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Chapter 2 Process Selection & Description
Chapter 2 Process Selection & Description
In this section we will discuss different methods to produce maleic anhydride and will select
the most suitable process for its production. Process for the manufacturing of MA is selected on
the basis of reactants to be oxidized for the production of MA.
2. By oxidation of Butane
Recent processes for the manufacture of maleic anhydride employ C4 hydrocarbons, such as
n-butane and n-butylene, as feedstock. Even existing processes originally using benzene as a
reactant are being converted to the C4 hydrocarbons due to the reasons:
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Chapter 2 PROCESS SELECTION AND DESCRIPTION
For all of these reasons, the n-butane process has been the only MA route that is mostly using
commercially.
Following are the type of catalysts that are being using in oxidation of butane:
But in 90% reactions, VPO catalyst is being using because of its following advantages over other
catalysts:
Several routes may be used to prepare the catalyst but the route favored by industries involves
the reaction of vanadium (V) oxide and phosphoric acid to produce vanadium-phosphorus-oxide.
The reaction of V2O5 with H3PO4 to form VOHPO4.0.5H2O can be carried out an aqueous or
organic medium such as isobutyl alcohol. The two possible routs are as follow:
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Chapter 2 PROCESS SELECTION AND DESCRIPTION
A number of options are there. Each having its advantages and disadvantages. Following
solvents are used most commonly:
2. Water
3. Ester
Pure gaseous butane and compressed air are mixed and fed to fluidized bed reactor at
conditions of 121°C and 275kpa, where butane is oxidized in the presence of VPO catalyst to
form maleic anhydride and water. Following reactions are taking place in reactor:
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Chapter 2 PROCESS SELECTION AND DESCRIPTION
First reaction is our main reaction. The conversion of butane is 82.2%. Selectivity for each
reaction is given below respectively:
The exothermic heat of reaction is removed by jacketing the reactor to maintain isothermal
conditions. The reactor effluent is cooled and sent to absorber, where maleic anhydride is
absorbed in solvent, dibutyl phthalate, and light gases and by-products are removed from top and
send to incinerator for burning. All maleic anhydride that is absorbed in solvent with trace
amount of by-products is sent to stripper after heating the mixture which contains N2 as stripping
gas. Stripper separates solvent from bottom for recycling into solvent storage tank after
purification and top product is sent to first distillation column. As solvent has highest boiling
point from all the products, so it is separated from bottom and is recycled back to solvent storage
tank while top product is finally sent to second distillation column where pure maleic anhydride
is separated from bottom. All trace amounts of by-products are sent to an incinerator before
entering into atmosphere to avoid pollution. So in this way, we get 99.8% pure maleic anhydride.
The detailed process can be seen in the process flow diagram attached below.
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Chapter 2 PROCESS SELECTION AND DESCRIPTION
REFERENCES
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Chapter 2 PROCESS SELECTION AND DESCRIPTION
1. G. Stefani, F. Budi, C. Fumagalli, G.D. Suciu, “Fluidized bed oxidation of n-butane: a new
commercial process for maleic anhydride,” in New Developments in Selective Oxidation,
edited by G. Centi and F. Trifiró (Elsevier, Amsterdam 1990).
2. S.C. Arnold, G.D. Sucium, L. Verde, A. Neri, “Use fluid bed reactor for maleic anhydride
from butane,” Hydrocarbon Processing (September 1985).
3. G. Stefani, F. Budi, C. Fumagalli, G.D. Suciu, “Fluidized bed oxidation of n-butane: a new
commercial process for maleic anhydride,” Chimica & Industria (Milano) 72 (1990).
4. US patent # 4,143,056.
5. US patent # 5,792,722.
6. US patent # 6,960,970.
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