Process Optimization and Techno-Economic Analysis for the Production of Phycocyanobilin from Arthrospira maxima-Derived C-Phycocyanin

C-Phycocyanin (C-PC) is a photosynthetic pigment found in cyanobacteria, notably in Arthrospira species. The extraction of phycocyanobilin (PCB), the chromophore of C-PC, is a common approach to address the instability of C-PC under light, heat, and acidic conditions. Methanol is typically used for PCB extraction. However, its use poses challenges for industrial applications owing to the need for solvent removal, extensive purification, and safety validation. Therefore, this study proposes ethanol as an alternative to methanol, optimizing the ethanol extraction conditions through response surface methodology (RSM) using a central composite design (CCD) and techno-economic analysis. The parameters evaluated were the extraction temperature, time, and C-PC/solvent ratio. Optimal conditions—68.81 °C, 14.91 h, and a C-PC to solvent ratio of 1:95 (w/v)— yielded a predicted PCB yield of 29.18%, closely aligning with the actual value of 29.67 ± 1.33%. A techno-economic analysis for pilot-scale PCB production showed that optimized ethanol extraction could yield 147.13 kg/year with 506 batches, compared with 84.31 kg/year standard methanol extraction with 317 batches. Furthermore, it was evaluated to have a unit production cost of USD 1,413,588/kg, an internal rate of return (IRR) of 53.36%, and a payback time of 1.6 years with increased yields and reduced toxic solvent disposal costs. This study supports scalable PCB production with a natural blue pigment suitable for the food, beverage, and cosmetics industries.