Detailed Project Report on Citric Acid (Anhydrous)

CITRIC ACID (ANHYDROUS)

[EIRI/EDPR/4276] J.C.: 2457XL

INTRODUCTION

Citric acid (C6H8O7, 2 - hydroxy - 1,2,3 - propane tricarboxylic acid), a natural constituent and common metabolite of plants and animals, is the most versatile and widely used organic acid in the field of food (60%) and pharmaceuticals (10%). It has got several other applications in various other fields. Currently, the global production of citric acid is estimated to be around 736000 Tons/Year (TPA). In Brazil, almost the entire demand of citric acid is met through imports. There is constant increase (3-4%) each year in its consumption, showing the need of finding new alternatives for its manufacture.

Citric acid was first isolated by Karls Scheels in 1874, in England, from the lemon juice imported from Italy. Italian manufacturers had monopoly for its production for almost 100 years, and it was sold at high cost. This led extensive attempts all over the world to find alternatives way for its production, which included chemical and microbial techniques. In 1923, Wehmer observed the presence of citric acid as a by-product of calcium oxalate produced by a culture of Penicillium glaucum. Other investigations showed the isolation of two varieties of fungi belonging to genus Citromyces (namely Penicillium). However, industrial trials did not succeed due to contamination problems and long duration of fermentation. The industrial process was first open by Currie, in 1917, who found that Aspergillus Niger had the capacity to accumulate significant amounts of citric acid in sugar based medium. He also showed that high concentrations of sugar favoured its production, which occurred under limitation of growth. In the thirties, some units were implanted in England, in Soviet Union, and in Germany for the commercial production. However, the biochemical basis was only cleared in the fifties with the discovery of the glycolytic pathway and the tricarboxylic acid cycle (TCA). Consequently, an improved process employing submerged fermentation was developed in United States.

Although methods were well developed to synthesis citric acid using chemical means also, better successes were achieved using microbial fermentations, and over the period of time, this technique has become the method of ultimate choice for its commercial production, mainly due to economic advantage of biological production over chemical synthesis. Much attention has been paid on research to improve the microbial strains, and to maintain their production capacity.

Citric  acid  was  first  isolated  from  lemon  juice   and crystallized  as  a  solid by Scheele in 1784.   It is found as natural constituent of citrus fruits, pine apples, peaches other fruits and tissues.  The citric acid  extracted  from these products is known as a “natural citric acid" in contrast  to "fermentation citric acid" lemons, limes and pine apples are  the principle  sources  of  natural citric acid,  which  is  produced chiefly  in  Italy, especially Sicily, and  also  in  California, Hawaii and the West Indies.

It has made the United States self-sufficient in respect  to the  citric acid supply and greatly changes the commerce  of  the world in citric acid and calcium citrate.

Recent developments in the citric acid fermentation include the change from the older established shallow   pan method to a deep tank submerged method.

A group headed by S.M. Martin of the National Research laboratory of Canada has been especially active in the development of the submerged production of citric acid from ferrocyanide-treated beet molasses by Aspergillus Niger.

It is intended to prepare a Feasibility Report to install a Citric Acid (Anhydrous) Powder production facility with an installed capacity of 30000 Tons / Year as a Green Field Project.

COST ESTIMATION

Plant Capacity                                    100 Ton/Day

Land & Building (16,725 sq.mt.)     Rs. 23.73 Cr

Plant & Machinery                              Rs. 88.93 Cr

Working Capital for 3 Months    Rs. 63.79 Cr

Total Capital Investment                   Rs. 181.16 Cr

Rate of Return                                     47%

Break Even Point                                 45%

CONTENTS

INTRODUCTION

MARKET OVERVIEW

MARKET SEGMENTATION

KEY MARKET PLAYERS OPERATING IN THE GLOBAL CITRIC ACID MARKET

WORLD PRODUCTION PATTERN OF CITRIC ACID

GLOBAL CONSUMPTION PATTERN OF CITRIC ACID

MICRO-ORGANISM FOR CITRIC ACID PRODUCTION

TABLE MICRO-ORGANISMS EMPLOYED FOR CITRIC ACID PRODUCTION

STRAINS SELECTION & IMPROVEMENT

INDUSTRIAL PRODUCTION OF CITRIC ACID

BLOCK DIAGRAM OF CITRIC ACID (ANHYDROUS) POWDER

RECOVERY OF CITRIC ACID (ANHYDROUS)

BASED ON THE FOLLOWING EMPIRICAL FORMULA

PRODUCTION TECHNIQUES & RAW MATERIALS

LIQUID FERMENTATION

TABLE RAW MATERIALS EMPLOYED IN SUBMERGED FERMENTATION FOR CITRIC ACID PRODUCTION

SOLID-STATE FERMENTATION

TABLE RAW MATERIALS EMPLOYED IN SOLID STATE FERMENTATION FOR CITRIC ACID PRODUCTION

PRODUCTION DETAILS OF CITRIC ACID

SURFACE CULTURES

SUBMERGED CULTURES

TECHNICALITIES IN CITRIC ACID PRODUCTION

SELECTION OF ORGANISM:-

SELECTION AND OPTIMIZATION OF MEDIA:-

OPTIMIZED MEDIA FOR SEED CULTURE:-

OPTIMIZED MEDIA IS USED FOR THE CITRIC ACID PRODUCTION IN FERMENTATION.

PREPARATION OF CULTURE

FERMENTATION:

ISOLATION

FERMENTER DESIGN/OPERATION CONCEPTS

THE FOLLOWING RECORDING INSTRUMENTS SHOULD BE PROVIDED WITH THE UNIT.

PROCESSING OF CITRIC ACID FROM SUGARCANE MOLASSES

PREPARATION OF INOCULUMS

FERMENTATION

ESTIMATION OF SUGARS

EXTRACTION OF CITRIC ACID

ESTIMATION OF CITRIC ACID

SAMPLE PREPARATION

HPLC ANALYSIS

STATISTICAL ANALYSIS

FACTORS AFFECTING CITRIC ACID PRODUCTION

PROCESS PARAMETERS

PROPERTIES

USES & APPLICATION OF CITRIC ACID

BIS SPECIFICATIONS

QUALITY TESTING REQUIRED FOR CITRIC ACID

QUALITY CONTROL TEST FOR RAW MATERIAL

MOLASSES

LIME

SULFURIC ACID

ANTIFOAMING OIL

RAW MATERIALS SUPPLIERS

SUPPLIERS OF PLANT & MACHINERY

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WASTE WATER

WASTE

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENTS

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)