Maleic Anhydride

99/00-5 June 2000

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TABLE OF CONTENTS Page

I EXECUTIVE SUMMARY A. INTRODUCTION B. TECHNOLOGY 1. Benzene-Based Systems 2. n-Butane-Based Systems 3. Alternative Recovery Systems C. ECONOMICS D. APPLICATIONS E. GLOBAL SUPPLY/DEMAND 1. Demand 2. Supply 3. Trade CURRENT COMMERCIAL TECHNOLOGY A. INTRODUCTION 1. Overview 2. Discussion B. CHEMISTRY 1. Properties of Maleic Anhydride 2. Chemistry of Maleic Anhydride Production C. PROCESS DESCRIPTIONS 1. Benzene-Based Systems (a) Overview (b) Process Technology (1) Reaction Section (2) Product Recovery Section (3) Purification Section 2. n-Butane-Based Systems (a) Overview (b) Fixed Bed Technology (1) Reaction Section (2) Product Recovery Section (3) Purification Section (4) Discussion (c) Fluid Bed Technologies (1) Reaction Section (2) Product Recovery Section (3) Purification Section (4) Discussion (d) Transport Riser-Bed Technology (1) Reaction Section 1 1 2 2 3 4 5 7 7 7 9 9 12 12 13 14 18 18 20 23 23 23 24 24 28 28 29 29 30 32 33 34 34 35 38 38 39 39 40 43

II

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TABLE OF CONTENTS (Continued) Page

(2) Product Recovery Section (3) Purification Section (4) Discussion (e) Offgas Recycle 3. Alternative Recovery Systems (a) Continuous (UCB) Aqueous Recovery System (b) Solvent Recovery Systems (1) ALMA Non-Aromatic Solvent System (2) Huntsman System (3) SISAS S.p.A./CONSER S.p.A. 4. Summary ECONOMIC ANALYSIS 1. Basis (a) Pricing Basis (b) Investment Basis (c) Cost of Production Basis 2. Investment 3. Production Costs 4. Sensitivity Analysis (a) Feedstock Costs (b) Operating Rate (c) Investment 44 44 45 45 47 47 50 50 50 52 55 56 56 56 56 57 58 61 68 68 68 74 76 76 76 78 79 80 82 84 91 91 91 91 91

D.

III

DEVELOPING TECHNOLOGY A. CATALYST DEVELOPMENTS 1. Introduction 2. BP Amoco 3. Lonza (ALMA) Fluid-Bed Catalyst 4. Mitsubishi B. USE OF PURE OXYGEN INSTEAD OF AIR IN MAN PRODUCTION C. ECONOMICS COMMERCIAL ANALYSIS A. APPLICATIONS 1. Unsaturated Polyester Resins 2. Fumaric, Malic, and Succinic Acids (a) Fumaric Acid

IV

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(1) Papermaking (2) Animal Feed (3) Unsaturated Polyester Resins (4) Alkyd Resins (5) Other Uses (b) Malic Acid (c) Succinic Acid 3. Lubrication Oil Additives 4. Agricultural Chemicals 5. Styrene Copolymers and Other Polymers (a) Styrene Maleic Anhydride (b) Olefin Copolymers (c) Maleic Anhydride Grafted Copolymers (d) Other Polymers (1) Bis-Maleimide Resins (2) Polybutadiene/Maleic Anhydride Adducts (3) Ethylene Vinyl Acetate - Maleic Anhydride Terpolymers (Ultrathene) (4) N-Phenylmaleimide (5) Other Polymeric Uses 6. Other Uses (a) 1,4-Butanediol/THF/gamma-Butyrolactone/NMP (b) Detergents (c) Aspartic Acid GLOBAL SUPPLY/DEMAND 1. Demand 2. Supply 3. Trade 93 93 94 95 95 96 6 97 97 97 97 98 99 99 100 100 101 101 101 102 102 103 104 104 104 105 105 111 112 113 118 123

B.

