Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 3
ICC - Report ID: 003-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Maleic Anhydride from Butane (Fixed-Bed Reactor + Solvent-Based Recovery)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 003-A,003-B,003-C,003-D,003-E
ICC - Related Reports List: 027-E,253-J
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/003-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Maleic Anhydride</b>. Maleic anhydride is a multifunctional chemical intermediate which find application in many fields of industrial chemistry. It is an important raw material used in the manufacture of polyester resins, lubricant additives, plasticizers, surface coatings, copolymers, and agricultural chemicals. It is produced by vapor-phase oxidation of n-butane (most common route) or benzene. </p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>n-Butane</b>. n-Butane is a saturated hydrocarbon containing 4 carbons, with unbranched structure. It is mainly used for gasoline blending, as a fuel gas and as a feedstock in the production of ethylene and Butadiene. Occurring in natural gas and in crude oil, butane is obtained mainly during the separation of natural gas into its components. The mixture of butane and propane is commercially referred as liquefied petroleum gas (or LPG).</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/003-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Reaction; (2) MAN Recovery; and (3) Purification.</p><p>Reaction. Fresh butane is vaporized and mixed with air before being fed to the reactor. The oxidation reactor consists of a fixed bed multi-tubular reactor containing a vanadium phosphorus-oxide catalyst supported on silica. The heat generated in the highly exothermic reaction is removed by a molten salt circulated through the jacket that surrounds the reactor tubes. The molten salt is then passed through an external cooler and cooled against boiler feed water, producing steam. The reactor exit gas stream is mainly comprised of maleic anhydride, water vapor, carbon oxides, oxygen, nitrogen and unconverted butane. This stream is then partially condensed. The condensate stream is sent to the purification area, while the gas stream is sent to an absorber column for recovery of the remaining MAN.</p><p>MAN Recovery. Uncondensed MAN is recovered by absorption with a solvent. The residual gas (containing mainly nitrogen, CO, CO2 and unreacted butane) is removed by column top. This stream is incinerated in a thermal oxidizer in the offsite facilities . The recovered stream from the bottom of the absorber column is sent to a solvent recovery column, in which MAN is recovered as the distillate. The MAN recovered in this step is mixed with the condensate from the reaction area and then sent to two purification steps for obtaining pure maleic anhydride. The solvent, recovered from the bottom of the solvent recovery column, is returned to the absorption column. A small portion of the solvent stream is sent to a solvent purification step for removal of impurities.</p><p>Purification. The purification area consists of two distillation columns for the removal of light end impurities and heavy end impurities. The final product from purification is MAN with purity >99.8 wt%.</p>
ICC - Short Description: This feasibility study presents an analysis of Maleic Anhydride production from n-butane in the United States using a process similar to the one developed by Huntsman. In this process, maleic anhydride is produced by the partial oxidation reaction of n-butane with oxygen carried out in a fixed-bed reactor, using a vanadium–phosphorus oxide (VPO) catalyst supported on silica. The reactor effluent is directed to a solvent-based recovery system for Maleic Anhydride separation.
ICC - Main Product: Maleic Anhydride
ICC - Plant Capacity: 60.00
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Maleic Anhydride from Butane (Fixed-Bed Reactor + Solvent-Based Recovery)

Maleic Anhydride Production Costs Report | Issue A | Q2 2024

Production Cost Report

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60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 60 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.

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Production Process Information

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

Plant Capital Cost Details

Operating Cost Details

Plant Cost Breakdowns

Plant Capacity Assessment

Process Flow Diagrams

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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Maleic Anhydride production plant examined

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements

Plant Cost Breakdowns

Breakdown of Maleic Anhydride process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Maleic Anhydride production plant studied

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Maleic Anhydride plant capacities

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

Other Maleic Anhydride Production Cost Reports

Maleic Anhydride from Butane (Fixed-Bed Reactor + Solvent-Based Recovery)

This feasibility study presents an analysis of Maleic Anhydride production from n-butane in the United States using a process similar to the one developed by Huntsman. In this process, maleic anhydride is produced by the partial oxidation reaction of n-butane with oxygen carried out in a fixed-bed reactor, using a vanadium–phosphorus oxide (VPO) catalyst supported on silica. The reactor effluent is directed to a solvent-based recovery system for Maleic Anhydride separation.

Details: 60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 60 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Maleic Anhydride from Butane (Two Fixed-Bed Reactors + Aqueous-Based Recovery)

This study presents an economic analysis of Maleic Anhydride production from n-butane in the United States using a process similar to the one developed by Scientific Design. In this process, Maleic Anhydride is produced by the partial oxidation reaction of n-butane with oxygen carried out in two fixed-bed reactors, using vanadium–phosphorus oxide (VPO) catalyst supported on silica. The Maleic Anhydride formed is recovered in an aqueous-based system.

Details: 50 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 50 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Maleic Anhydride Production from Butane (Fluid Bed Reactor)

This report provides the economics of a process similar to CB&I Lummus ALMA for Maleic Anhydride production from n-butane in the United States. The process examined in this report uses a fluid bed reactor. In this case, the recovery system is solvent-based. This process is similar to Lummus ALMA.

Details: 80 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 80 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Maleic Anhydride Production from Benzene

This study provides a techno-economic analysis of a process for Maleic Anhydride production from benzene in the United States. This process highlights a benzene oxidation to maleic anhydride in a fixed-bed reactor combined with an aqueous-based recovery system.

Details: 80 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $799 USD

The cost analyses presented in this report target a 80 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Maleic Anhydride Production from Butenes

This study reviews the economics of a process for Maleic Anhydride production from butenes. In the process examined, Maleic Anhydride is produced by the oxidation of n-butenes with air in a fluidized-bed reactor. The economic analysis performed is based on a plant constructed in the United States.

Details: 60 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue E   From $999 USD

The cost analyses presented in this report target a 60 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Other Related Production Cost Reports

Butanediol Production from Maleic Anhydride

This report presents an economic analysis of 1,4-Butanediol (BDO) production from maleic anhydride in the United States using a process similar to the one proposed by JM Davy. Initially, maleic anhydride is reacted with methanol to produce dimethyl maleate (DMM). The DMM is then hydrogenated to BDO.

Details: 75 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue E   From $799 USD

The cost analyses presented in this report target a 75 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Succinic Acid Production from Maleic Anhydride

This report analyses the economics of a Succinic Acid production from maleic anhydride. In this process, maleic anhydride is first hydrogenated to produce succinic anhydride, which is then hydrated to produce Succinic Acid. The economic analysis presented is based on a plant constructed in the United States.

Details: 30 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue J   From $1,199 USD

The cost analyses presented in this report target a 30 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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