Commodity Production Costs Report

3-Hydroxypropionic Acid Production from Glucose

3-Hydroxypropionic Acid Operating Costs & Plant Construction Costs

200 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $799 USD | See Report Editions Prices

This report presents the economics of 3-Hydroxypropionic Acid (3-HPA) production from glucose syrup using a fermentation process similar to the one developed by Cargill. The main fermentation is carried out in fed-batch mode and under aerobic conditions. The economic analysis provided assumes a plant located in the United States.

The report provides a comprehensive study of 3-Hydroxypropionic Acid production and related 3-Hydroxypropionic Acid production cost, covering three key aspects: a complete description of the 3-Hydroxypropionic Acid production process examined; an in-depth analysis of the related 3-Hydroxypropionic Acid plant capital cost (Capex); and an evaluation of the respective 3-Hydroxypropionic Acid plant operating costs (Opex).

The 3-Hydroxypropionic Acid production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The 3-Hydroxypropionic Acid plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The 3-Hydroxypropionic Acid plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.

Key reference(s): ?

3-Hydroxypropionic Acid Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Fermentation; (2) Separation; and (3) Purification.

* Fermentation. The culture media used in the pre-fermentation and in the fed-batch fermentation are prepared by diluting the glucose syrup (fermentable carbon source) and nutrients (source of nitrogen, vitamins and minerals) in water. The main fermentation is carried out in fed-batch mode and under aerobic process conditions. The pH control is made by addition of a solution of ammonia, so as to keep the pH of the fermentation broth around 7. Due to the presence of the ammonium hydroxide, most of the 3-Hydroxypropionic Acid produced is neutralized to 3-hydroxypropionate, in such a way that the broth contains 3-Hydroxypropionic Acid mainly in its conjugate base form.

* Separation. After fermentation, cell debris and other suspended solids are removed from the broth by ultrafiltration. The permeate is pumped to Evaporators, while the retentate – mostly biomass/water – is disposed. The concentrated broth is fed to an agitated vessel operating under vacuum, along with tricaprylamine (organic solvent) and dodecanol (cosolvent). The mixture is heated so that the ammonium salt of the 3-Hydroxypropionic Acid splits, producing ammonia and 3-HP. The liquid stream from the Salt-Splitting is then back-extracted in countercurrent contact with hot water, yielding an aqueous phase rich in 3-HP and a 3-HP-lean organic phase.

* Purification. The rich aqueous solution of 3-HP is subjected to a demineralization step for removal of inorganic cations and anions from the solution and then concentrated. The concentrated 3-HP solution is finally fed to two wiped film evaporators operating in series, under vacuum, for product purification. The final product obtained in this process is an aqueous solution containing 60 wt% of 3-Hydroxypropionic Acid.

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 80 Pages | 22 Tables | 9 Images

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  • Operating Cost Summary
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • 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
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the 3-Hydroxypropionic 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 3-Hydroxypropionic 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 3-Hydroxypropionic 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 3-Hydroxypropionic 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

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