Production Cost Report
cr-e21a
Polychloroprene
Polychloroprene Production
(1) "Chloroprene", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition (2) "Polychloroprene", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition

This report presents an up-to-date, detailed cost analysis of Chloroprene Rubber (also known as Polychloroprene) production from butadiene and chlorine. The process examined is a typical vapor phase butadiene chlorination process, followed by a typical emulsion polymerization process. In this process butadiene is first chlorinated producing two chlorinated isomers, 1,4-dichloro 2-butene and 3,4-dichloro 1-butene. In a second step, 1,4-isomers are isomerized to 3,4-dichloro 1-butene. This chemical is then dehydrochlorinated in the presence of caustic soda producing chloroprene and sodium chloride. Finally, chloroprene is polymerized to form Polychloroprene.
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CR E21A
This study provides an economic analysis of Polychloroprene production starting from butadiene and chlorine, based on a plant located in the United States. In the first step, butadiene is chlorinated, generating dichlorobutenes, which are subjected to an isomerization to convert them to 3,4-dichloro-1-butene. It is undergoes an hydrochlorination, forming chloroprene. Finally, chloroprene is polymerizated the respective rubber.

Polychloroprene Production

Cost Analysis Report | CR E21A

Production Cost Report

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Report Basis:   United States   |   2019 Q1   |   106 pages   |   Buy  From

This report presents a cost analysis of a United States-based industrial plant. You can add an extra cost analysis, for another plant location (country), during the order process.

This report presents an up-to-date, detailed cost analysis of Chloroprene Rubber (also known as Polychloroprene) production from butadiene and chlorine. The process examined is a typical vapor phase butadiene chlorination process, followed by a typical emulsion polymerization process. In this process butadiene is first chlorinated producing two chlorinated isomers, 1,4-dichloro 2-butene and 3,4-dichloro 1-butene. In a second step, 1,4-isomers are isomerized to 3,4-dichloro 1-butene. This chemical is then dehydrochlorinated in the presence of caustic soda producing chloroprene and sodium chloride. Finally, chloroprene is polymerized to form Polychloroprene.

This report, CR E21A, is a best-in-class examination of Polychloroprene production, providing in-depth, comprehensive techno-economic analysis of the production technology examined, including:

  • Process Description: raw materials and utilities consumption, products generation, labor requirements, list of equipment, characterization of site infrastructure, process flow diagram (PFD).
  • Capital Cost Analysis: costs of plant construction, working capital, owners' costs, commissioning, start-up and contingency.
  • Operating Cost Analysis: variable costs, fixed costs (salary, benefits & maintenance) and corporate overhead costs.
  • And much more . . .

Key reference(s): (1) "Chloroprene", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition (2) "Polychloroprene", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition

Report Content

Key Process Information

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Assessment presenting relevant technical coefficients, accompanied by process description:

  • Raw materials consumption
  • Products generation
  • Labor requirements
  • Main process units description
  • Site infrastructure description
  • Block Flow Diagram

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Capital Cost Analysis

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Analysis depicting all costs involved in starting a new industrial plant (capital investment):

  • Cost of construction
    (main process units, infrastructure, contingency)
  • Additional owner’s costs
  • Working capital
  • Plant commissioning and start-up

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Utilities Consumption

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Detailed assessment of utilities consumption:

  • Utility consumption rates per unit of product generated.
  • Share of each utility in the total utility costs.

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Operating Cost Analysis

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Analysis depicting all costs surrounding the production of chemical:

  • Raw materials acquisition & utilities generation (variable manufacturing costs)
  • Labor wages, maintenance, operating charges, overhead, taxes and insurance (fixed manufacturing costs).
  • Corporate overhead costs

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Implementation Schedule

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Preliminary project implementation schedule, encompassing:

  • Basic Engineering
  • Detailed Engineering
  • Procurement
  • Construction
  • Plant Start-up

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Capacity Analysis

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Analysis of process economics for alternative plant capacities:

  • Plant costs of construction
  • Working capital
  • Variable and fixed operating costs
  • Depreciation
  • Corporate overhead

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Process Flow Diagram

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Schematic representation of relevant process operations:

  • Main process streams
  • Main pieces of equipment
  • Main utilities consumed

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Construction Cost Details

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  • Process unit (ISBL): cost for each functional unit (e.g. distillation, reaction, evaporation)
  • Infrastructure (OSBL): cost for each storage facility, utility facility and auxiliary facility
  • Costs for plant construction, per discipline

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Included Content:

Key Process Information

  • Raw materials consumption
  • Block Flow Diagram
  • Technology Readiness

Capital Cost Analysis

  • Costs of construction (process units, infrastructure, contingency)
  • Working capital, owners' costs, commissioning and start-up

Operating Cost Analysis

  • Fixed and variable costs
  • Overhead

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All Basic Content Plus:

Capacity Analysis

  • Capital and operating costs breakdown for different plant capacities

Pricing Basis

  • Main prices considered in the analysis (raw materials, by-products, utilities)

Utilities Consumption

  • Breakdown presenting utility consumption rates (steam, cooling water, electricity, etc.)

Implementation Schedule

  • Schedule including duration of major project phases

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 Updated with 2019 Q1 Data

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All Extended Content Plus:

Process Flow Diagrams

  • Schematic representation of relevant operations of the process, indicating main process streams, equipment and utilities.

Construction Cost Details

  • Breakdown of process unit (ISBL) costs
  • Breakdown of infrastructure (OSBL) costs
  • Plant construction cost breakdown per discipline (bare equipment, equipment setting, piping, civil, steel, instrumentation & control, etc)

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 Updated with 2019 Q1 Data

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Each Intratec report targets a specific production process, and is available in three different versions: basic, extended and advanced.

The basic version describes the industrial plant, including main process units and site infrastructure, and presents an independent analysis of capital and operating costs.

For those needing more in-depth, comprehensive analyses, Intratec offers the extended and the advanced versions.

The extended version includes everything of the basic version plus an extra appendix, in which it is presented the following analyses: Economics of Different Capacities; Utilities Consumption Breakdown; Construction Implementation Schedule.

Finally, the advanced version includes everything of the extended version plus another extra appendix, in which it is presented: Process Unit Cost Breakdown per Equipment; Infrastructure Cost Breakdown per Equipment; Plant Construction Cost Breakdown per Discipline; Process Flow Diagrams.

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I need an economic analysis, like the one presented in the report, but for another plant location… could you provide me that?

Yes! For each report, Intratec Offers an optional analysis called "Cost Analysis in Another Location" Intratec offers, for each report, an optional analysis called “Cost Analysis in Another Location”, which presents capital and operating costs of an industrial plant identical to the one discussed in the report but located in a country selected by you.

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