Why Maleic Anhydride Is Essential for Industrial Applications?

Since its first preparation in the 1830s, maleic anhydride has evolved to become a highly versatile chemical compound. Today, maleic anhydride finds a diverse array of applications across several sectors, ranging from food additives to agriculture chemicals and pharmaceuticals. But what is it about maleic anhydride that makes it such a versatile chemical intermediate?

In this blog post, we take you on an exciting journey to the world of maleic anhydride, explaining to you its basics, properties and production process. Also, we shed light on the various applications of maleic anhydride and examine the top manufacturers of the organic compound. Stick with us!

What is Maleic Anhydride?

Maleic Anhydride is a chemical intermediate that appears as colorless crystalline flakes, pellets, needles, lumps, or a fused mass. It is the acid anhydride of maleic acid and plays the role of an allergen. Maleic anhydride melts at 113 °F and is available in both solid and molten states. The flash point of the organic compound is 218 °F, whereas its autoignition temperature is 890 °F. Maleic anhydride is a chemically reactive intermediate that can be reactive with polyamides and hydroxyl. It is widely used in the formulation of resins. Also, it finds applications in coatings and polymers.

How is Maleic Anhydride Manufactured?

Traditionally, maleic anhydride was produced by the oxidation of benzene or other chemical compounds. Today, only a small number of plants make use of benzene owing to the increasing benzene prices. Instead, most plants now make use of n-butane as a feedstock in maleic anhydride production.

The process of manufacturing maleic anhydride involves multiple steps. They include

Mixing: The process starts with the mixing of pure butane and compressed air and feeding it into an adiabatic reactor.

Rection: The reaction between oxygen and hydrocarbon leads to the formation of maleic anhydride. The reaction taking place here is exothermic, meaning the release of energy to its surroundings is by heat. As such, a packed bed reactor or a fluidized bed reactor is used for heat removal.

Cooling and Breaking Down: After cooling, the reactor effluent is sent to a packed bed absorber. Here, it’s contacted with water for the removal of light gases and maleic anhydride. The vapor effluent, which comprises non-condensables, is passed through an after-burner for the removal of any carbon monoxide before venting into the atmosphere.

Distillation: The next stage involves sending the reactor effluent to a distillation column. Here, the separation of maleic anhydride and water takes place. The distillate makes its way to waste treatment, and the bottoms of the manufacturing unit consist of 99-wt.% maleic anhydride.

Uses of Maleic Anhydride

Maleic anhydride Is a chemical intermediate with several applications. These include:

Chemical Synthesis: Maleic anhydride finds applications in the development of acids and agrochemicals. Also, it’s used to create resins, lubricants, and pharmaceuticals.

Co-polymer: Maleic anhydride finds applications as a co-polymer in the production of polyester and other resins. These resins are widely utilized in marine, automotive, and construction applications.

Food Additives: Food additives, including malic acid, fumaric acid, and succinic acid, are created using maleic anhydride. The food additives made using maleic acid are commonly used as preservatives or flavor enhancers.

Corrosion Inhibitors: The chemical intermediate finds applications in the development of polymeric corrosion inhibitors, which can safeguard carbon steel from corrosion.

Adhesives and Dispersants: Maleic anhydride can be found in adhesives, construction adhesives, and dispersants. Also, they are a part of coatings, cosmetics, thickeners, hair sprays, and protective colloids.

Antimicrobial Polymers: Maleic anhydride is used in the production of antimicrobial polymers, which can help prevent microbes from infecting humans.

Safety and Handling of Maleic Anhydride

Maleic anhydride is an important industrial chemical, but it also carries potential health hazards. As such, some safety precautions must be taken when handling maleic anhydride. These include:

Skin Protection: Maleic anhydride can be irritating to the skin. As such, skin contact with the chemical intermediate must be avoided.

Eye Protection: If maleic anhydride comes in contact with the eyes, they must be rinsed with water immediately. In serious instances, it’s recommended to call an ophthalmologist.

Respiratory Protection: When handling maleic anhydride, a NIOSH-approved air-purifying respirator with organic vapor cartridges and a particulate prefilter must be used.

Storage: Maleic anhydride must be kept away from food, drink, and animal feed. Also, it should not be stored in containers usually used for food or drink.

Fire and Explosion: In the case of a fire or explosion, individuals should fight the fire from a safe distance and by wearing a self-contained breathing apparatus.

Who Manufactures Maleic Anhydrides?

The market for maleic anhydrides is highly competitive, with the presence of both domestic and international players. BASF SE, Mitsubishi Chemical Corporation, Huntsman Corporation, Arkema S.A., Evonik Industries AG, Saudi Basic Industries Corporation (SABIC), LyondellBasell Industries Holdings B.V., Daicel Corporation, and Formosa Plastics Corporation are some of the top players in the market.   Several factors, including market reach, technological innovation, and production capacity, shape the market’s competitive landscape. Some of the latest market developments are:

• November 2023: Jiangsu Shenghong Petrochemical Co., Ltd (Shenghong Petrochemical) purchased Clariant’s SynDane catalyst for its new plant. The new plant, located in Lianyungang, Jiangsu province, China and having an annual capacity of 200,000 tons of Maleic anhydride, produces maleic anhydride for biodegradable plastics.
• June 2023: PETRONAS Chemicals reached the final investment decision (FID) with BASF. The FID was for the complete acquisition of the 113 kilo-tonnes per annum (ktpa) maleic anhydride based out of Gebeng, Kuantan.

Conclusion

To conclude, maleic anhydride is a versatile chemical compound with an acrid odor. It is widely used in the manufacturing of additives, resins, and a variety of other products. As technology advances and manufacturers continue to innovate, the potential applications of maleic anhydride will only increase in the upcoming years.