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

1
Harvesting Algae to Form a Neutraceutical,
Specifically Creating a Functional Food
Team Alpha
Travis Dallas Eric Graves Joaquin Martinez Chris
McNinch Ramune Otterson Meskyte Charu Saini
Crypthecodinium Cohnii
2
Beer Still Bottom
Water
Glucanex
Biomass Water Hexane
Glucose
Water
Antifoam
Vent
Sterile air
Dissolved Air Floatation
Fermentation
Centrifuge
CO2 Lysing
Hexane Extraction
Algae
Salt
CIP System
Steam Cooling Water
Air
CO2
Sodium methoxide Citric Acid Water
Refrigerant
Interesterification
Emulsification
Pasteurization
Scraped Surface Heat Exchanger
Gum Water
Citric Acid Acid Activated Clay
Degumming
Bleaching Removal FFA Deodorization
Centrifuge
Water
Crude SBO
Packaging
Steam
Sea Salt
Hardfat SBO
Lecithin
Diacetyl
Sodium methoxide
Mono/Diglycerides
Citric Acid
Steam
Citric Acid
Citric Acid
B-Carotenes
Water
To Wholesaler
Enzyme
Acid Activate Clay
Sorbic Acid
Water
Ergocaliferols
NaOH
3
Key Points

1. Plant Layout
2. Controls
3. Sanitation Design
4. Calculations
5. Economics
6. Changes
7. Future Endeavors
8. PFD
9. Report

4
Wind Direction
Gate
D
A
B
Fencing
C
E
F

1. Storage/Boilers
2. Fermentation
3. Offices/Labs/Miscellaneous Space
4. Water Cooling Tower
5. SBO Refining
6. Margarine Processing

General Plant Layout Alpha Algae Plant 1928 SE
Otis Rd Cedar Rapids, IA 52401
Otis Rd
Cargill
5
Fermentation Layout
115 ft
Cooling Tower
Ethanol Bottoms
Salt
Boiler
Glucose Storage
Electrical Room
35 ft
Glucanex
Antifoam
Seed 1
Fermenter 1
RXN 1
Harvest Tank
S1
RXN 2
Seed 2
Fermenter 2
S2
DAF
85 ft
Mix Tank
Absorption
Lipid Storage
Fermenter 3
Lysed Tank
Seed 3
S3
Fermenter 4
Centrifuge 1
Centrifuge 2
Seed 4
S4
C3
C4
Dryer
Silo
6
Refining Layout
SoftWaterStorage
CrudeSBOStorage
DegumSBOStorage
Mixers
Surge Tank
WaterSoftener
Batch Rx

