PROCESS ECONOMICS PROGRAM

Transcription

1 PROCESS ECONOMICS PROGRAM SRI lnternatlonal Menlo Park, California ABSTRACT Process Economics Program Report 46C MALEIC ANHYDRIDE (October t 989) This study presents designs and economics for the production of maleic anhydride for those processes of current industry importance. Processes which use various reaction systems (i.e., fixed bed, fluid bed, moving bed) are covered. Two types of recovery systems, water or organic solvent, are evaluated in conjunction with the various reactor types. All of the processes covered in the report are commercial, with the exception of the one using a moving bed reaction system. In our studies we have concentrated on processes that use n-butane as a feedstock, since it is becoming the preferred feedstock worldwide. However, for comparison we present one process that uses benzene feedstock. In addition, the report includes a section on the present status of the maleic anhydride industry, with a list of estimated plant capacities, and a section on the chemistry entailed in the various manufacturing processes. Patents issued on maleic anhydride since the last report on the subject, Report 468 issued in April 1983, are discussed. PEP 88 KB

2 Report No. 46C MALEIC ANHYDRIDE SUPPLEMENT C by KATHRYN B. BRYAN October 1989 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMlCAL ECONOMCS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMlCALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI D/RECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe ii

4 1 INTRODUCTION l-l 2 SUMMARY... 2-l ECONOMIC ASPECTS... 2-l TECHNICAL ASPECTS RAW MATERIALS STEAM CREDIT INDUSTRY STATUS MALEIC ANHYDRIDE MARKET AND CONSUMPTION DATA... 3-l 1988 Maleic Anhydride Apparent Consumption Maleic Anhydride End Uses (1988) PRODUCTION AND PLANT CAPACITIES PRICES RAW MATERIALS CHEMISTRY... 4-l n-butane OXIDATION... 4-l BENZENE OXIDATION MALEIC ANHYDRIDE HYDRATION AND DEHYDRATION FUMARIC ACID HYDROCARBON CONCENTRATION IN REACTOR FEED PATENT REVIEW Hydrocarbon Concentration in Reactor Feed Catalysts CONVERSION, SELECTIVITY, AND YIELD MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: PROCESS REVIEW... 5-l PROCESS DESCRIPTION III -

5 CONTENTS 5 MALEIC ANHYDRIDE FROM n-butane; FLUID BED REACTOR; (Continued) PROCESS DISCUSSION Reactor Absorber Design Purification Section Design Materials of Construction CAPITAL AND PRODUCTION COSTS CATALYST COSTS MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR; DIRECT DEHYDRATION... 6-l PROCESS REVIEW... 6-l PROCESS DESCRIPTION... 6-l PROCESS DISCUSSION MA Reactor... 6-l 2 Stabilizer for Molten Maleic Anhydride... 6-l 2 CAPtTAL AND PRODUCTION COSTS... 6-l 2 CATALYST COSTS MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR... 7-l PROCESS REVIEW... 7-l PROCESS DESCRIPTION PROCESS DISCUSSION Reactor and Catalyst Regeneration Butane Recovery Maleic Anhydride Recovery and Purification CAPITAL AND PRODUCTION COSTS Catalyst Costs MALEIC ANHYDRIDE FROM n-butane: FIXED BED REACTOR: DIRECT DEHYDRATION... 6-l PROCESS REVIEW... 8-l PROCESS DESCRIPTION... 8-l - iv -

