Economic evaluation of citric acid production from molasses using SuperPro designer: A process simulation approach

This study presents a techno-economic evaluation of citric acid production from molasses, by Aspergillus niger, modeled and analyzed through SuperPro Designer software. The process simulation included fermentation, solvent extraction, crystallization, and waste treatment, forming a complete industrial production cycle. Capital and operating costs were estimated using built-in costing tools, incorporating international benchmarks for raw materials prices, labor, utilities and equipment. Economic evaluation showed noteworthy results as the process is deemed viable and economically feasible according to the Economy Evaluation Report. The total capital investment was estimated at 110.06 million USD, with fixed capital accounting for 84% of the total. Annual production was projected at 60.6 million kg of citric acid, generating revenues of approximately 90.89 million USD against annual operating costs of 71.82 million USD. The resulting net profit of 12.4 million USD yields a payback period of 8.9 years and a return on investment (ROI) of 11.2%. Results found in this paper demonstrated the potential of using SuperPro Designer® as a simulation tool in estimating costs and predicting the process feasibility. The analysis confirmed that the process is capital-intensive but economically sustainable, especially at large-scale production. These findings support the potential implementation of the proposed citric acid production facility in an industrial context.