PHTHALIC ANHYDRIDE PROCESS ECONOMICS PROGRAM I. Supplement. June A private report by the STANFORD RESEARCH INSTITUTE I MENLO PARK, CALIFORNIA

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1 Report No. 34A PHTHALIC ANHYDRIDE Supplement A by LLOYD M. ELKIN June 1974 A private report by the PROCESS ECONOMICS PROGRAM I STANFORD RESEARCH INSTITUTE I MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY... 3 General Aspects Economic Aspects... 4 Technical Aspects INDUSTRY STATUS CHEMISTRY Phthalic Anhydride from o-xylene by Vapor Phthalic Anhydride from Naphthalene by Vapor PHTHALIC ANHYDRIDE FROM o-xylene BY AIR OXIDATION IN FIXED BED REACTORS... Review of Patents... Process Description... Process Discussion... Air Compressor... Xylene Injection... Air Preheater... Reactor Design... Steam Pressures... Switch Condensers... Beat Balance... Off-Gas Treatment... Heat Treatment... Distillation System... Maleic Anhydride... Storage... F... Cost Estimates... Capital Costs... Production Costs... SRI Versions of the BASF, Von Heyden, and Rhone-Progil Processes... High Temperature Process Vii

3 CONTENTS 6 PHTHALIC ANHYDRIDE FROM o-xylene BY LIQUID PHASE OXIDATION Review of Patents... Process Description... Process Discussion... Material and Heat Balances... Conversions, Yields, and Yield Structures in Oxidation Reactors... Overall Yield... Water Removal Column and Benzene Adsorber Hydrolyzer... Crystallizer... Acetic Acid Wash Stream... Bleed Stream... Distillation Columns... Material of Construction... Cost Estimates... Capital Costs... Production Costs PHTHALIC ANHYDRIDE FROM NAPHTHALENE BY AIR OXIDATION IN FIXED BED REACTORS Explosive Limits Capital and Production Costs Low-Temperature Oxidation _ High-Temperature Oxidation (3 PHTHALIC ANHYDRIDE FROM o-xylene OR NAPHTHALENE IN FLUID BED REACTORS Review of Patents Capital and Production Costs RECOVERY AND PURIFICATION OF CRUDE PHTHALIC ANHYDRIDE Review of Patents APPENDIX DESIGN AND COST BASIS CITED REFERENCES PATENT REFERENCES BY COMPANY... 1 viii

4 ILLUSTRATIONS 5.1 in Fixed Red Reactors: Low-Temperature Process in Fixed Red Reactors: Low-Temperature Process Effect of Operating Level and on Production Cost Effect of Operating Level and on Production Cost ix

5 TABLES Cost Comparison Summary of Process Conditions for Vapor Phase Processes Summary of Process Conditions for a Liquid Phase Process United States ,.....,..., The Americas Other than the United States..., Western Europe , Eastern Europe Japan Asia, Australia, and South Africa in Fixed Bed Reactors Patent Summary (Catalysts) in Fixed Bed Reactors Patent Summary (Reactor Design) Major Process Equipment and Utilities Summary Stream Flows, Total Capital Investment Production Costs xi

6 TABLES Process Information Process Summary.., Cost Comparison in Fixed Bed Reactors: High-Temperature Process Major Process Equipment and Utilities Summary in Fixed Bed Reactors: High-Temperature Process Total Capital Investment in Fixed Bed Reactors: High-Temperature Process Production Costs Patent Summary, Major Process Equipment and Utilities Summary Stream Flows Process Conditions in Oxidation Reactors Total Capital Investment...., Production Costs.., xii

7 TABLES Phthalic Anhydride from Naphthalene by Air Oxidation in Fixed Bed Reactors Patent Summary (Catalysts) Phthalic Anhydride from Naphthalene by Low-Temperature Oxidation in Fixed Bed Reactors Capital and Production Costs Phthalic Anhydride from o-xylene or Naphthalene in Fluid Bed Reactors Patent Summary (o-xylene Feed) Phthalic Anhydride from o-xylene or Naphthalene in Fluid Bed Reactors Patent Summary (Naphthalene Feed) Phthalic Anhydride from o-xylene or Naphthalene in Fluid Bed Reactors Patent Summary (Reactor Design or Related Subjects) Phthalic Anhydride from Petroleum Naphthalene by a Fluid Bed Process Major Process Equipment Phthalic Anhydride from Petroleum Naphthalene by a Fluid Bed Process Total Capital Investment Phthalic Anhydride from Petroleum Naphthalene by a Fluid Red Process Production Costs Phthalic Anhydride from Coal-Tar Naphthalene by a Fluid Bed Process Production Costs Phthalic Anhydride from o-xylene by a Fluid Bed Process Production Costs Condensation of Phthalic Anhydride Patent Summary Thermal or Chemical Treatment of Crude Phthalic Anhydride Patent Summary xiii

8 TABLES 9.3 Distillation of Phthalic Anhydride Patent Summary.... i Recovery of Phthalic Anhydride from Still Residue Patent Summary Treatment of Off-Gas Patent Summary Miscellaneous Patent Summary xiv