# EPDM: Production route

Solution, slurry or gas phase: three ways to make it

Source page: https://www.materialinsights.org/chemicals/epdm/routes/

What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.

EPDM is made by copolymerising ethylene and propylene with a diene. The main technologies differ in reactor and catalyst. Solution processes in hexane are the most common. Slurry processes polymerise in liquid propylene. Gas-phase processes avoid solvent. Older plants use vanadium Ziegler-Natta catalysts; newer ones use metallocene or constrained-geometry catalysts (Dow Nordel, Arlanxeo Keltan ACE) that give tighter control and lower energy. Grades are defined by ethylene content, ENB level and Mooney viscosity.

#### Routes compared

| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| **Solution polymerisation** | about 75-80% (indicative) | about 0.6 t ethylene, 0.33 t propylene, 0.07 t ENB (typical grade, indicative) | 50-200 kt/yr lines | over 95% on monomers after recycle (indicative) | none material; solvent recycled | monomer cost about $900/t at late-2025 Asian prices (0.6 x ethylene $700s/t + 0.33 x propylene $700s/t + 0.07 x ENB about $3,000/t, indicative) plus about $400-600/t conversion (indicative) |
| **Slurry (suspension) polymerisation** | about 10-15% (indicative) | similar monomer ratios (indicative) | 50-100 kt/yr | not published | none | lower energy than solution (indicative) |
| **Gas-phase polymerisation** | about 5-10% (indicative) | similar, plus carbon black flow aid (indicative) | about 100 kt/yr | not published | none | low energy (indicative) |

#### How each route works
**Solution polymerisation**

Ethylene, propylene and ENB are dissolved in hexane and polymerised with vanadium or metallocene catalysts at moderate pressure. The polymer solution is steam-stripped or devolatilised, then dried and baled. Used by Dow, ExxonMobil, Arlanxeo, Mitsui and Kumho (indicative).

Flexible grades; high steam use for solvent removal.
 ethylene and propylene tiles (ChemOrbis Dec 2025); indicative **Slurry (suspension) polymerisation**

Monomers are polymerised in liquid propylene, which acts as both reactant and diluent, removing the need for hexane. Used by Versalis (Dutral) (indicative).

Less energy; narrower grade range.
 indicative **Gas-phase polymerisation**

Monomers are polymerised in a fluidised bed with carbon black as a flow aid, giving granular EPDM without solvent. Developed by Union Carbide, now Dow (Nordel MG) (indicative).

No solvent; product contains carbon black.
 indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.

## Other sections

- [Summary](https://www.materialinsights.org/chemicals/epdm/index.md)
- [Overview](https://www.materialinsights.org/chemicals/epdm/overview/index.md)
- [Correlation](https://www.materialinsights.org/chemicals/epdm/correlation/index.md)
- [Production](https://www.materialinsights.org/chemicals/epdm/production/index.md)
- [Feedstocks](https://www.materialinsights.org/chemicals/epdm/feedstocks/index.md)
- [Cycles](https://www.materialinsights.org/chemicals/epdm/cycles/index.md)
- [Trading](https://www.materialinsights.org/chemicals/epdm/trading/index.md)
- [Movement](https://www.materialinsights.org/chemicals/epdm/movement/index.md)
- [Regulation](https://www.materialinsights.org/chemicals/epdm/regulation/index.md)
- [Characteristics](https://www.materialinsights.org/chemicals/epdm/characteristics/index.md)
- [Emissions](https://www.materialinsights.org/chemicals/epdm/emissions/index.md)
- [Relationships](https://www.materialinsights.org/chemicals/epdm/links/index.md)