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Butadiene: properties, production, applications

Butadiene (1,3-butadiene, divinyl) is the most important representative of diene hydrocarbons and one of the key monomers in the modern petrochemical industry. Its chemical formula is C₄H₆ (CH₂=CH–CH=CH₂), with a molar mass of 54.09 g/mol. Butadiene is the primary monomer used in the modern industrial production of synthetic rubbers. The production of the vast majority of general-purpose synthetic rubbers is based on butadiene.

Physicochemical Properties

1,3-Butadiene is a colourless, flammable, non-corrosive gas with a weak gasoline-like odour. Its melting point is –108.9 °C, and its boiling point is –4.4 °C. The density at boiling point is 0.6211 g/cm³. Butadiene is slightly soluble in water (1 g/L at 20 °C), more soluble in methanol and ethanol, and readily soluble in organic solvents such as cyclohexane. The vapour pressure is 243,180 Pa. The explosive limits are from 2 vol.%. The refractive index is 1.4292.

In terms of chemical properties, butadiene exhibits all the characteristic reactions of alkadienes with conjugated double bonds. It can undergo polymerisation, copolymerisation, and Diels-Alder reactions to form cycloalkanes and cycloalkenes. Butadiene is prone to spontaneous polymerisation; therefore, inhibitors (stabilisers) are added during storage to prevent this process.

Production Methods

Currently, butadiene is obtained from petroleum feedstock by two main methods:

1. Extraction from the C₄ fraction of steam cracking — the most common method. Butadiene is a by-product of ethylene and other olefin production from gases generated during petroleum product pyrolysis. The process involves extractive distillation.

2. Dehydrogenation of butane and butenes — catalytic hydrogen abstraction from C₄ hydrocarbons (n-butane and n-butenes). This method is the main direction in modern butadiene production technology. The dehydrogenation process is carried out at temperatures up to 923–973 K (650–700 °C) using catalysts. A characteristic feature of dehydrogenation reactions is the limitation of conversion by equilibrium conditions; the degree of conversion increases with temperature rise and pressure reduction.

Historically, the first industrial methods for butadiene production were developed by S.V. Lebedev (USSR) — from ethyl alcohol, as well as the Reppe method — from acetylene and formaldehyde (Germany). Later, processes via aldol condensation of acetaldehyde were developed.

Synthetic Rubber Production

Up to 95% of all butadiene produced is used for the production of synthetic rubbers. Based on butadiene, the following are produced:

  • Stereoregular 1,4-cis-polybutadiene rubbers (BR) — possess high abrasion resistance, low heat build-up and crack resistance. Widely used in the tyre industry, especially in truck and passenger car treads.

  • Styrene-butadiene rubbers (SBR) — the most mass-produced general-purpose rubbers.

  • Nitrile-butadiene rubbers (NBR) — special-purpose rubbers with high oil and fuel resistance.

  • Butadiene-methylstyrene and butadiene-methylvinylpyridine rubbers — special grades.

In addition to synthetic rubber production, butadiene is used on an industrial scale for the production of synthetic resins, adiponitrile (in polyamide production) and sebacic acid.

Applications

The main consumer of butadiene rubbers is the production of automotive tyres — over half of all usage. Other applications include:

  • production of high-impact polystyrene and ABS plastics (acrylonitrile-butadiene-styrene);

  • rubber technical products (hoses, belts, gaskets);

  • footwear industry;

  • wire and cable insulation;

  • conveyor belts;

  • paper coatings, artificial turf coatings, carpets, gloves, wetsuits, toys and other consumer products;

  • nylon carpet backing;

  • chemical intermediate (e.g., for fungicides, latex adhesives).

Global Market

The global 1,3-butadiene market shows steady growth. In 2025, the market was valued at USD 37.2 billion, with projections to reach USD 59.4 billion by 2032 at a CAGR of 6.9%. According to other estimates, the market was USD 12.3 billion in 2025 with a projected growth to USD 17.1 billion by 2032 (CAGR 4.8%).

In 2025, global butadiene capacity is expected to reach 20.3 million tonnes per year. Over the past five years, more than 3 million tonnes of new capacity have been added globally. China is the largest producer: by the end of 2025, China's capacity will reach 7.577 million tonnes per year, up 14.16% year-on-year, accounting for approximately 36% of global capacity. The largest producers are Sinopec (over 1.7 million tonnes), PetroChina (over 1.1 million tonnes) and others. Global capacity is projected to grow by 13% by 2029 compared to 2024, with the production centre continuing to shift from west to east.

In Russia, butadiene is produced by PJSC Nizhnekamskneftekhim (a unit with a capacity of 89,300 tonnes per year has been commissioned), as well as as part of SIBUR's EP-600 complex with a capacity of 88,000 tonnes of butadiene per year.

The main market growth driver is the expansion of automotive production and the growing demand for high-performance tyres. The development of electric vehicles creates new opportunities: the tyre replacement cycle for EVs is shorter due to increased wear, and synthetic rubber is more suitable for EVs due to its high resistance. Bio-based butadiene production technologies from renewable sources (biomass or sugars) are also being actively developed.

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