6 CONTENTS 5 MALEIC ANHYDRIDE FROM n-butane; FIXED BED REACTOR; DIRECT DEHYDRATION (Continued) PROCESS DISCUSSION Reactor Entry Temperature Reactor Conditions Recovery and Purification CAPITAL AND PRODUCTION COSTS... 8-l 3 Unit Cost of Catalyst, Cost of Initial Catalyst Charge, and Catalyst Life Cost Case for Fixed Bed Reactor with Organic Solvent Absorber MALEIC ANHYDRIDE FROM BENZENE; FIXED BED REACTOR; DIRECT DEHYDRATION... 9-l PROCESS REVIEW... 9-l PROCESS DESCRIPTION PROCESS DISCUSSION... 9-l 3 CAPITAL AND PRODUCTION COSTS Unit Cost of Catalyst, Cost of Initial Catalyst Charge, and Catalyst Life COMPARISON OF PROCESS ROUTES TO MALEIC ANHYDRIDE l TECHNICAL ASPECTS l ECONOMIC ASPECTS... 1 o-3 RAW MATERIALS... 1 o-4 STEAM CREDIT Appendix A: PATENT SUMMARY TABLES... A-l Appendix B: DESIGN AND COST BASES... B-l DESIGN CONDITIONS... B-3 COST BASES... B-3 Capital Investment... B-3 Production Costs... B-5 Effect of Operating Level on Production Costs... B-5 Appendix C: CITED REFERENCES... c-1 Appendix D: PATENT REFERENCES BY COMPANY D-l Appendix E: PROCESS FLOW DIAGRAMS E-l -v-

7 ILLUSTRATIONS 5.1 MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR; E MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: PRODUCT VALUE SENSITIVITIES MALEIC ANHYDRIDE FROM n-butane: ,......,... E MALEIC ANHYDRIDE FROM n-butane: PRODUCT VALUE SENSITIVITIES....I MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR m... E-l MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR PRODUCT VALUE SENSITIVITIES,...m...*.,...,.., MALEIC ANHYDRIDE FROM n-butane: FIXED BED REACTOR: DIRECT DEHYDRATION..#...,... E MALEIC ANHYDRIDE FROM n-butane: FIXED BED REACTOR: DIRECT DEHYDRATION PRODUCT VALUE SENSITIVITIES., MALEIC ANHYDRIDE FROM BENZENE: E-l MALEIC ANHYDRIDE FROM BENZENE: PRODUCT VALUE SENSITIVITIES PROCESS COMPARISON AT VARIOUS PLANT CAPACITIES O-l PROCESS COMPARISON BETWEEN FLUID BED (OSA) AND MOVING BED PROCESSES AT VARIOUS BUTANE PRICES O PROCESS COMPARISON BETWEEN FLUID BED (OSA) AND MOVING BED PROCESSES AT VARIOUS STEAM PRICES......, O-14 - vii -

8 TABLES 2.1 PRODUCTION OF MALEIC ANHYDRIDE (MOLTEN) COST COMPARISON I MALEIC ANHYDRIDE PLANT CAPACITY IN THE UNITED STATES , MALEIC ANHYDRIDE PLANT CAPACITY IN THE AMERICAS OUTSIDE THE 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 PATENT SUMMARY (FLUID-BED SYSTEMS)..#...,...,...,...,.. A MALEIC ANHYDRIDE PATENT SUMMARY (FIXED BED SYSTEMS) A MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: DESIGN BASES MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR; OXIDATION REACTOR CONDITIONS ,, MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: MAJOR EQUIPMENT * MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: UTILITIES SUMMARY.,...,..,..,.., MALEIC ANHYDRIDE FROM n-butane; FLUID BED REACTOR; STREAM FLOWS MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: REACTOR COOLING REQUIREMENTS WITH VARIOUS CATALYSTS MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: TOTAL CAPITAL INVESTMENT a...m ix -

9 TABLES MALEIC ANHYDRIDE FROM n-butane; FLUID BED REACTOR; CAPITAL INVESTMENT BY SECTION * MALEIC ANHYDRIDE FROM n-butane; FLUID BED REACTOR; PRODUCTION COSTS I MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR; DIRECT COSTS BY SECTION m MALEIC ANHYDRIDE FROM n-butane; DESIGN BASES MALEIC ANHYDRIDE FROM n-butane: MAJOR EQUIPMENT * MALEIC ANHYDRIDE FROM n-butane: UTILITIES SUMMARY I MALEIC ANHYDRIDE FROM n-butane; STREAM FLOWS.,...,.,...,...,.,..., MALEIC ANHYDRIDE FROM n-butane: TOTAL CAPITAL INVESTMENT..a MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR: DIRECT DEHYDRATlON CAPITAL INVESTMENT BY SECTION,...,... 6-l 5 MALEIC ANHYDRIDE FROM n-butane: PRODUCTION COSTS MALEIC ANHYDRIDE FROM n-butane: FLUID BED REACTOR; DIRECT COSTS BY SECTION MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR DESIGN BASES x-

