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What are the main production routes for propylene and how do their cost structures compare?

Olivier Dupont
Published on 2026-08-29

What are the main production routes for propylene and how do their cost structures compare?
Propylene supply comes from three main routes: steam cracking of naphtha, refinery FCC units, and on-purpose PDH. Naphtha cracking remains cost-sensitive, with naphtha accounting for about 75% of propylene costs and closely tracking crude oil. FCC is the lowest-cost route due to minimal depreciation allocation, but output depends on refinery configuration and product slate. PDH is growing fastest in China — 15 units totaling 7.06 million tons — yet construction is complex and operations demanding. Coal-to-olefins, another route, sees coal costs representing 79% of propylene costs, with consumption now below 7 tons per ton of olefin. During the 14th Five-Year Plan, PDH is expected to overtake FCC as China's second-largest production route, driven by low oil prices and carbon trading pressures on coal-based processes.

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  • Elena Vasquez 2026-08-30 16:43
    Cost competitiveness is shifting. With carbon markets expanding, coal-to-olefins faces rising compliance costs, while PDH benefits from cheap US propane. But PDH margins hinge on propane-propylene spread — currently thin as PP prices near propylene costs, squeezing integrated producers.
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