PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Park, California 94025 Abstract Process Economics Program Report No. 46B MALEIC ANHYDRIDE (April 1983) This study presents preliminary designs and estimated costs of maleic anhydride processes, either commercialized or in the development stage, that use benzene, n-butane, or n-butene feeds, fixed bed or fluid bed reactors, and water or organic-solvent recovery systems. Por- tions of the report also summarize and discuss the patents on maleic anhydride (and associated subjects) that have issued sincew1973. [Report 46Al was issued in 1973.1 In addition, the report includes a section on the present status of the maleic anhydride industry, with a listing of estimated plant capacities, and a section on the chemistry entailed in the various manufacturing processes. The results of the evaluations lead to the following generaliza- tions if the commercial/developmentalstatus of the various processes is disregarded: (1) (2) (3) With n-butane (96 wt%), n-butenes (w90 wt%), and benzene (100 wt%) valued at 16, 17.3, and 21c/lb, respectively, the relative economic attractiveness of processes that are other- wise equivalent is: n-butane>benzene>n-butenes. Fluid bed processes are more attractive economically than fixed bed processes. The relative economic attractiveness of the three recovery systems we have considered is: organic solvent>axeotropic distillation>direct dehydration. PEP '81 LMR
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PROCESS ECONOMICS
PROGRAM SRI INTERNATIONAL
Menlo Park, California
94025
Abstract
Process Economics Program Report No. 46B
MALEIC ANHYDRIDE
(April 1983)
This study presents preliminary designs and estimated costs of
maleic anhydride processes, either commercialized or in the development
stage, that use benzene, n-butane, or n-butene feeds, fixed bed or
fluid bed reactors, and water or organic-solvent recovery systems. Por-
tions of the report also summarize and discuss the patents on maleic
anhydride (and associated subjects) that have issued sincew1973.
[Report 46Al was issued in 1973.1 In addition, the report includes a
section on the present status of the maleic anhydride industry, with a
listing of estimated plant capacities, and a section on the chemistry
entailed in the various manufacturing processes.
The results of the evaluations lead to the following generaliza-
tions if the commercial/developmental status of the various processes
is disregarded:
(1)
(2)
(3)
With n-butane (96 wt%), n-butenes (w90 wt%), and benzene (100 wt%) valued at 16, 17.3, and 21c/lb, respectively, the relative economic attractiveness of processes that are other- wise equivalent is:
n-butane>benzene>n-butenes.
Fluid bed processes are more attractive economically than fixed bed processes.
The relative economic attractiveness of the three recovery systems we have considered is:
5 MALEIC ANHYDRIDE FROM BUTANE; FIXED BED REACTOR; DIRECT DEHYDRATION, ...................
Process Description ................... Process Discussion. ................... Air Compressor K-101. ................. Reactor Entry Temperature ............... Reaction Conditions .................. Yield and Productivity Relationship .......... Steam Generation. ................... Partial Condenser E-201 ................ Absorbers C-201A and B. ................ Dehydration Operations. ................ Distillation Columns. ................. Stabilizer for Molten Maleic Anhydride. ........ Off-G98 Incineration. .................
Capital and Production Costs, .............. Unit Cost of Catalyst, Cost of Initial Catalyst Charge, and Catalyst Life ................ Cost of Special Equipment ................ Oxidation Reactor ................... Air Compressor. .................... Incinerator ...................... Thin Film Evaporator. .................
6 MALEIC ANHYDRIDE FROM n-BUTANE; FIXED BED REACTOR; ORGANIC SOLVENT ABSORBER. ................
Process Description ................... Process Discussion. ................... Choice of Design Patent ................ Oxidation Section ................... Partial Condenser E-201 ................ Solvent Purification. ................. DesignImprovements ..................
Capital and Production Costs. .............. Cost Comparison of Organic Solvent Method with Direct Dehydration. ................... Other Catalysts .....................
7 MALEIC ANHYDRIDE FROM n-BUTANE; FLUID BED REACTOR; ORGANIC SOLVENT ABSORBER. ................
Process Review, ..................... Process Description ...................
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IV
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CONTENTS
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l Process Discussion. ................ Air Compressor Drive. .............. Design Basis for Fluid Bed Reactors ....... Quench Section in Reactor ............ Catalyst Regeneration .............. Absorber Design .................
Capital and Production Costs. ........... Unit Cost of Catalyst, Cost of Initial Catalyst Charge, and Catalyst Life ............. Cost Cases for Recovery by Water Scrubbing Followed by Direct Dehydration ............... Cost Comparison of Organic Solvent Method with Direct Dehydration. ................
8 MALEIC ANHYDRIDE FROM n-BUTENES; FLUID BED REACTOR; DIRECT DEHYDRATION. ...................
Process Review. ..................... Process Description ................... Process Discussion. ................... Reaction Conditions .................. Butene and Butane Conversion. ............. Carbon Monoxide and Carbon Dioxide Mol Ratio in Reactor Effluent .................. Off-Gas Incineration. ................. Additional Beat Recovery. ............... Recovery Method .................... Utilities Consumption .................
Capital and Production Costs. .............. Unit Cost of Catalyst, Cost of Initial Catalyst Charge, and Catalyst Life ................
9 MALEIC ANRYDRIDE FROM BENZENE; FIXED BED REACTOR; DIRECTDERYDRATION ....................
Process Description ................... Process Discussion. ................... Choice of Design Patents. ............... Pressure Drops. .................... Flammability Limits .................. Partial Condenser E-201 ................ Impurities in Crude Maleic Anhydride. ......... Off-Gas Incineration. ................. Benzene in Aqueous Effluent Stream. ..........
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CONTENTS
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Capital and Production Costs. .............. Unit Cost of Catalyst, Cost of Initial Catalyst Charge, and Catalyst Life ................ Cost of Special Equipment ................
10 MALEIC ANHYDRIDE FROM BENZENE; FIXED BED REACTOR; AZEOTROPIC DEHYDRATION. .................
Process Description ................... Process Discussion. ................... Continuous and Batch Distillation Design. ....... Entrainer .......................
Capital and Production Costs. .............. Cost Comparison of Azeotropic Dehydration Method with Direct Dehydration ................. Alusuisse Italia Process. ................
APPENDIX A DESIGN AND COST BASIS. . . . . . . . . . . . . .
APPENDIX B MALEIC ANHYDRIDE FROM N-BUTENES; FIXED BED REACTOR; DIRECT DEHYDRATION. . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Direct Operating Costs by Section . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor (Ralcon Catalyst); Azeotropic Dehydration Rough Estimate of Capital and Production Costs. . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor (Alusuisse Italia Catalyst); Organic Solvent Absorber Rough Estimate of Capital and Production Costs. . . . .