Commodity Production Costs Report
Bio-Methionine Production from Glucose
Methionine Operating Costs & Plant Construction Costs
This report presents the economics of L-Methionine production from glucose syrup in the United States using a process similar to the technology developed by Metabolic Explorer. In this process, glucose is fermented in an aerobic environment to produce L-Methionine.
The report provides a comprehensive study of Methionine production and related Methionine production cost, covering three key aspects: a complete description of the Methionine production process examined; an in-depth analysis of the related Methionine plant capital cost (Capex); and an evaluation of the respective Methionine plant operating costs (Opex).
The Methionine 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 Methionine 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 Methionine plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
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The process under analysis comprises five major sections: (1) Media Preparation; (2) Fermentation; (3) Clarification and Demineralization; (4) Pre-concentration, Crystallization and Filtration; and (5) Products Recovery.
Media preparation. Culture media used in the fermentation is prepared by mixing water, corn syrup (70 wt% glucose), and ammonium thiosulfate solution (60 wt% in water) in the medium vessels.
Fermentation. L-methionine is produced through aerobic fermentation, which is divided into a batch phase and a fed-batch phase. First, the fermenters are filled with batch medium and fermentation takes place until the glucose is exhausted, then more medium is continuously fed until fermentation is complete.
Clarification and demineralization. Culture broth is clarified by centrifugation and ultrafiltration. Next, the broth is demineralized in ion exchange resins to remove cations and anions.
Pre-concentration, crystallization, and filtration. L-methionine is concentrated in an evaporator prior to crystallization under vacuum by water evaporation. Then, precipitated methionine is sent to a vacuum filter, where it is separated from the crystallization mother liquor that still contains dissolved methionine.
Products recovery. Filtered L-methionine is dried, resulting in L-methionine powder with 99.5 wt% of dry matter (90 wt% of methionine). Water evaporated is sent to a wash column and used in methionine washing. Also, the crystallization mother liquor is acidified and concentrated, resulting in the liquid L-methionine compound by-product, which presents 60 wt% of dry matter (22 wt% of methionine).
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Methionine 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 Methionine 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 Methionine 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 Methionine 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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Other Methionine Production Cost Reports
Bio-Methionine Production from Raw Sugar
This report presents the economics of L-Methionine production from raw sugar (sucrose) in Germany using a process similar to the technology developed by Metabolic Explorer. In this process, sucrose is diluted and sucrose is hydrolyzed into glucose and fructose (invert sugars). The invert sugars are then fermented in an aerobic environment to produce L-Methionine.
Details: 80 kta Germany-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
DL-Methionine Production from Acrolein, Methyl Mercaptan and HCN
This report presents the economics of DL-Methionine production from acrolein, methyl mercaptan, and hydrogen cyanide (HCN) in the United States. In this process, refined acrolein and methyl mercaptan are reacted to form MMP (also called methional), which is further reacted with HCN to generate DL-Methionine via a typical carbonate process.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD
Methionine Hydroxy Analog from Acrolein, Methyl Mercaptan and HCN
This study presents the economics of Methionine Hydroxy Analog production from acrolein, methyl mercaptan, and hydrogen cyanide (HCN) in the United States. In this process, acrolein and methyl mercaptan are reacted to form methional. The methional reacts with HCN to produce hydroxy methylthiobutyronitrile (HMBN) intermediate, which is hydrolyzed to Methionine Hydroxy Analog.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $1,199 USD
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