Commodity Production Costs Report

Ethylene Propylene Rubber Production

EPDM Rubber Operating Costs & Plant Construction Costs

100 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $799 USD | See Report Editions Prices

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.

Key reference(s): ?

EPDM Rubber Production Cost Report 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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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • See All Features

 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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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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