Currently, there
is increased interest in biosurfactants as a substitute
for surfactants synthesized from petroleum due to their superior properties
and biodegradability. Palm oil derivatives, which can be converted
to various products, were selected for biosurfactant synthesis. This
paper simulated the biosurfactant production process from palm fatty
acid distillate, that is, methyl ester sulfonate (MES), alkyl sulfate,
alkyl phosphate, and alkyl carboxylate. Aspen Plus software was used
to estimate the thermodynamic properties of intermediate aliphatic
organic acids, e.g., methyl ester sulfonic acid, fatty alcohol sulfuric
acid, and fatty alcohol phosphoric acid. The chemical process equipment
was designed and evaluated to be used in techno-economic analysis,
with comparison to petroleum source surfactant production, that is,
sodium dodecylbenzenesulfonate (SDBS). The total production cost of
each biosurfactant was expressed in terms of minimum selling price.
The profitability of each project was determined and compared using
three economic indicators: net present value (NPV), payback period,
and internal rate of return (IRR). The life cycle assessment methodology
was then used to evaluate the environmental impact of surfactant production.
The results showed that all surfactant production processes, except
for alkyl phosphate, were attractive alternatives as the project yielded
a positive value of NPV. The highest NPV of 13.1 million USD was obtained
from the MES production process, while the maximum IRR of 79.81% and
payback period of 1.49 years were obtained from the alkyl carboxylate
production process at a capacity of 1 ton/h. However, the sulfate
production process caused more environmental impact than the other
two surfactants (MES and carboxylate) due to more CO2 emission
per product unit at the level of 2.88 tons CO2/ton surfactant,
which is also more than the SDBS surfactant production process that
released 2.46 tons CO2/ton surfactant.