10 7.2 MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR OXIDATION REACTOR CONDITIONS , m , MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR MAJOR EQUIPMENT.,...,..,a..,..., MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR UTILITIES SUMMARY,...*...,.., MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR STREAM FLOWS m... 7-l MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR TOTAL CAPITAL INVESTMENT MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR CAPITAL INVESTMENT BY SECTION MALEIC ANHYDRIDE FROM n-butane MOVING BED REACTOR PRODUCTION COSTS MALEIC ANHYDRIDE FROM n-butane: MOVING BED REACTOR DIRECT COSTS BY SECTION., MALEIC ANHYDRIDE FROM n-butane: FIXED BED; DIRECT DEHYDRATION DESIGN BASES a...#...* MALEIC ANHYDRIDE FROM n-butane; REACTOR CONDITIONS.,~.,...,...#...,.,,..,.,.., MALEIC ANHYDRIDE FROM n-butane: MAJOR EQUIPMENT.....,, MALEIC ANHYDRIDE FROM n-butane: FIXED BED REACTOR; DIRECT DEHYDRATION UTILITIES SUMMARY..,...,...,..., MALEIC ANHYDRIDE FROM n-butane: STREAM FLOWS a xi -

11 8.8 MALEIC ANHYDRIDE FROM n-butane: TOTAL CAPITAL INVESTMENT MALEIC ANHYDRIDE FROM n-butane; FIXED BED REACTOR; DIRECT DEHYDRATION CAFJITAL INVESTMENT BY SECTION n MALEIC ANHYDRIDE FROM n-butane: FIXED BED REACTOR; DIRECT DEHYDRATION PRODUCTION COSTS m MALEIC ANHYDRIDE FROM n-butane; DIRECT COSTS BY SECTION MALEIC ANHYDRIDE FROM n-butane: FIXED BED REACTOR: PRODUCTION COSTS MALEIC ANHYDRIDE FROM BENZENE: DESIGN BASES MALEIC ANHYDRIDE FROM BENZENE: FIXED BED REACTOR; DIRECT DEHYDRATION OXIDATION REACTOR CONDITIONS I MALEIC ANHYDRIDE FROM BENZENE: RECOVERY MAJOR EQUIPMENT MALEIC ANHYDRIDE FROM BENZENE: FlXED BED REACTOR: DIRECT DEHYDRATION RECOVERY UTlLlTlES SUMMARY MALEIC ANHYDRIDE FROM BENZENE: STREAM FLOWS MALEIC ANHYDRIDE FROM BENZENE; FIXED BED REACTOR; DIRECT DEHYDRATION RECOVERY TOTAL CAPITAL INVESTMENT MALEIC ANHYDRIDE FROM BENZENE: RECOVERY CAPlTAL INVESTMENT BY SECTION xii -

12 TABLES MALEIC ANHYDRIDE FROM BENZENE: RECOVERY PRODUCTION COSTS l 7 MALEIC ANHYDRIDE FROM BENZENE; FIXED BED REACTOR; DIRECT DEHYDRATION RECOVERY DIRECT COSTS BY SECTION SUMMARY OF PROCESS CONDITIONS.,a...,...,...,... 1 O-6 PRODUCTION OF MALEIC ANHYDRIDE (MOLTEN) COST COMPARISON,...,...,...,#...#.,...,... 1 O-6 PRODUCTION OF MALEIC ANHYDRIDE (MOLTEN) PROCESSES USING AN ORGANIC ABSORBER RECOVERY SYSTEM..... lo-10 PRODUCTION OF MALEIC ANHYDRIDE (MOLTEN) PROCESSES USING A DIRECT DEHYDRATION RECOVERY SYSTEM l XIII -