The main isocyanates are the aromatic products toluene diisocyanate (TDI) and methylene diphenyl diisocyanate (MDI). Both products undergo a series of complex manufacturing stages: the starting point for TDI is Toluene and nitric acid, which thereafter undergoes phosgenation (COCl2) reactions as well as distillation to arrive at the final range of TDI isomers. MDI starts with benzene and nitric acid, and via aniline and Formaldehyde reactions is also subsequently phosgenated to the final mix of isomers, which are distilled to the desired series of end-products. Both products are used in the polyurethane chemistry by reaction with polyols, to produce a wide range of flexible and rigid foams, and elastomers, adhesives and coatings. Global capacity for TDI in 2004 is some 2.2 million tpa, and for MDI is over 3 million tpa, with significant expansions planned for both products notably in Asia. In both cases the processes generate significant quantities of Hydrochloric Acid, which must find a commercially viable outlet as part of the overall production economics.
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