Bio-Methionine Production from Raw Sugar
Methionine Production Costs Report | Issue B | Q3 2024
| Report Details |
| 80 kta Germany-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 80 kta (kilo metric ton per annum) Germany-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
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.
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.
Process Schematic
The process under analysis comprises four major sections: (1) Fermentation; (2) Clarification and Demineralization; (3) Pre-concentration, Crystallization and Filtration; and (4) Products Recovery.
Fermentation. Culture media used in the fermentation is prepared by mixing water, invert sugar (glucose and fructose), and ammonium thiosulfate solution (60 wt% in water) in the medium vessels. A microorganism is used to produce L-methionine through aerobic fermentation, which is divided in two phases: batch and fed-batch phases. During the first, the fermenters are filled with batch medium and fermentation occurs until glucose exhaustion, when the fed-batch phase is started by addition of the fed-batch medium until the end of the fermentation.
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 directed to a dryer, where L-methionine powder with 99.5 wt% of dry matter (90 wt% of methionine) is obtained. Water evaporated is sent to a wash column and then used in methionine washing. Also, the crystallization mother liquor is acidified with hydrogen chloride, and then 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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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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
Process Flow Diagrams
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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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