Cent-5
Vacuum Mixer
Surge Tank
RefinedSBOStorage
VacuumVessel
ElectricalRoom
Mixers
InteresterSBOStorage
InteresterificationTank
HardfatSBOStorage
Cent-6
Cent-7
CA
ProcessingTank
72ft x 34ft
7
50 x 66
8
Margarine Plant Mezzanine Layout
Ingredient Storage Tank Area
Electrical Room
4 feet
9
Fermentor Controls
TK-1
TK-2
TK-3
TK-4
TK-5
P- 2
P- 10
Glucose
Salt
P- 1
P- 5
P- 6
Ethanol Bottoms
STEX-1
Filter 3
MT-1
Direct Steam Injection
Sterile Glucanex
P- 11
P- 3
Water
Water
Sterile Anti-foam
Steam
Vented Air
Filter 2
13
Vent
10 Seed Fermenter
Harvest Tank
Main Fermenter
1000 L Seed Fermenter
250 mL Shake Flasks
10 L Seed Fermenter
To DAF
P- 7
P- 8
P- 9
Sparged Steam
Cooling Water
Sterile Air
Compressor 1
Sparged Steam
Air
Cooling Water
Filter
Filter 1 1
Sterile Air
Compressor 1
Air
10
Fermentor Controls
Sterile Glucanex
Filter 3
Sterile Anti-foam
11
P- 6
10
P- 3
Vented Air
Filter 2
13
Foam
Main Fermenter
Turbidity
P- 8
14
9
Cooling Water
Sparged Steam
8
Filter 1
Compressor 1
Sterile Air
Air
11
Dissolved Air Flotation Controls
20
Vented Air
DAF Tk-7
1
Fermented Algae
Tk-6
16
Cv-23
Cv-25
P11
FIC
FIC
Rxn tank B
22
23
FIC
P12
Cv-20
Conc. Algae
15
18
P-01
19
FIC
2
FIC
Tk-7
Cv-22
Cv-26
17
Rxn tank A
FIC
Fermented Algae
21
P10
Sterilized Air
Water
45
PIC
Water
PIC
46
12
18
18
Water to Cargill treatment
Cv-21
Cv-24
Sterilized Air
Sterilize Air
Sterilized Air
12
CO2 Lysing Controls
Cv-30
Conc. Algae
CO 2 Compressor 2
27
23
Vented CO2
3
Stir tank
Filter 4
Lysed Algae Tower Tk- 9
Baffle tray Tower Tk- 8
24
Cv-29
PIC
Sterilized CO2
Cv-30
FIC
FIC
Cv-28
25
26
29
CO2 Absorbed Algae
Lysed Algae CO2
Lysed Algae
Throttle Valve
P14
TIC
28
Cv-31
48
P13
47
FIC
Cv-27
Steam in out
13
Main Centrifuge Controls
Algae Oil Holding tank TK-20
Lysed Algae
29
Algae Wet Biomass
Algae Oil
31
30
Disc Centrifuge
Cv-32
FIC
35
Algae Oil
P15
14
Separation Process Controls
Cv-36
FIC
Wet Biomass Tank Tk-12
40
Wet Biomass
Wet Biomass
41
P19
Biomass
Cv-37
FIC
Dynamic Cross Flow Filtration
42
39
Water
P21
15
Dryer Process Controls
Exhauster
Purge
Air seal dust valve
Fume controller
37
42
PIC
Recycle
Filter
Rotary Dryer
49
43
Dry Biomass
Steam in
50
Steam out
Conveyor Belt
TIC
Collection Hopper
Shipping container
Dried Algae Distributor
Conveyor Belt
16
Degumming Controls
TK-53 4 NaOH Storage
TK-54 10 Enzyme Refrigerated Storage
PIC
N2 Gas
TK-52 45 Citric Acid Storage
P-54
P-53
TC
TK- 51 Crude SBO Storage
PIC
Batch Reactor
FIC
N2 Gas
TK-55 Surge Tank
pHC
QIC
LIC
P-52
HX-5
HX-6
PIC
QIC
P-56
LIC
P-51
P-55
N2 Gas
TIC
LIC
TIC
CLR-1
LLO
HLO - Gums
TIC
FIC
TK-56 Degummed SBO Storage
Cent-5
17
Refining Controls
TK-58 Acid Activated Clay Tank
TK-59 Water Storage
VP-1
PIC
TK-57 50 Citric Acid Storage
PIC
VP-2
Vacuum Vessel
FIC
N2 Gas
Vacuum Mixer
PIC
TK-56 Degummed SBO Storage
CLR-2
RP-1
P-60
P-58
TIC
FIC
TIC
FIC
P-62
HX-11
HX-9
LIC
Filter
HX-8
P-57
P-59
P-61
PIC
MX-1
MX-1
FIC
N2 Gas
Steam
TIC
TK-60 Surge Tank
To MX-101
LIC
P-64
PIC
N2 Gas
LIC
P-63
FIC
HX-10
CLR-3
TK-61 Refined SBO Storage
To Vacuum Mixer
18
PIC
Interesterification Controls
N2 Gas
TK-67 Soft Water Storage
Water Softener
TK-62 SBO Hardfat Storage
LIC
P-71
FIC
QIC
P-65
PIC
HX-16
N2 Gas
FIC
TIC
TK-63 SBO Hardfat Heating Tank
TK-64 CH3ONa Storage
TK-65 20 Citric Acid Storage
FIC
MX-3
MX-4
P-68
P-69
TIC
TC
PIC
P-66
HX-14
LIC
QIC
FIC
N2 Gas
P-72
P-73
PIC
HLO
HLO
TIC
N2 Gas
TK-66 Mixing Tank
TC
LIC
TK-61 Refined SBO Storage
Cent-7
Cent-6
QIC
PIC
TK-68 SBO Storage
N2 Gas
P-67
HX-15
TC
TIC
P-70
CLR-4
TIC
FIC
FIC
Filter
19
Margarine Controls 1
QIC
Algae Oil Storage
TK-20
P-30
CIP
CIP
CIP
QIC
Refined SBO Storage
Warm Water
TK-21
P-31
CIP
QIC
Lecithin Storage
TIC
Oil
Oil Phase Prep. Tank 1
TK-22
QIC
P-35
Beta CaroteneStorage
TK-23
TK-31
QIC
QIC
Diacetyl Storage
TK-24
CIP
QIC
P-34
E
Sorbic Acid Storage
TK-25
Oil
Oil Phase Prep. Tank 1
CIP
QIC
Mono- di glycerides Storage
TK-26
TK-32
QIC
QIC
Aqueous Phase Prep.
Ergo- califerol Storage
TK-27
P-33
TK-30
QIC
TIC
Water Storage
P-35
Sea Salt Storage
TK-28
Warm Water
QIC
P-32
TK-29
Pasteurization
Warm Water
20
Margarine Controls 2

