Commodity Production Costs Report

L-Lysine-HCl Production from Raw Sugar

Lysine Operating Costs & Plant Construction Costs

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

This report presents the economics of Lysine production from raw sugar (sucrose). Sucrose is initially hydrolyzed into glucose and fructose (invert sugar). The invert sugars are then fermented to produce L-Lysine, which is recovered as L-Lysine-HCl. The economic analysis provided assumes a plant located in Germany.

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

The Lysine 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 Lysine 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 Lysine 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): ?

Lysine Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Fermentation; (2) Product Recovery; and (3) Product concentration, Drying and Packaging.

Fermentation. The culture media used in fermentation is prepared by mixing process water, invert sugar and nutrients. The fermentation is performed in fed-batch mode and under aerobic conditions. At the batch phase, the microorganism seed is fed into the fermenters, which were previously filled with the fermentation batch medium. After glucose exhaustion, the batch phase is finished and the fed-batch phase is started, during which, glucose and nutrients are continuously supplied until the desired L-lysine concentration is achieved. At the end of the fermentation, the broth is sent to a buffer tank to provide a continuous flow in the further process steps.

Product recovery. The fermentation broth is sent to an ultrafiltration system for the removal of cell debris and other suspended solids. Subsequently, the liquor from ultrafiltration is fed to ion exchange columns, where L-lysine is selectively adsorbed. The L-lysine adsorbed is eluted from the ion exchange resins by washing with an aqueous ammonia solution.

Product concentration, drying and packaging. The L-lysine eluate from ion exchange columns is mixed with mother liquor from product filtration and concentrated by evaporation. The concentrated lysine solution is acidified with hydrochloric acid, and free L-lysine is converted to L-lysine HCl. Subsequently, the L-lysine HCl solution is sent to the crystallizer, and lysine salt is filtered. The mother liquor is recycled to the evaporator and the wet cake is conveyed to dryers. Final dry L-lysine-HCl (98.5 wt%) is obtained and sent to packaging line before being stored in bags.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 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
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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 Lysine 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 Lysine 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 Lysine 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 Lysine 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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This feasibility study approaches an economic analysis of L-Lysine Monohydrochloride (or L-Lysine-HCl) production from glucose syrup in the United States using a conventional fermentation process. The L-Lysine-HCl is recovered via ion-exchange absorption and crystallization.

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