REFERENCES APPENDICES APPENDIX I APPENDIX II PERP TITLE INDEX

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TABLES Page
Table I.C.1 Table I.E.1 Table II.A.1 Table II.B.1 Table II.B.2 Table II.B.3 Table II.C.1 Table II.C.2 Table II.C.3 Table II.C.4 Table II.C.5 Table II.C.6 Table II.D.1 Table II.D.2 Table II.D.3 Table II.D.4 Table II.D.5 Table II.D.6 Table II.D.7 Table II.D.8 Table II.D.9 Table II.D.10 Maleic Anhydride Process Options Global Maleic Anhydride Demand Comparison of MAN Reactor Technology Properties of Pure Maleic Anhydride Typical Maleic Anhydride Specifications Properties of Maleic and Fumaric Acids Specifications of Nitration-Grade Benzene Huntsman Reference List Scientific Design Recent Reference List Lonza Reference List for Fixed-Bed Plants ALMA Reference List Maleic Anhydride Process Options Price and Utilities Basis U.S.G.C. Invest Cost Summary for Maleic Anhydride Plant Employing Fixed Bed Reactor and Solvent Recovery System U.S. Gulf Coast Maleic Anhydride Plant Capital Investment Cost of Production Estimate for: Maleic Anhydride Process: Benzene Fixed Bed Cost of Production Estimate for: Maleic Anhydride Process: n-Butane Feed Fixed Bed/Aqueous (Batch) Recovery Cost of Production Estimate for: Maleic Anhydride Process: n-Butane Feed Fixed Bed/Solvent Recovery Cost of Production Estimate for: Maleic Anhydride Process n-Butane Feed Fluid Bed/Aqueous Recovery Cost of Production Estimate for: Maleic Anhydride Process: n-Butane Feed Fixed Bed/Solvent Recovery Cost of Production Estimate for: Maleic Anhydride Process: n-Butane Feed Transport Bed/Solvent Recovery Cost of Production Estimate for: Maleic Anhydride Process: n-Butane Feed Fixed Bed/Solvent W/C4 Recovery Comparison of Fluid-Bed Reactor Performance Data from Patent 4,987,239 Cost of Production for: Maleic Anhydride Process: n-Butane Feed Fixed Bed/Solvent Recovery Latest Amoco Catalyst 5 9 16 19 19 20 27 31 32 32 35 55 56 59 60 62 63 64 65 66 67 69 82 84

Table III.A.1 Table III.B.1 Table III.C.1

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TABLES (Continued) Page

Table III.C.2 Cost of Production for: Maleic Anhydride Process: n-Butane Feed Fixed Bed/Solvent Recovery Latest Lonza Catalyst Cost of Production Estimate for: Maleic Anhydride Process: n-Butane Feed Fluid Bed/Solvent Recovery W/C4 Recycle - Latest Mitsubishi Catalyst/Use of O2 Global Maleic Anhydride Demand Maleic Anhydride Capacity, 1999

86

Table III.C.3

88 105 106-108

Table IV.B.1 Table IV.B.2

Appendix Tables: Table A1 Man Fixed-Bed Reactor Process - Equipment Specification and Cost Estimate Reaction Section Table A.2 Man Fixed-Bed Reactor Process - Equipment Specification and Cost Estimate Purification Section Table A.3 Man Fixed-Bed Reactor Process - Equipment Specification and Cost Estimate Adsorption Section Table A.4 Man Fixed-Bed Reactor Process - Equipment Specification and Cost Estimate Incineration Section Table A.5 Man Fixed-Bed Reactor Process - Equipment Specification and Cost Estimate Storage

113 114 115 116 117

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FIGURES Page
Figure I.C.1 Figure I.D.1 Figure I.E.1 Figure I.E.2 Figure II.B.1 Figure II.C.1 Figure II.C.2 Figure II.C.3 Figure II.C.4 Figure II.C.5 Figure II.C.6 Figure II.C.7 Figure II.C.8 Figure II.D.1 Figure II.D.2 Figure II.D.3 Figure II.D.4 Figure II.D.5 Figure II.D.6 Figure III.A.1 Figure III.C.1 Figure III.C.2 Figure IV.A.1 Figure IV.B.1 Figure IV.B.2 Maleic Anhydride Production Costs Maleic Anhydride End Use Pattern Global Maleic Anhydride Capacity, 1999 Global Maleic Anhydride Trade Routes to Maleic Anhydride Derivatives Maleic Anhydride Fixed Bed Process Reaction Section Maleic Anhydride Aqueous Recovery and Purification ALMA Process Flow Diagram Maleic Anhydride DuPont Process Reaction/Recovery Conser (Pantochim) Maleic Anhydride Process Maleic Anhydride UCB Aqueous Recovery & Purification System Huntsman (Monsanto) MAN Solvent Recovery System Sisas Solvent Recovery Process Flow Diagram Maleic Anhydride Production Costs Price History - n-Butane and Benzene Maleic Anhydride Production Costs Maleic Anhydride Economics Sensitivity to Butane Price Maleic Anhydride Economics Sensitivity to Operating Rate Maleic Anhydride Economics Sensitivity to Investment Maleic Anhydride Fluid Bed Process with Recycle using Oxygen MAN Economics using Pure Oxygen - Sensitivity to Oxygen Price Developmental Maleic Anhydride Process Production Costs Maleic Anhydride End Use Pattern Global Maleic Anhydride Capacity, 1999 Global Maleic Anhydride Trade 6 8 10 11 21 25 26 37 42 46 48 51 54 70 71 72 73 74 75 81 89 90 92 109 110

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