Process design and economic studies of two-step fermentation for production of ascorbic acid
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Process design and economic studies of two‑step fermentation for production of ascorbic acid Shi Min Lim1 · Michelle Siao Li Lau1 · Edward Ing Jiun Tiong1 · Mun Min Goon1 · Roger Jhee Cheng Lau1 · Wan Sieng Yeo1 · Sie Yon Lau1 · Nabisab Mujawar Mubarak1 Received: 7 November 2019 / Accepted: 26 March 2020 © Springer Nature Switzerland AG 2020
Abstract The current study presents the conceptual design of a chemical plant for an annual production of 500 tonne ascorbic acid or Vitamin C with a high purity of 95% via fermentation of d-sorbitol. In this study, two-step fermentation with a single culture process is operated with a proper ISO 14000 Environmental Management procedure. A process flow diagram of the processing plant and the plant-wide simulation flowsheet that was generated by SuperPro Designer Simulation software, as well as the material and energy balances are also depicted. Meanwhile, the process is optimized through the recycling of sorbose and heat integration. By recycling sorbose, the production of ascorbic acid has increased by 24% while the total energy consumption had reduced by 20% after heat integration. Furthermore, economic and sensitivity analysis was performed to calculate the profitability of the plant and predict the effect of market conditions on the investments. After the economic analysis, total capital investment and total production cost for the best scenario were found to be roughly USD 52 million and USD 43 million, respectively with a return on investment of 78.73% and a payback period of 1.17 years since the selling price of Vitamin C is high. Keywords Ascorbic acid · SuperPro Designer · Fermentation · Biomass · Esterification · Economic analysis Abbreviations Cc Concentration of biomass CO2 Carbon dioxide Cp Specific heat capacity CSTR Continuous stirred tank reactor DC Direct cost FC Fixed charges FCI Fixed capital investment GCE Glassy carbon electrode GE General expenses H2O Water IC Indirect cost MC Maintenance and repairs cost MnOx-MoOx Manganese and molybdenum mixed oxides NaHCO3 Sodium bicarbonate
NaOH Sodium hydroxide NPV Net present value OL Operating labour OS Operating supervision PE Purchased equipment PED Purchased equipment delivered P&ID Piping and instrumentation diagram POC Plant overhead cost Pt Platinum ROI Return on investment SF Scale factor T Temperature Tc Critical temperature TCI Total capital investment TMC Total manufacturing cost TPC Total production cost
* Wan Sieng Yeo, [email protected] | 1Department of Chemical Engineering, Curtin University Malaysia, CDT 250, 8009 Miri, Sarawak, Malaysia. SN Applied Sciences
(2020) 2:816
| https://doi.org/10.1007/s42452-020-2604-8
Vol.:(0123456789)
Research Article
SN Applied Sciences
(2020) 2:816
V Working volume of fermenter VPC Variable production cost
1 Introduction Ascorbic acid (Vitamin C) is the most abundant natural hydro-soluble antioxidant used as a dietary supplement for the human [1], and it exists in various fruits and vegetables such as lemons,
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