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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:
organic solvent>axeotropic distillation>direct dehydration.
PEP '81 LMR
-
a Report No. 466
MALEIC ANHYDRIDE
SUPPLEMENT B
by LLOYD M. ELKIN
April 1983
A private report by the
PROCESS ECONOMICS PROGRAM
Menlo Park, California 94025
For detailed marketing data and information, the reader is
referred to one of the SRI programs specializing in marketing
research. The CHEMICAL ECONOMICS HANDBOOK Program covers
most major chemicals and chemical products produced in the
United States and the WORLD PETROCHEMICALS Program covers
major hydrocarbons and their derivatives on a worldwide basis.
In addition, the SRI DIRECTORY OF CHRMICAL PRODUCERS services
provide detailed lists of chemical producers by company, prod-
uct, and pXant for the United States and Western Europe.
ii
CONTENTS
1 INTRODUCTION..,.............,...... 1
2 SUMMARY,........,...............
General Aspects . . . . . . . . . Technical Aspects . . . . . . . . General Process Scheme. , . . . Process Features. . . . . . . .
Economic Aspects. . . . . . . . . Process Comparison. . . , . . . Raw Material Prices . . . . . . Uncertainties in Catalyst Costs Steam Credit. . . . . . . . . . Additional Steam Credit . . . . Other Processes . . . . . . . . Capital Cost Estimating Method.
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3 INDUSTRY STATUS . . . . . . . . . . . . . . . . . . . . .
4 CHEMISTRY AND PATENT REVIEW . . . . . . . . , . . . . . .
Chemistry .................... n-Butane Oxidation. .............. n-Butenes Oxidation .............. Benzene Oxidation ............... Maleic Anhydride Hydration and Dehydration. .. Fumaric Acid ..................
Patent Review .................. General Scope ................. Data Reliability. ............... Hydrocarbon Concentration in Reactor Feed ... Catalysts ................... Reactor Design. ................ Reactor Operating Conditions. ......... Conversion, Selectivity, Yield, and Space-Time-Yield. ............... Recovery Procedures .............. Dehydration Methods .............. Final Purification. .............. Stabilizers .................. Treatment of Off-Gas by Incineration or Carbon Adsorption. ..................
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3
3 3 3 4 7 7 10 11 12 12 13 14
15
23
23 23 25 26 28 28 29 29 29 29 30 31 31
32 33 33 33 34
34
iii
CONTENTS
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 ...................
35
35 46 46 46 46 47 47 47 49 49 49 49 50 51
51 52 52 52 52 52
59
59 67 67 67 67 68 68 69
75 75
79
79 80
IV
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CONTENTS
7 (Continued)
. . . 88
. . . 88
. . . 88
. . . 88
. . . 88
. . . 89
. . . 90
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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. ..........
90
91
91
99
99 99 106 106 106
106 106 107 107 108 108
109
115
115 124 124 124 124 125 125 126 126
V
CONTENTS
9 (Continued)
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. . . . . . . . . . .
CITEDREFERENCES.......................
PATENT REFERENCES BY COMPANY.................
127
127 127
133
133 139 139 139 139
140 140
147
151
209
223
Vi
l 5.1
5.2
l 6.1
7.1
8.1
9.1
a 10.1
B.l
a
l
a
ILLUSTRATIONS
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Flow Diagram. . . . . . . . . . *. . . . . . . . . . .
Maleic Anhydride from n-Butane Yield and Productivity Relationship . . . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Flow Diagram......................
Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Flow Diagram......................
Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Flow Diagram. . . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Flow Diagram. . . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Flow Diagram......................
Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Flow Diagram. . . . . . . . . . . . . . . . . . . . . .
Vii
227
48
231
233
237
239
243
245
TABLES
2.1
2.2
3.1
3.2
3.3
3.4
3.5
3.6
4.1
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Summary of Process Conditions . . . . . . . . . . . . . .
Production of Maleic Anhydride (Molten) Cost Comparison . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride Production Capacity Worldwide. . . . .
Maleic Anhydride Plant Capacity in the United States . . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride Plant Capacity in the Americas Outside United States. . . . . . . . . . . . .
Maleic Anhydride Plant Capacity in Western Europe . . .
Maleic Anhydride Plant Capacity in Eastern Europe . . .
Maleic Anhydride Plant Capacity in the Far East and Africa. . . . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride PatentSummary.....................
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration MajorEquipment....................
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Utilities Sunnnary . . . . . . . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration StreamFlows. . . . . . . . . . . . . . . . . . . , . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Oxidation Reactor Conditions. . . . . . . , . . , , , .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Total Capital Investment. . . . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Capital Investment by Section . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Production Costs. . . . . . . . . . . . . . . . . . . .
iX
5
8
16
18
19
20
21
22
168
40
42
43
45
53
54
55
TABLES
5.8
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6;lO
7.1
Oleic Anhydride from n-Butane; Fixed Bed Reactor; Direct Dehydration Direct Operating Costs by Section . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Major Equipment....................
