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Maleic Anhydride Plant Please click on our logo or any link in this presentation to be redirected to our website, or other documentation. Thank You! 17A Marlen Drive Hamilton, NJ USA Tel: (609) Fax: (609)
General Overview Start Up:1970 Shut Down:July 2007 Capacity:15 kmta (starting with benzene) Technology:Benzene oxidation process Upgrades: 8MM invested in 2000
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
General Overview Electricity Natural Gas Water Steam (produced from the exothermic reaction) Benzene or Butane Air Vanadium Catalyst Utilities Consumed:Raw Materials: Maleic Anhydride Products Produced: 1235kWh of electricity 22.5kw of LNG 9 tons of steam 5.7m 3 of demineralized water 9.8kg of Nitrogen Consumption Figures: 11.9 tons of steam 750 kWh through a thermic fluid Production Figures:
Process Description Maleic anhydride is a solid at room temperature, but the plant maintains the process temperature above the 40°C 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). Summary of Operations 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. 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
Process Description Summary of Operations 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 32m 2 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. The oxygen is obtained from air, which is compressed to the reactor pressure of 4 bar with a large 40,000 m 3 /hr Brown Boveri-Sulzer centrifugal compressor with a 1,250 kw electric drive.
Process Description Utilities 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. 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. 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.
Equipment Reactor –78m 3 capacity, 316L Exchanger – A285 grade C shell, (2) A201 grade B plates, (493) A179 tubes Exchanger – 1,750 liter capacity Exchanger – 373.5m 2 capacity, AC (1278) tubes Exchanger – 240m 2 capacity, 316L Exchanger – 316L (2) Exchangers – A285 grade C Sima Exchanger – 373.5m 2, double jacket, A283 grade C shell, A42 C1 inside, A 179 tubes Turbo Compressor – Cast Iron / CS Tank – A42 C1 double jacket, 316L Tank – 35m 3 capacity, 316L Tank – 55m 3 capacity, SS 23 CN 18-10, Salt tank with coil – 42m 3 capacity, A42 C1 Absorption Column – 316L Section 100: