Harvesting Algae to Form a Neutraceutical, Specifically Creating a Functional Food Team Alpha Travis Dallas Eric Graves Joaquin Martinez Chris McNinch.

Harvesting Algae to Form a Neutraceutical, Specifically Creating a Functional Food

Team Alpha

Travis DallasEric Graves

Joaquin MartinezChris McNinch

Ramune Otterson MeskyteCharu Saini

Crypthecodinium Cohnii

Outline

• Flow Sheeting

• Energy Sinks/Loads and Streams

• Equipment Sizing

• Costing

DegummingBleaching

Removal FFADeodorization

CentrifugeCrude SBO

Citric AcidGumWater

Citric Acid

Citric AcidAcid Activated Clay

Enzyme

Water

Acid ActivateClay

Interesterification

Hardfat SBO

Emulsification Pasteurization

Water

Sea Salt

Lecithin

Diacetyl

Mono/Diglycerides

B-Carotenes

Sorbic Acid

Ergocaliferols

Sodium Hydroxide

Citric Acid

Water

Sodium HydroxideCitric AcidWater

ScrapedSurface HeatExchanger

Packaging

Refrigerant

To Wholesaler

DissolvedAir

FloatationFermentation Centrifuge

CO2

LysingGlucose

Beer Still Bottom

Antifoam

Water

Algae

Glucanex

SteamCoolingWater

Sterile air

Vent

Water

Air CO2

LHO-BiomassWater

NaOH

Steam

Steam

Salt

CIPSystem

Main Fermenter

Steam Cooling Water

Sparged Steam

Vented Air 13

14

Sterile Air

10% Seed Fermenter

Steam Cooling Water

Sparged Steam

Vent

9

Sterile Air

1000 L Seed Fermenter

10 L Seed Fermenter

250 mL Shake Flasks

Water Water

Direct Steam Injection

MT-1

Salt

Ethanol Bottoms

Glucose

Sterile Glucanex

Sterile Anti-foam

1

2

3

4 5

7

8

11

10

12

Compressor 1

Filter 1 1 Air

Filter 2

TK-1 TK-2 TK-3

TK-4 TK-5

STEX-1

Steam 4a

P- 1 P- 2

P- 3

P- 5 P- 6

P- 7 P- 8

Filter 3 1

To DAF

15

P- 9

Harvest Tank

Fermentor PFD

912

8

611 13

DAF PFD

10

14Rxn tank A

Rxn tank B

18

15

16

17

19

18

22

21

20

P-01P-02

P-03

211423

FermentedAlgae

FermentedAlgae

FermentedAlgae

Sterilized Air

Sterilized AirVented Air

Conc. Algae

Waste Water

Conc. Algae

18

Sterilized Air

22

23

24

1

Baffle trayTower

LysedCO2Holdingtank

CO2 Lysing PFD

24

24

24

23

25

24

26

27

28

Conc. Algae

Sterilized CO2

CO2 AbsorbedAlgae

LysedAlgae&CO2

Vented CO2

LysedAlgae

Throttle Valve

3

Main Centrifuge PFD

13

1331

29

30

Centrifuge

Lysed Algae

Biomass

Algae Oil

TK- 01Crude SBO

Storage

P-015 4

32

N2 Gas

1

6

TK-0245% Citric

Acid Storage

P-02

7

8

9

10

P-03 P-04 P-05

TK-034% NaOHStorage

TK-04Water

Storage

TK-0510% EnzymeRefrigerated

Storage

12 11

13

14

N2 Gas

CoolingHeating

23 22

15 16

HLO - Gums19

TK-06Batch

Reactor

P-06 P-07

TK-07SurgeTank

20

24

