Commodity Production Costs Report

Polychloroprene Production from Butadiene and Chlorine

Neoprene Operating Costs & Plant Construction Costs

50 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

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 then dehydrochlorinated, forming chloroprene. Finally, chloroprene is polymerized to the respective rubber.

The report provides a comprehensive study of Neoprene production and related Neoprene production cost, covering three key aspects: a complete description of the Neoprene production process examined; an in-depth analysis of the related Neoprene plant capital cost (Capex); and an evaluation of the respective Neoprene plant operating costs (Opex).

The Neoprene 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 Neoprene 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 Neoprene 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): ?

Neoprene Production Cost Report Process Schematic

The process under analysis comprises two major sections: (1) Butadiene Chlorination; and (2) Chloroprene Polymerization.

Butadiene Chlorination. In the first step, butadiene, chlorine and recycled butadiene and hydrochloric acid are mixed and fed to the chlorination reactor, where butadiene is chlorinated in the vapor phase. A large excess of butadiene is used to prevent the formation of super chlorinated species during this reaction. The two main products of the chlorination are 1,4-dichloro-2-butene and 3,4-dichloro-1-butene. An isomerization step is used to convert 1,4-dichloro-2-butene into 3,4-dichloro-1-butene (precursor to chloroprene), conducted in the reboiler of a distillation column. Caustic soda is diluted in process water, mixed with the 3,4-dichloro-1-butene stream and fed to a series of continuously stirred vessels. The gaseous chloroprene-rich stream is separated from heavy ends by means of stripping, evaporation and distillation steps.

Chloroprene Polymerization. The Polymerization is comprised of continuously stirred jacketed tank reactors connected in series, cooled by a brine solution. Chloroprene is first mixed with emulsifier, demineralized water and initiators (hydroperoxides/ferrous sulfates). The polymer molecular weight is controlled by means of a chain-transfer agent (tertiary dodecyl mercaptan). The reaction termination is accomplished with the addition of shortstop agents.The latex produced is steam-stripped for the removal of residual chloroprene, recycled. The hot latex is mixed with antioxidant and fed to a freeze roll to be coagulated into a polymer sheet, which is fed to a wash belt for removing polymerization reaction medium. The washed Polychloroprene film is dried in squeeze rolls and continuous-belt dryers. After drying, the film is formed into a rope and cut into polychloroprene chips, packed in bags.

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  • 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
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 90 Pages | 28 Tables | 13 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
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Neoprene 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 Neoprene 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 Neoprene 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 Neoprene 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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