Extraction of Soybean Oil with Pressurized Ethanol: Prospects for a New Processing Approach with an Analysis of the Physical Properties of Crude Oil and Implementation Costs through Scale-Up in an Intermittent Process

New environmentally friendly methods for extracting vegetable oils are in development, with a focus on pressurized liquid extraction (PLE) in an intermittent process. Ethanol, a renewable and generally recognized as safe (GRAS) solvent, is gaining prominence in this process. It is crucial for these methods to maintain the physicochemical characteristics of the extracted oils and be economically viable on a large scale. Using SuperPro Design software v 8.5, a simulation of PLE scaled up to industrial levels was conducted. Measurements of oils extracted with pressurized hexane and ethanol showed minimal density variations, with slightly higher viscosity for ethanol-extracted oil. Accelerated oxidative degradation revealed a longer induction period for hexane-extracted oil, indicating that ethanol-extracted oil degrades more easily. The antioxidant activity of the oil extracted with hexane was lower than that with ethanol. In the differential scanning calorimetry analysis, the oils extracted with hexane and ethanol presented onset melting point temperatures of −43.2 and −36.1 °C, respectively. The economic assessment considered 16 scenarios, showing a return on investment ranging from 9.0 to 133.5% in the first year and payback times from 0.7 to 11.1 years. Scenario 8, involving two 5000 L extractors, ethanol recycling, and an annual production of 3,325,300 L of soybean oil at USD 1.25/L, demonstrated the best return on investment (133.5%) in less than one year. Overall, this study suggests that industrial-scale soybean oil extraction via PLE in an intermittent process can be more cost-effective than conventional methods, making implementation feasible.