Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 95
ICC - Report ID: 095-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Citric Acid Production
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 095-A
ICC - Related Reports List: 202-D,003-A,241-C,002-C
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/095-A.jpg
ICC - Process Overview Text: <h6>Products</h6> <p><b>Citric Acid</b>. Citric Acid is a naturally occurring tricarboxylic acid commonly found in plants and animals. In its pure form, it is a colorless compound readily soluble in water. Citric acid can be obtained from natural sources (e.g. lemon, lime and orange) and synthetically produced either via chemical reaction or microbial fermentation. Large-volume industrial production of Citric Acid, however, is based almost exclusively on microbial fermentation of carbohydrate substrate, in which a strain of Aspergillus niger is employed to convert sugar to citric acid.</p> <p><b>DDGS</b>. DDGS are the non-fermented material (residues consisting mainly of protein, fibre, fat and moisture) obtained after Ethanol separation from the fermentation broth. It is used as a lower cost feed ingredient for animal feed.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Corn</b>. Corn is available at relatively low and steady prices, it has high starch content, is easily stored, transported and handled. Such characteristics led naturally to the development of several processes to recover its starch and to process it into several industrial products. Most industrial processes make use of the shelled corn, which has been stripped from the cob during harvesting. The shelled corn is converted to other products through milling and refining. Corn milling processes can be divided in two main groups, wet milling and dry milling. In the wet milling, the corn kernel is milled in such a way that its components can be separated in an aqueous medium. In the dry milling the components of the kernel are separated using screening and air classification, but the fractionation is less efficient. Wet milling is generally used to produce high quality corn starch at high yields along with its by-products used in the animal feed (corn gluten meal and corn gluten feed) and food (corn oil) industries. Dry milling is widely used in the production of fuel Ethanol by fermentation of raw corn starch, other uses include the brewing and cereals industries.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/095-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Production of sugars from corn; (2) Fermentation; and (3) Citric Acid recovery.</p><p>Production of sugars from corn. Corn is fed to hammer mills to be crushed into a coarse grind meal containing all kernel components, which is routed to a liquefaction vessel, along with hot process condensate and alpha-amylase enzymes. The corn starch is enzymatically hydrolyzed, producing maltose and higher oligomers. The slurry from this step is sent to a saccharification tank, where it is mixed with gluco-amylase enzymes, that cleave the maltose and higher oligomers into glucose.</p><p>Fermentation. Fermentable carbon source (glucose) is mixed with process water and nutrients, and fed to the fermenters. Fermentation is performed in fed-batch mode and under aerobic process conditions in agitated, jacketed fermenters. After glucose exhaustion, the batch phase is finished, and the fed-batch phase is started. During the fed-batch phase, glucose and nutrients are continuously supplied.</p><p>Citric Acid recovery. After fermentation, the fermentation broth is sent to a rotary vacuum filter, separating non-fermented biomass from a liquid stream containing the citric acid. The separated biomass is washed and the biomass cake is dried, generating dried distiller´s grains with solubles (DDGS) as by-product. The separated liquid stream containing the citric acid is concentrated by means of evaporation, and then sent to a chromatographic separation to remove biomass residues. The citric acid solution is further purified in an ion exchange column and subsequently fed to a crystallization step. The citric acid cake is finally dried and solid Anhydrous Citric Acid substantially pure (99.5 wt%) is obtained as the final product.</p>
ICC - Short Description: This report presents the economics of Citric Acid production from corn via a fermentation process. Initially, corn starch is hydrolyzed to fermentable sugars, which are bioconverted to Citric Acid via fermentation. The economic analysis is based on a plant constructed in the United States.
ICC - Main Product: Citric Acid
ICC - Plant Capacity: 40.00
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Citric Acid Production

Citric Acid Production Costs Report | Issue A | Q2 2024

Production Cost Report

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40 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 40 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.

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Production Process Information

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

Plant Capital Cost Details

Operating Cost Details

Plant Cost Breakdowns

Plant Capacity Assessment

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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Citric Acid production plant examined

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements

Plant Cost Breakdowns

Breakdown of Citric Acid process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Citric Acid production plant studied

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Citric Acid plant capacities

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

Other Citric Acid Production Cost Reports

Citric Acid Production

This report presents the economics of Citric Acid production from corn via a fermentation process. Initially, corn starch is hydrolyzed to fermentable sugars, which are bioconverted to Citric Acid via fermentation. The economic analysis is based on a plant constructed in the United States.

Details: 40 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $1,999 USD

The cost analyses presented in this report target a 40 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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