N2 GasTK-08

DegummedSBO

StorageHeating

HX-1

HX-3LLO

21

18 17

HX-2

Cent-01

Degumming PFD

24

N2 Gas

TK-08Degummed

SBOStorage

28 27

HX-4

25 26

TK-0950% Citric

AcidStorage

29

P-08

P-09

30

TK-10Acid

ActivatedClay Tank

32

31

P-10

33

P-11

TK-11Water

Storage

34

35

36

3837

P-12HX-5

40

39

P-13

VP-1

TK-12Mixer

4241

43

N2 Gas

TK-13SurgeTank

44

P-14

45

47

48

46

MX-2MX-1

49

VP-2

50

51

52

53

54

Steam

55

5657

58

To MX-1

P-15

59

60

6263

64

N2 Gas

61

TK-14Refined

SBOStorage

HX-6

HX-7

HX-8

HX-9

Filter

VacuumVessel

3837

Refining PFD

64

N2 Gas

TK-14Refined

SBOStorage

65

N2 Gas

TK-15SBO

HardfatStorage

67

N2 Gas

TK-16SBO

HardfatHeating

Tank

66

6869

70

74

73 72

77 76

71

75

P-17

P-18

HX-10

HX-11

78

VP-3

7980

81

P-19

TK-17CH3ONaStorage

82

TK-19MixingTank

P-20

85P-21

Filter

86

89

90

87 88

91

92 93

94

TK-20Soft

WaterStorage

HX-12

HLO

P-22

P-23 P-24

95 HLO96

Cent-03Cent-02

TK-1820% Citric

AcidStorage

TK-21Dryer

9798

P-252A 1A

99 00

3A

N2 Gas

TK-22SBO

Storage84

83

HX-13

MX-3 MX-4

WaterSoftener

Interesterification PFD

E

Algae OilStorage

Refined SBO Storage

Lecithin Storage

Beta CaroteneStorage

DiacetylStorage

Sorbic AcidStorage

Mono- di glyceridesStorage

Ergo-califerolStorage

WaterStorage

Oil

CIP

Aqueous PhasePrep.

10

TK-01

TK-02

TK-03

TK-04

CIPCIP

TK-05

TK-06

TK-07

TK-08

TK-11

TK-12

TK-13

Oil Phase Prep.Tank 1

CIP

P-01

P-02

P-03

P-04

Warm Water

Oil Oil Phase Prep.Tank 1

CIP

9

12

8

7

6

5

3 4

1 2

13Sea SaltStorage

TK-10

P-05

14

15

TK-09

16

11

11

17

CIP

19

18

16

19

18

20

Margarine PFD

Warm Water

High Pressure Pump

P-06

AmmoniaCompressor

Pin Rotor Machine

ScrapedSurface Heat Exchanger

Packaging

P-07

CIP

20

22

23

Plate HX 01Pasteurization

24

31

25

26

CIP

27

27

30

Margarine PFD

21

Overall Mass Balance for Oil

• Algae Oil Produced In Fermentation– 127,606 kg / year

• Refined SBO Produced– 3,424,720 kg / year

• Margarine Produced– 117,520 kg / year Algae Oil– 3,424,720 kg / year refined SBO

Energy Sinks/Loads and Streams

• Steam Boiler Q = 2,035,547 BTU / hr• Fermentor

• Heat Exchanger Silicone Antifoam

• Direct Steam Rejector

• Paratherm Boiler Q = 895024.3 BTU / hr

• Water Cooler

48.9 °C – 29.4 °C Q = 482,348.6 BTU / hr

• Emulsification

25 °C – 35.78 °C Q = 28,600 BTU / hr

• Pasteurization

35.78 °C – 43.3 °C Q = 9,500 BTU / hr

• Crystallization

43.3 °C – 10 °C Q = - 57,200 BTU/ hr

Equipment Sizing For Fermentation Process

Equipment Size (gal)

