Transcript 500 TPD Nitric Acid Plant - International Process Plants

Maleic Anhydride
Plant
Please click on our
logo or any link in
this presentation to
be redirected to our
website, email or
other
documentation.
Thank You!
17A Marlen Drive w Hamilton, NJ 08691 w USA
Tel: (609) 586-8004 w Fax: (609) 586-0002
www.ippe.com
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
Utilities Consumed:
Raw Materials:
 Electricity
 Benzene or Butane
 Natural Gas
 Air
 Water
 Vanadium Catalyst
 Steam
(produced from the exothermic reaction)
Consumption Figures:
 1235kWh of electricity
Products Produced:
 Maleic Anhydride
 22.5kw of LNG
 9 tons of steam
Production Figures:
 5.7m3 of demineralized water
 11.9 tons of steam
 9.8kg of Nitrogen
 750 kWh through a thermic fluid
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.
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.
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.
Process Flow
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
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
Photos
Photos
Photos
Contact Information
MICHAEL JOACHIM
DIRECTOR, PLANTS DEPT.
Tele: 609-838-5930 (direct)
Mobile: 609-516-9107
[email protected]
SANJEEV REGE
VP GLOBAL PLANT SALES
Tele: 609-838-5938 (direct)
Mobile: 609-510-2616
[email protected]