Citric Acid Plants

Know-how and technology licensing.

Vogelbusch Citric Acid Technology

Citric acid is one of the most indispensable and frequently used organic acids. It is in widespread use as an acidifier, a pH buffer and — in combination with other materials — as a preservative by the food processing and beverage industries. Its sequestration characteristics and its biodegradability make it a favoured ingredient in detergents, pharmaceuticals and cosmetics.

Citric acid occurs naturally in various citrus fruits. To cover the industrial demand, large scale production of citric acid is based on various starch hydrolysates, cane or beet molasses, and from sugar.

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Block diagram

Vogelbusch process for citric acid production

Handling impurities in the substrates
RAW MATERIAL PREPARATION

Due to very widely-differing levels of impurity of substrates, Vogelbusch has customized technologies for raw material processing which are adapted to the individual situation. 

Molasses often requires hexacyanoferrate clarification, with simultaneous boiling and sterilization.

In the case of starch hydrolysates with relatively low impurity, and also with sugar solutions, raw material preparation consists of decationization and subsequent continuous sterilization.

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Fermentation
BIOREACTION

Vogelbusch licenses own strains of Aspergillus niger that have been selected and improved for industrial citric acid fermentation. 

The fermentation procedures are precisely matched to the raw material concerned as to maximize yields. To start the process the fermenter is inoculated with spores which are propagated and pilot tested on site. The well-aimed addition of nutrients, trace elements and specific inhibitors regulates the metabolic activity of the micro-organisms and thus provides for constant high production rates. 

Our bubble column (air-lift) fermenter system for submerged citric acid fermentation stands out for its simple design and low energy consumption.

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Spore propagation

A precondition for an efficient microbial production process is the availability of high-quality inoculation material. In the case of citric acid synthesis, the inoculation material is added to the fermenter in the form of spores. Taking account of the demand for high quality for this material, Vogelbusch has developed appropriate technology for spore propagation, harvesting and testing. The spores are dried which improves the storage stability as well as the ease of dosage.

More on VB Sporebox

Process parameter

Summary of process parameters achieved in the Vogelbusch fermentation process on the examples of a pure substrate (raw sugar, glucose, hydrolysate) and molasses. Depending on raw material quality and the impurity of the fermented mash, a yield of 90 to 92% is achieved in the product isolation and purification stages.

Parameter
Unit
Pure substrate
Molasses
Yield g CAM/g DS* min 0.84 min 0.80
Final concentration g CAM/l min 140 min 100

*) fermentable sugars as disaccharide

Separation and conditioning of final products
PRODUCT ISOLATION AND CONCENTRATION

The object of citric acid isolation is to obtain a largely pre-purified citric acid solution from the fermented mash. The mash is subjected to several process stages to separate the mycelium and to isolate the citric acid solution. 

While most of our plants use the traditional lime-sulphuric acid process for purification this step can be substituted now by chromatographic methods.

The final purification of the citric acid is effected by treating the isolated citric acid solution with activated carbon, cation and anion exchange resins in fixed bed reactors. Thanks to their automation and reactor design concept, these process stages also meet all the demands of a modern production process.

For final processing the citric acid solution is treated  in multistage falling film evaporators combining the advantages of delicate product handling with high energy efficiency. The specific energy requirement can be reduced even further by thermal vapor compression or alternatively by mechanical vapor compression.

Continuously operated forced-circulation vacuum crystallizers are used for the crystallization of the citric acid. The appropriate measuring and control strategies, and a crystallizer design matched to suit them, allow Vogelbusch plants to produce citric acid monohydrate as well as anhydrous using the same equipment. Sophisticated strategies for the recirculation of the mother liquor, separated from the crystal mash in a continuous centrifuge, allow for effective control of the quality of the final product.

Fluidized bed drying takes full account of the high demands for the quality of the final product by providing delicate product handling. Subsequent screening of the dried final product allows customer-specific fractioning according to particle size.

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Quality built to international standards

Citric acid is available in both powder and liquid forms. Our product purification and crystallisation processes are compatible with a wide range of product grades including

  • CAM - citric acid monohydrate,
  • CAA - citric acid anhydrate,
  • syrup and
  • sodium citrate

and comply with international quality standards for food, industrial and pharmaceutical grades, including BP, USP and FCC.

Producer-independent technology provider

Your benefits from our expertise:

  • Own development of high-performance production technology 
  • In-house laboratory available to test and optimize the process for individual raw materials
  • Selected, well tried upstream and downstream processes ensure optimum product quality
  • Proprietary apparatus for spore propagation and pilot fermentation
  • Reference projects spread across four continents
  • Starch milk

    Consumption for 1,000 kg CAM
    Glucose 1,350 kg
    Process water * 48
    Demineralized water 16
    Cooling water 24 °C 510
    Cooling water 29 °C 430
    Steam 9 bar 7,200 kg
    Electrical energy 2,350 kWh
    *) Actual process demand; overall consumption can be reduced by recycling of treated waste water.

    Additionally chemicals are required; consumption depends on raw material quality and process combination.
  • Molasses

    Consumption for 1,000 kg CAM
    Beet molasses 3,000 kg
    Sugar content * 50 %
    Process water ** 45
    Demineralized water 2
    Cooling water 24 °C 600
    Cooling water 29 °C 450
    Steam 9 bar 7,200 kg
    Electrical energy 2,500 kWh
    *) Fermentable sugar as disaccharides
    **) Actual process demand; overall consumption can be reduced by recycling of treated waste water.

    Additionally chemicals are required; consumption depends on raw material quality and process combination.
4 KGG
Citric Acid Plant in Kermanshah
KIMIA GHARB GOSTAR Industries Co. - Kermanshah, Iran

The plant has a capacity of 36 tons per day and is the first citric acid plant built in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either of the two commercially available forms of...

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Citric Acid Plant near Cairo
CITRO MISR Co. - 10th of Ramadan City, Egypt

Raw sugar from local production was the substrate of choice for Citro Misr Co. of Egypt. This raw material required a new approach in the fermentation process to assure the economic feasibility of the plant. The spore cultivation was adapted and the fructose utilization was optimized for the substrate. Products include...

Relevant processes

Find out more about the processes used in citric acid production:

Treating of input materials for bioconversion.
Raw Material Preparation
Enzymatic conversion of starch into sugar.
Hydrolysis
Converting substrates by using micro-organisms.
Fermentation
Separating solid-liquid and liquid-liquid media.
Centrifugation
Concentrating products and treating effluents.
Evaporation
Removing of ionic impurities and colors.
Ion exchange
Separating suspended particles.
Filtration
Cleaning and product formulation.
Crystallization
Finishing of products and co-products.
Drying

News

Vogelbusch Hong Kong: Business News
30 Mar 2017

Hoong Chee Kean takes over as Head of Business Development