Report No. 46. by PARK L. MORSE. January A private report by the PROCESS ECONOMICS PROGRAM PARK, CALIFORNIA STANFORD RESEARCH INSTITUTE I

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1 Report No. 46 MALEIC ANHYDRIDE by PARK L. MORSE January 1969 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY INDUSTRY STATUS MALEIC ANHYDRIDE FROM BENZENE Chemistry... Review of Processes... Effect of Temperature and Pressure... Catalysts... Reactor Types... Effect of Air to Benzene Ratio... Space Velocity, Yield, Conversion, and Selectivity By-Products... Recovery of Maleic Anhydride (Cr or benzene feed) Dehydration, Purification, and Color Stabilization benzene feed)... Description of Design Case... Discussion of Design Case... Cost Estimates ic; Ar' ' MALEIC ANHYDRIDE FROM n-butane Chemistry Review of Processes Selection of Data for Design Case Description of Design Case Discussion of Design Case Cost Estimates MALEIC ANHYDRIDE FROM C4 OLEFINS... I Chemistry... Review of Processes... Effect of Temperature and Pressure... Catalysts... Reactor Types... Effect of Air to C, Olefin Ratio... Space Velocity, Yield, Conversion, and Selectivity... By-Products... Recovery and Purification of Maleic Anhydride... Description of Design Case iii

3 CONTENTS (continued) Discussion of Design Case Cost Estimates.., MALEIC ANHYDRIDE FROM BUTENE-BUTADIENE FEED Description of Design Case Discussion of Design Case Cost Estimates MALEIC ANHYDRIDE FROM BENZENE--HIGH SPACE VELOCITY CASE Background for Design Case... Description of Design Case... Fixed Capital and Production Costs... Discussion of Results FUMARIC ACID FROM MALEIC ANHYDRIDE... Review of Processes... Industry Status APPENDIX A APPENDIX B APPENDIX C APPENDIX D DESIGN CONDITIONS, COST BASIS AND DEFINITIONS... PHYSICAL DATA... SPECIFICATIONS... HANDLING AND SAFETY CITED REFERENCES... SUPPLEMENTARY REFERENCES iv

4 ILLUSTRATIONS cost Rate Data for Catalytic Oxidation of Benzene to Maleic Anhydride and Carbon Oxides Alternative Purification System (Maleic Anhydride from Benzene) cost Maleic Anhydride from n-butene Maleic Anhydride from Butene cost., Maleic Anhydride from Butene-Butadiene Feed Maleic Anhydride from Butene-Butadiene Feed cost V

5 TABLES Process Costs for Producing Maleic Anhydride... 5 Maleic Anhydride Producers Recent New Plants and Expansions Summary of Processes Recovery of Maleic Anhydride Summary of Processes Dehydration and Purification Summary of Processes Major Process Equipment and Utilities Summary Stream Flows Battery Limits and Utilities Investment Total Capital Investment Production Costs Summary of Processes Major Process Equipment and Utilities Summary Stream Flows Battery Limits and Utilities Investment Total Capital Investment Production Costs Maleic Anhydride from C, Olefins Summary of Processes vii

6 TABLES 6.2 Maleic Anhydride from n-butene Major Process Equipment and Utilities Summary Maleic Anhydride from n-butene Stream Flows Maleic Anhydride from n-butene Battery Limits and Utilities Investment Maleic Anhydride from n-butene Total Capital Investment Maleic Anhydride from n-butene Production Costs Maleic Anhydride from Butene-Butadiene Feed Major Process Equipment and Utilities Summary Maleic Anhydride from Butene-Butadiene Feed Stream Flows Maleic Anhydride from Butene-Butadiene Feed Battery Limits and Utilities Investment Maleic Anhydride from Butene-Butadiene Feed Total Capital Investment..,, Maleic Anhydride from Butene-Butadiene Feed Production Costs......, High Space Velocity Case Utilities Summary High Space Velocity Case Battery Limits and Utilities Investment High Space Velocity Case Total Capital Investment High Space Velocity Case Production Costs Fumaric Acid from Maleic Anhydride Summary of Processes viii

7 1 INTRODUCTION This report describes processes for producing maleic anhydride from four starting materials--benzene, normal butane, normal butenes, and a mixture of 1,3-butadiene and normal butenes. Both low and high space velocity design cases using benzene as feed are evaluated. scopeofthereportwasexpandedtoincludeabriefdiscussiononfumaric The original acid. Information for the study was obtainedonly from patents and general literature sources. Stanford Research Institute did not have access to unpublished process diagrams or plans of any company. None of the process designs developed completely represents the technology of one company. Because the patents reviewed describe only limited parts of a process, it was necessary to use personal judgment to integrate and complete the design. The Institute does not know whether the patents used for the design cases also were the basis for commercial installations. However, it is known that, with the exception of butane, the starting materials studied have been used, or will be used,in the near future, as feedetocks for maleic anhydride plants.

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