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<p>Chicken processing uses feathers as a vital byproduct. A chicken’s feathers weigh 5–7% of its weight. Large amounts of poultry processing waste feathers are hard to recycle. Over several million tons of feather biomass are produced annually, causing chicken cholera and chlorosis, and solid waste management issues. The present work examined the optimization of keratin extraction from chicken feathers and assessed the feasibility of keratin production investment using a techno-economic analysis. Central composite design (CCD) was employed to improve the primary parameters influencing keratin yield. These parameters are temperature (60–80) ℃, extraction time (1–3) h, concentration of sodium hydroxide (0.3-1) M, and liquid-solid ratio (10–30) mL.g<sup>− 1</sup>. The maximum keratin yield was found to be 63.1% at a temperature of 65.6℃ and a liquid-solid ratio of 10:1 mL.g<sup>− 1</sup> at an extraction time of 1&#xa0;h using a sodium hydroxide solution with a concentration of 0.86&#xa0;M. Different analyses were performed on the extracted keratin, which include FTIR, XRD, TGA, SEM, and SDS Page. The extracted keratin has an average molecular weight of 52&#xa0;kDa and possesses a relatively high surface area. Keratin extraction was simulated in Aspen Hysys version 14, using the Non-Random Two-Liquid (NRTL) fluid package. According to the simulation results, the production process is viable on an industrial scale. The economics of keratin production were investigated. The entire capital investment was $5.4&#xa0;million, with an internal rate of return (IRR) of 47.1% and a payback period of 2.12 years, proving that keratin production is viable and profitable.</p>

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Optimization, simulation, and techno-economic analysis of keratin extraction from poultry waste using central composite design

  • 期刊论文

  • 发表日期：

    2026年7月29日

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  • Eman M. Abdel Hamid,
  • Ahmed T. Darwish,
  • Carlos E. Abdo,
  • Hossam M. Mahmoud,
  • Mostafa M. Ahmed,
  • Eman R. Radwan,
  • Youssef A. Mohamed,
  • Hager Mohamed

摘要

Chicken processing uses feathers as a vital byproduct. A chicken’s feathers weigh 5–7% of its weight. Large amounts of poultry processing waste feathers are hard to recycle. Over several million tons of feather biomass are produced annually, causing chicken cholera and chlorosis, and solid waste management issues. The present work examined the optimization of keratin extraction from chicken feathers and assessed the feasibility of keratin production investment using a techno-economic analysis. Central composite design (CCD) was employed to improve the primary parameters influencing keratin yield. These parameters are temperature (60–80) ℃, extraction time (1–3) h, concentration of sodium hydroxide (0.3-1) M, and liquid-solid ratio (10–30) mL.g− 1. The maximum keratin yield was found to be 63.1% at a temperature of 65.6℃ and a liquid-solid ratio of 10:1 mL.g− 1 at an extraction time of 1 h using a sodium hydroxide solution with a concentration of 0.86 M. Different analyses were performed on the extracted keratin, which include FTIR, XRD, TGA, SEM, and SDS Page. The extracted keratin has an average molecular weight of 52 kDa and possesses a relatively high surface area. Keratin extraction was simulated in Aspen Hysys version 14, using the Non-Random Two-Liquid (NRTL) fluid package. According to the simulation results, the production process is viable on an industrial scale. The economics of keratin production were investigated. The entire capital investment was $5.4 million, with an internal rate of return (IRR) of 47.1% and a payback period of 2.12 years, proving that keratin production is viable and profitable.