Commodity Production Costs Report

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

Maleic Anhydride Operating Costs & Plant Construction Costs

60 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $799 USD | See Report Editions Prices

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): ?

Maleic Anhydride Production Cost Report Process Schematic

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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 80 Pages | 22 Tables | 9 Images

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  • Operating Cost Summary
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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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
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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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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