Polyurethanes (MDI, TDI, polyols): Overview
From mattresses to cold-chain insulation
What this tab covers What the chemical is, how big its market is, what it is used for (with shares, volumes, why it wins and what could replace it), and its chain from raw material to end user. Ends with three things to remember.Polyurethanes are a family of polymers made at the point of use by mixing an isocyanate (MDI or TDI) with a polyol. The isocyanates come from benzene or toluene, nitric acid and chlorine-derived phosgene; polyols mostly come from propylene oxide. World MDI demand was about 8.6 Mt in 2025 (faxiangongchang, 2026) and the whole system is about 25 Mt a year (indicative). Five companies hold over 90% of MDI capacity, and Wanhua alone about 30%. India makes no MDI and imports most polyols, so its mattress, appliance and insulation makers depend on Chinese, European and Gulf supply.
Volume about 25 Mt a year of polyurethane raw materials (2025, indicative, basis: MDI demand 8.6 Mt + TDI about 3.3 Mt + polyols about 11 Mt + additives and blowing agents) Market value about $36 billion for the main raw materials (2025, indicative, basis: MDI $18.0 bn and TDI $5.1 bn (faxiangongchang, 2026) plus about 11 Mt polyols x about $1,200/t) Growth MDI demand about 5% a year to 2031 (11.64 Mt by 2031, CAGR 5.13%); TDI market about 5% a year to 2032 faxiangongchang China MDI/polyurethane report, 2026 (MDI demand, MDI and TDI market values, growth); TDI and polyol tonnages and polyol price indicativeKey uses
| Use | Share | Annual volume | Why this commodity | Alternatives |
|---|---|---|---|---|
| Flexible foam (mattresses, furniture, car seats) | 30% | about 7.5 Mtbasis | TDI or MDI with long-chain polyether polyols gives a light, resilient open-cell foam that can be poured in continuous slabs or moulded to shape. Nothing else matches its comfort-to-cost ratio for bedding and seating. indicative share (basis: industry end-use splits) | latex foam spring units polyester fibrefill polyolefin foams |
| Rigid foam (building insulation, refrigerators, cold chain) | 26% | about 6.5 Mtbasis | Polymeric MDI with rigid polyols gives closed-cell foam with very low thermal conductivity, so thinner panels insulate as well as thicker mineral wool or EPS. Rigid foam is about 32% of China's PU revenue (faxiangongchang, 2026). indicative share; China rigid foam share from faxiangongchang 2026 | mineral wool EPS and XPS polystyrene phenolic foam vacuum insulation panels |
| Coatings (floors, industrial, automotive, wood) | 13% | about 3.3 Mtbasis | Aliphatic and aromatic isocyanate hardeners give tough, abrasion and chemical-resistant films that cure at room temperature. indicative share | epoxy coatings acrylics polyaspartics (also isocyanate based) |
| Elastomers and TPU (shoe soles, wheels, hoses, films) | 10% | about 2.5 Mtbasis | Cast and thermoplastic polyurethanes combine rubber-like elasticity with wear resistance. Asia-Pacific held 58.6% of TPU demand in 2025 (faxiangongchang, 2026). indicative share; TPU regional share from faxiangongchang 2026 | rubber thermoplastic elastomers (TPE, TPV) PVC |
| Adhesives and sealants | 8% | about 2.0 Mtbasis | Moisture-curing and two-part PU adhesives bond wood, metal and plastics in shoes, packaging laminates, cars and construction. indicative share | epoxy silicones hot-melt and acrylic adhesives |
| Binders, spandex fibre and other (wood panels, foundry, carpet underlay) | 13% | about 3.3 Mtbasis | MDI binds wood strands into formaldehyde-free OSB and particleboard; MDI with PTMEG makes spandex (elastane) fibre for stretch textiles. indicative share | urea- and phenol-formaldehyde binders rubber elastic |
From raw material to user
- Benzene or toluene MDI needs about 0.62 t benzene per t via aniline; TDI needs about 0.53 t toluene per t (stoichiometric, indicative).
- Nitration and hydrogenation Benzene to nitrobenzene to aniline; toluene to dinitrotoluene to toluenediamine (TDA). TDI uses about 0.72 t nitric acid per t (stoichiometric).
- Phosgenation Chlorine and carbon monoxide make phosgene on site; the amines are phosgenated to isocyanates, releasing about 0.58 t HCl per t MDI and 0.84 t per t TDI (stoichiometric).
- Polyols Propylene oxide (and some ethylene oxide) is added to glycerine, sucrose or glycols; PO makes up about 74-82% of polyol GWP (ISOPA eco-profile, 2021).
- Systems houses and converters Isocyanate and polyol are blended with catalysts, surfactants and blowing agents and reacted in foam lines, moulds or spray rigs.
Made from (commodity table)
Oil Crude oilGas Natural gasNaCl SaltThree things to know
- MDI is an oligopoly: the top five producers hold over 90% of capacity, and Wanhua has 3.8 Mt/yr, about 30% (faxiangongchang, 2026).
- India imported about 500 kt of polyether polyols in 2024 against domestic capacity of about 77 kt/yr (PU Daily, 2025) and has no MDI plant.
- European MDI and TDI carry about 2.8-3.1 t CO2e per t cradle-to-gate, three-quarters of it from aniline or nitric acid and toluene (ISOPA, 2021).