TK-1 11,000

TK-2 40,000

TK-3 1,200

TK-4 300

TK-5 300

MT-1 22,000

10L Seed Fermenter 2.65

1000L Seed Fermenter 265

10% Seed Fermenter 3,500

Main Fermenter 35,000

CO2 Lysing Tank 12,000

DAF Tank 24,000

Equipment for SBO Refining

Component Sizing

Component Sizing

TK-01 20000 gal

TK-02 25 gal

TK-03 400 gal

TK-04 600 gal

TK-05 15 gal

TK-06 1500 gal

TK-07 1500 gal

TK-08 4000 gal

TK-09 35 gal

TK-10 250 gal

TK-11 600 gal

Component Sizing

Component Sizing

TK-12 100 gal

TK-13 1500 gal

TK-14 4000 gal

TK-15 10000 gal

TK-16 1000 gal

TK-17 250 gal

TK-18 1200 gal

TK-19 400 gal

TK-20 7500 gal

TK-21 400 gal

TK-22 5000 gal

MX-1 100 gal

MX-2 100 gal

MX-3 500 gal

MX-4 500 gal

Component Sizing

Component Sizing

HX-1 202490.49 BTU/hr

HX-2 12603.83 BTU/hr

HX-3 12603.83 BTU/hr

HX-4 15340.19 BTU/hr

HX-5 19900.73 BTU/hr

HX-6 36567.59 BTU/hr

HX-7 109454.00 BTU/hr

HX-8 39541.70 BTU/hr

HX-9 97016.05 BTU/hr

HX-10 49571.68 BTU/hr

HX-11 159620.87 BTU/hr

HX-12 92228.34 BTU/hr

HX-13 46342.34 BTU/hr

Tanks Heat Exchangers

Margarine Equipment Sizing

Component Size

P-01 0.25 GPM

P-02 3.5 GPM

P-03 1 GPM

P-04 1 GPM

P-05 3.5 GPM

P-06 110 GPM

P-07 4.25 GPM

Emulsion Tank 1 2000 L

Emulsion Tank 2 2000 L

High Pressure Pump 2475 L / hr

Plate Heat Exchanger 6 ft^2

Scraped Surface Heat Exchanger 2150 L / hr

Pin Rotor Machine 2000 L/hr

Tub Filling Machine 2740 L/hr

Ammonia Compressor 18 ton

Component Size

TK-01 1000 L

TK-02 5000 L

TK-03 20 L

TK-04 2 L

TK-05 2 L

TK-06 5 L

TK-07 10 L

TK-08 2 L

TK-09 500 L

TK-10 1000 L

TK-11 500 L

TK-12 1500 L

TK-13 1500 L

CostingCapitol Costs

-Refining

$ 11.54 Million

- Algae Oil Production

$ 20.25 Million

- Margarine Production

$ 1.8 Million

- Chemicals and Ingredients

$ .22 Million

Operating Costs

- Refining

$ 2.64 Million

- Algae Oil Production

$ 6.10 Million

- Margarine Process

$ 0.24 Million

- Chemicals and Ingredients

$ 4.7 Million

Capital Costs

-Refining

$ 11.54 Million

- Algae Oil Production

$ 20.25 Million

- Margarine Production

$ 1.8 Million

- Chemicals and Ingredients

$ .22 Million

Chemical Unit Price Amt. Required Yearly Price Total

Crude SBO $867.40/ton 3,196.9423 tons $2,773,027.75

SBO Hardfat $0.46/lb 1,544,895.744 lb $710,652,04

50% Citric Acid $8.51/gal 9,118.579 gal $77,599.11

Acid Activated Clay $209/ton 15.887 tons $3,320.38

99% Sodium Methoxide $14/kg 6,863.348 kg $96,086.87

Nitrogen $7.7825/m³ 13.114 m³ $102.06

Paratherm NF * $21.21/gal 10,000 gal $212100.00

4% Sodium Hydroxide $4.39/L 484.737 L $2,128.00

Enzyme $576/L 60.053 L $34,590.53

Sea Salt (Fermentation) $600/ton 672.44 tons $403,464.00

Ethanol bottoms $140/ton 199.46 tons $27,924.40

CO2 Free 1,096,000 kg -

Lecithin $0.81/lb 19,534.7 lb $15,823.10

Sea Salt (Margarine Process) $600/ton 739.449 tons $443,669.40

Ergocaliferol $18234/kg 0.36628 lb $3,029.43

Mono/Di Glycerides $0.1/kg 48,836.8 lb $10,780.75

Beta-Carotene $1250/kg 193.8 lb $109,883.00

Diacetyl $2.5/kg 24.42 lb $27.69

Ammonia * $500/ton 18 tons $9,000.00

Sorbic Acid $8250/ton 9,767.36 $40,290.40* Only capitol costs

Chemical Costs

Questions

?

TK-3Acidic Solution

TK-4Alkaline Solution

TK-5Reclaim Water

TK-6FreshWater

11 12 1310 21 22 23 24

20

TK-1Alkaline Storage

TK-2Acidic Storage

2 1

CIP Returning Liquid

3 4 5

Water

8 9 6

14

15

16

Steam

HX-1

17

CIP Supplying Liquid

Drain

7

19

18

Filter

CIP System

Drying Process

33 34 35

Biomass + Water In Biomass Water Out

22,902.52 6,168.82 16,733.71

Liquid Liquid Liquid

19,146 3,829 15,317

2,011 1,990.42 20.11

1,746 349 1,397

36 37

Dry Biomass Evaporated Water

2,339.66 3,829.16

Solid Liquid

Centrifuge 2 Dryer