH; DINP: 0.35 t PA + 0.69 t isononanol (stoichiometry) | plants of 50-300 kt/yr; KLJ Silvassa 330 kt/yr (phthalate and non-phthalate) | over 98% on anhydride (indicative) | water; recovered excess alcohol | feedstock about 85-90% of cash cost (indicative) |
| Terephthalates (DOTP/DEHT) | fast-growing share of the non-phthalate 45% (indicative) | 0.43 t PTA + 0.67 t 2-EH (stoichiometry) | plants of 50-200 kt/yr (indicative) | high (indicative) | water | close to DOP; tracks 2-EH |
| Cyclohexanoates (DINCH) and other hydrogenated esters | small (indicative) | DINP plus hydrogen (indicative) | BASF plants in Germany and China (indicative) | not published | none | premium to DINP (indicative) |
| Trimellitates, adipates, polymerics and bio-based (TOTM, DOA, ESBO, citrates) | small | varies | small plants | not published | none | premium; TOTM prices soft as TMA supply improves (ResourceWise) |
How each route works
Orthophthalates (DOP/DEHP, DINP, DIDP, DPHP)Phthalic anhydride from o-xylene oxidation is esterified with 2-ethylhexanol (DOP), isononanol (DINP) or C10 alcohols (DIDP, DPHP). Cheap and versatile. DEHP is restricted in the EU and US for many uses; higher phthalates (DINP, DIDP) are less restricted.
Lowest cost; regulatory pressure on low phthalates.
S&P Global CEH (2021); ICIS (16 Feb 2021, KLJ) Terephthalates (DOTP/DEHT)PTA (or DMT) esterified with 2-EH. Similar performance to DOP without the ortho-phthalate classification; the main replacement in North America and growing in China and India.
Safe-harbour substitute; US anti-dumping cases on imports.
S&P Global CEH (2021); ResourceWise (2025) Cyclohexanoates (DINCH) and other hydrogenated estersDINP-type ester is ring-hydrogenated; BASF's Hexamoll DINCH is the main product, used in toys, medical and food contact.
Strong toxicology profile; costlier.
indicative Trimellitates, adipates, polymerics and bio-based (TOTM, DOA, ESBO, citrates)TOTM from trimellitic anhydride for high-temperature cables and car interiors; adipates for cold flexibility; epoxidised soybean oil as co-stabiliser; acetyl tributyl citrate for medical and toys.
Niche performance and bio content; higher cost.
ResourceWise (2025) Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.