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Maleic Anhydride Plant

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Presentation on theme: "Maleic Anhydride Plant"— Presentation transcript:

1 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 w Hamilton, NJ w USA Tel: (609) w Fax: (609)

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

3 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

4 General Overview Utilities Consumed: Raw Materials:
Electricity Natural Gas Water Steam (produced from the exothermic reaction) Benzene or Butane Air Vanadium Catalyst Consumption Figures: Products Produced: 1235kWh of electricity 22.5kw of LNG 9 tons of steam 5.7m3 of demineralized water 9.8kg of Nitrogen Maleic Anhydride Production Figures: 11.9 tons of steam 750 kWh through a thermic fluid

5 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 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). 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.

6 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.

7 Environmental, Health & Safety
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.

8 Process Flow

9 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

10 Equipment Section “200”: Section “300”:
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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14 Contact Information MICHAEL JOACHIM DIRECTOR, PLANTS DEPT. Tele: (direct) Mobile: SANJEEV REGE VP GLOBAL PLANT SALES Tele: (direct) Mobile:

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