Maleic Anhydride Plant

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Maleic Anhydride Plant
Maleic Anhydride Plant
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• 17A Marlen Drive w Hamilton, NJ 08691 w USA Tel
  [phone] w Fax [phone] www.ippe.com

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General Overview

• Start Up 1970
• Shut Down July 2007
• Capacity 15 kmta (starting with benzene)
• Technology Benzene oxidation process
• Upgrades 8MM invested in 2000

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General Overview

• Access to road and rail service with a harbor
  less than 100 km away
• Large quantity of new spare parts
• Process equipment was cleaned with water and is
  currently being kept under a nitrogen pad
• Process area footprint is 100m by 50m and the
  highest structure is about 35m tall
• There are no other chemical facilities located in
  the immediate area

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General Overview
Utilities Consumed
Raw Materials

• Electricity
• Natural Gas
• Water
• Steam (produced from the exothermic reaction)

• Benzene or Butane
• Air
• Vanadium Catalyst

Products Produced
Consumption Figures

• Maleic Anhydride

• 1235kWh of electricity
• 22.5kw of LNG
• 9 tons of steam
• 5.7m3 of demineralized water
• 9.8kg of Nitrogen

Production Figures

• 11.9 tons of steam
• 750 kWh through a thermic fluid

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Process Description
Summary of Operations

• The plant produces 15 kmta of maleic anhydride
  starting with benzene due to a partnership with a
  neighboring coal processing plant which produced
  a benzols stream.
• This process of extracting benzols from the
  benzols stream has been removed from the site.
• The process currently uses benzene reacted with
  oxygen over a vandium catalyst to produce maleic
  anhydride

• Maleic anhydride is a solid at room temperature,
  but the plant maintains the process temperature
  above the 40C melting point to keep the product
  fluid. This process is very efficient regarding
  benzene conversion with only 2 ppm of residual
  benzene remaining (specification is 5 ppm).

• The reaction is highly exothermic, producing 60
  kmta of 18 bar steam.
• The Gillendorf reactor runs at 4 bar pressure and
  is basically a large shell and tube exchanger
  with over 1,000 tubes packed with the vanadium
  catalyst.

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Process Description
Summary of Operations

• The oxygen is obtained from air, which is
  compressed to the reactor pressure of 4 bar with
  a large 40,000 m3/hr Brown Boveri-Sulzer
  centrifugal compressor with a 1,250 kw electric
  drive.

• The 100 section of the plant consists of the
  main reaction oxidation of benzene. It also
  includes the condensation reaction and subsequent
  adsorption of the product into water with a
  packed tower.

• The 200 section of the plant is dehydration
  utilizing a 32m2 Luwa wiped film evaporator.

• The 300 section of the plant vacuum distills
  the crude Maleic Anhydride, removing residual
  impurities and residue. The vacuum is created by
  modern, liquid-ring vacuum pumps.

• The control system for the plant is a relatively
  new Foxboro DCS system with flat screen monitors.

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Process Description
Utilities

• A natural gas-fired hot oil furnace using
  Marlotherm as the heat exchange fluid is used for
  much of the process heating.
• The reactor is cooled with a molten salt system
  circulating 80 metric tons per hour of salt.

• There is a demineralized water system used in the
  adsorption process.
• The system produces a very high quality water
  product due to the requirements for process water
  in the plant.

Environmental, Health Safety

• A stainless steel carbon bed vent adsorption
  system was installed in 2001 to remove all
  benzene and other hydrocarbons from the process
  vents.
• The final vent goes to the atmosphere, with a gas
  chromatograph on the vent stack to detect any
  residual hydrocarbons.

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Process Flow
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Equipment
Section 100

• Reactor 78m3 capacity, 316L
• Exchanger A285 grade C shell, (2) A201 grade B
  plates, (493) A179 tubes
• Exchanger 1,750 liter capacity
• Exchanger 373.5m2 capacity, AC (1278) tubes
• Exchanger 240m2 capacity, 316L
• Exchanger 316L
• (2) Exchangers A285 grade C
• Sima Exchanger 373.5m2, double jacket, A283
  grade C shell, A42 C1 inside, A 179 tubes
• Turbo Compressor Cast Iron / CS
• Tank A42 C1 double jacket, 316L
• Tank 35m3 capacity, 316L
• Tank 55m3 capacity, SS 23 CN 18-10,
• Salt tank with coil 42m3 capacity, A42 C1
• Absorption Column 316L

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Equipment
Section 200

• Evaporator 12m2 capacity, 316L
• Luwa Evaporator 316L
• SMS Tank 800 liter capacity, CS, double jacket,
  
• Sima Tank 30m3 capacity, CS double jacket, 316L
  shell
• (3) Tanks 316L
• (2) Exchangers 316L
• Exchanger A42Cl shell, 316Ti tubes

Section 300

• Exchanger CS shell, 316L tubes/top
• Exchanger NS22 S double jacket, 316L tubes
• Exchanger NSMC shell w/ 316L tubes
• Tank 316L shell and A37S coil
• Distillation Column 316L
• Tank CS double jacket, 316L shell

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Photos
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Photos
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Photos
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Contact Information
MICHAEL JOACHIM DIRECTOR, PLANTS DEPT. Tele 609-838-5930 (direct) Mobile [phone] MichaelJ_at_ippe.com
SANJEEV REGE VP GLOBAL PLANT SALES Tele 609-838-5938 (direct) Mobile [phone] SanjeevR_at_ippe.com