Evaluation of the environmental impacts related to EPDM rubber production through Life Cycle Assessment

The chemical and petrochemical industry are highly resource-intensive and among the most impactful within the industrial sector, making sustainability a crucial concern. The corporate-driven structure and scale of the industry place corporations as central drivers of change, holding both the power and responsibility to steer a paradigm shift toward a more sustainable future for the sector. In this context, this study evaluates the environmental impacts of Ethylene Propylene Diene Monomer (EPDM) rubber production at Eni Versalis’ Ferrara petrochemical site, using Life Cycle Assessment (LCA), a standardized methodology that evaluates the environmental impacts associated with a product, process or service throughout its entire life cycle. As the first comprehensive analysis of this industrial process, LCA is applied to the production of an EPDM grade in GP27, one of the plants operated by Versalis in Ferrara. Environmental performance was assessed using the LCIA method ReCiPe 2016, using primary data extracted from Versalis’ proprietary systems and modeled using software from the University of Bologna. Key findings indicate that the most significant environmental impacts arise from monomer production and energy consumption. Specifically, ecotoxicity and human toxicity impacts are particularly influenced by the monomer supply chain, while resource depletion and climate change impacts reflect fossil-based raw materials dependence and high energy consumption. Ethylene and propylene production are identified as major contributors across all impact categories. Improvement pathways are discussed, like technological innovations for alternative monomers production and transition to bio-feedstocks and bio-based monomers. A Monte Carlo simulation assessed model robustness, showing overall consistency despite variability in specific impact categories. Sensitivity analysis confirmed electricity sourcing as a key factor, emphasizing the need for low-carbon energy sources.