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Utilities Summary . . . . . . . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Stream Flows. . . . . . . . . . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Absorption Column Conditions. . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Total Capital Investment. . . . . . . . . . . . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Capital Investment by Section . . . . . . . , . . . . .
Maleic Anhydride from n-Butane; Fixed Bed Reactor; Organic Solvent Absorber Production Costs. . . . . , . . . . . . . . . . . . . .
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. . . . .
Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Major Equipment . . . . . . . . , . . . . . . . . . . .
57
62
64
65
66
70
71
72
74
77
78
83
X
TABLES
7.2 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Utilities Sumnary . . . . . . . . . . . . . . . . . . .
7.3 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Stream Flows. . . . . . . . . . . . . . . . . . . . , .
7.4 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Oxidation Reactor Conditions. . . . . . . . . . . . . .
7.5 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Total Capital Investment. . . . . . . . . . . . . . . .
7.6 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Capital Investment by Section . . . . . . . . . . . . .
7.7 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Production Costs. . . . . . . . . . . . . . . . . . . .
7.8 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Organic Solvent Absorber Direct Operating Costs by Section , . . . . . . . . . .
7.9 Maleic Anhydride from n-Butane; Fluid Bed Reactor; Direct Dehydration Production Costs. . . . . . . . . . . . . . . . . . . .
8.1 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Major Equipment....................
8.2 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Utilities Summary . . , . . . . . . . . . . . . . . . .
8.3 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Stream Flows. . . . . . . , . . . . . . . . . . . . . .
8.4 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Oxidation Reactor Conditions. . . . . . . . . . . . . .
85
86
87
92
93
94
96
97
102
103
104
105
Xi
8.5 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Total Capital Investment. . . . . . . . . . . . . . . .
8.6 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Capital Investment by Section . . . . . . . . . . . . .
8.7 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Production Costs. . . . . . . . . . . . . . . . . . . .
8.8 Maleic Anhydride from n-Butenes; Fluid Bed Reactor; Direct Dehydration Direct Operating Costs by Section . . . . . . . . . . .
9.1 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Major Equipment. . . . . . . . . . . . . . . . . . . .
9.2 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Utilities Summary . . . . . . . . . . . . . . . . . . .
9.3 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Stream Flows. . . . . . . . . . . . . . . . . . . . . .
9.4 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Oxidation Reactor Conditions. . . . . . . . . . . . . .
9.5 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Total Capital Investment. . . . . . . . . . . . . . . .
9.6 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Capital Investment by Section . . . . . . . . . . . . .
9.7 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Production Costs. . . . . . . . . . . . . . . . . . . .
9.8 Maleic Anhydride from Benzene; Fixed Bed Reactor; Direct Dehydration Direct Operating Costs by Section . . . . . . . . . . .
110
111
112
114
119
121
122
123
128
129
130
132
xii
TABLES
10.1 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Major Equipment . . . . . . . . . . . . . . . . . . . .
10.2 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Utilities Summary . . . . . . . . . . . . . . . . . . .
10.3 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Stream Flows. . . . . . . . . . . . . . . . . . . . . .
10.4 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Total Capital Investment. . . . . . . . , . . . . . . .
10.5 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Capital Investment by Section . . . . . . . . . . . . .
10.6 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Production Costs. . . . . . . . . . . . . . . . . . . .
10.7 Maleic Anhydride from Benzene; Fixed Bed Reactor; Azeotropic Dehydration Direct Operating Costs by Section . . . . . , . . , . .
B.l Maleic Anhydride from n-Butenes in Fixed Bed Reactors Comparison of Reactor Conditions given in Pertinent Patents . . . . . . . . . . . . . . . . . . .
B.2 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Major Equipment . . . . . . . . . . . . . , . . . . . .
B.3 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Utilities Sunnnary . . . . . . . . . . . . . . . . . . .
B.4 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Stream Flows. . . . . . . . . . . . . . . . . . . . . .
B.5 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Total Capital Investment. . . . . . . . . . . . . . . .
135
137
138
142
143
144
146
153
156
157
158
160
Xiii
- ---. -.. _-.. __
TABLES
B.6 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Capital Investment by Section , . . . . . . . . . . . . 161
B.7 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Production Costs. , . . . . . . . . . . . , . . . . . . 162
B.8 Maleic Anhydride from n-Butenes; Fixed Bed Reactor; Direct Dehydration Direct Operating Costs by Section . . . . . . . . . . . 164
xiv
