Ethylene Propylene Rubber Production
EPDM Rubber Production Costs Report | Issue A | Q2 2024
| Report Details |
| 100 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 100 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report analyses the economics of Ethylene Propylene Diene Rubber (EPDM rubber) production from ethylene and propylene in the United States, via a suspension polymerization process using Ziegler-Natta catalyst. Ethylidene norbornene is also used as termonomer to allow vulcanization of the polymer.
The report provides a comprehensive study of EPDM Rubber production and related EPDM Rubber production cost, covering three key aspects: a complete description of the EPDM Rubber production process examined; an in-depth analysis of the related EPDM Rubber plant capital cost (Capex); and an evaluation of the respective EPDM Rubber plant operating costs (Opex).
The EPDM Rubber production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The EPDM Rubber plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The EPDM Rubber plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Polymerization; (2) Purification; and (3) Finishing.
Polymerization. Initially, the monomers are treated and mixed is continuously supplied to a stirred, jacketed reactor, as well as a solution with the catalysts. The reaction occurs substantially in the liquid phase, with an excess of liquid propylene –used as diluent. The rate of polymerization is controlled by the rate of catalyst addition, while temperature control is readily accomplished by controlled evaporation of the propylene. As the polymer is formed, it precipitates out of the reaction medium.
Purification. The slurry is pumped into a vessel, where reaction is terminated and the slurry is mixed with small amounts of toluene and water. The toluene allows that the water extracts the catalyst entrained in the polymer. Subsequently, unreacted monomers and solvent are removed from the catalyst-free polymer slurry in steam strippers containing water as dispersing medium, and are recyled to polymerization reactor.
Finishing. The rubber polymer, present in the form of wet crumbs in water, is fed to a drum with auxiliary agents like anti-agglomerant , so as to ensure that copolymer particles stay suspended and show a reduced tendency to agglomerate. The crumb slurry, with moisture content as high as 90 wt%, is then pumped to a rotary screen where most of the free water is removed. The wet polymer is conveyed through a single screw extruder. While being conveyed through the extruder, water is expelled from the polymer. The extruded dried crumb, containing less than 0.5 wt% of water, is cooled down, baled and packed
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Production Process Information
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the EPDM Rubber production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of EPDM Rubber process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the EPDM Rubber production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different EPDM Rubber plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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