Commodity Production Costs Report
Maleic Anhydride from Butane (Fixed-Bed Reactor + Solvent-Based Recovery)
Maleic Anhydride Operating Costs & Plant Construction Costs
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.
The report provides a comprehensive study of Maleic Anhydride production and related Maleic Anhydride production cost, covering three key aspects: a complete description of the Maleic Anhydride production process examined; an in-depth analysis of the related Maleic Anhydride plant capital cost (Capex); and an evaluation of the respective Maleic Anhydride plant operating costs (Opex).
The Maleic Anhydride production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Maleic Anhydride plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Maleic Anhydride plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Reaction; (2) MAN Recovery; and (3) Purification.
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.
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.
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%.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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
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Other Maleic Anhydride Production Cost Reports
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 | Q3 2024 | 107 pages | Issue B | From $799 USD
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 | Q3 2024 | 107 pages | Issue C | From $799 USD
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 | Q3 2024 | 107 pages | Issue D | From $799 USD
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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 | Q3 2024 | 107 pages | Issue J | From $1,199 USD
Butanediol Production from Maleic Anhydride
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