P-36
Plate HX
TIC
CIP
CIP
High Pressure Pump
PIC
PIC
Pin Rotor Machine
Scraped Surface Heat Exchanger
P-37
VIC
TIC
Ammonia Compressor
Tub Filling and Packaging
21
CIP Controls
Water
CIP Returning Liquid
CIP Supplying Liquid
P-42
FIC
Strainer
TIC
P
P
HX-41
CS
TK-41 Acidic Solution
TK-42 Alkaline Solution
TK-43 Reclaim Water
TK-44 Fresh Water
P-41
Alkaline Storage
Acidic Storage
Drain
22
Sanitary Design

• Equipment Design
• Cleanable to microbial level
• Made of compatible materials
• Accessible for inspection, maintenance and
  cleaning
• No liquid collection and no niches
• Equipment must perform as designed
• Hygienic compatibility with other plant systems
• Validated cleaning procedures

23
Sanitary Design (cont)

• Facility Design
• Physical separation of distinct hygienic zones
• Material flow and personnel movement control
• Prevent water accumulation inside building
  materials
• Temperature and humidity control
• Air flow and air quality control
• Building envelope sanitary conditions
• Interior spatial design that enables cleaning
• Sanitation integrated into facility design

24
Calculations Fermentation Process

• Fermentation Time Requirement (hours/batch)
• Lag Phase Growth Phase Stationary Phase
  Maintenance
• 0 ln(27.7 g/L)-ln(2 g/L) / 0.03747 hr-1
  20 12
• 102.14 hours
• Algae Production (tons/batch)
• Final Concentration (g/L) x Broth Volume (L) /
  (1000 g/kg) x (2.2046lb/kg) / (2000lb/ton)
• 27.7 x 79,500 / 1000 2.2045 / 2000
• 2.427 tons/batch
• Annual Amount of Algae Produced (tons)
• Oil needed (tons) / 0.2 (g lipids / g dw
  cells)
• 133 / 0.2
• 665.0 tons
• Annual Amount of Batches Required
• 665.0 tons / (2.427 tons/batch)
• 274.0 batches

25
Plant Economics

• Total Project Capital Cost
• 37,328,232.77 USD
• Operating Costs 18,962,032.85 USD/Year
• Raw Materials 6,031,280.00 USD/Year
• Utilities 3,532,157.83 USD/Year
• Maintenance 2,030,000.00 USD/Year
• Operating Labor Costs 2,828,000.00 USD/Year
• Operating Charges 707,000.00 USD/Year
• Plant Overhead 2,429,000.00 USD/Year
• G and A Costs 1,404,594.96 USD/Year
• Total Product Sales
• 25,963,238.43 USD/Year
• Payback Period
• 5.7 Years
• Tax Rate is 40

26
Changes
27
Separation Process PFD
Wet Biomass Tank Tk-12
40
Wet Biomass
Wet Biomass
41
P19
Biomass
Dynamic Cross Flow Filtration
42
39
Water
P21
28
Dryer Process PFD
Exhauster
Purge
Air seal dust valve
Fume controller
37
42
Recycle
Filter
Rotary Dryer
49
43
Dry Biomass
Steam in
50
Steam out
Conveyor Belt
Collection Hopper
Shipping container
Dried Algae Distributor
Conveyor Belt
29
Degumming (Changes)
TK-53 4 NaOH Storage
TK-54 10 Enzyme Refrigerated Storage
N2 Gas
TK-52 45 Citric Acid Storage
131
P-53
P-54
N2 Gas
TK- 51 Crude SBO Storage
138
139
143
Batch Reactor
TK-55 Surge Tank
P-52
HX-5
HX-6
136
132
133
137
142
144
N2 Gas
TK-56 Degummed SBO Storage
P-51
P-55
P-56
153
135
145
147
134
146
141
140
CLR-1
LLO
HLO - Gums
150
148
149
152
151
Cent-5
30
N2 Gas
Interesterification (Changes)
TK-67 Soft Water Storage
193
Water Softener
TK-62 SBO Hardfat Storage
P-71
P-65
214
N2 Gas
194
217
HX-16
195
218
TK-63 SBO Hardfat Heating Tank
TK-64 CH3ONa Storage
TK-65 20 Citric Acid Storage
216
215
196
MX-3
MX-4
197
P-68
P-69
P-66
HX-14
N2 Gas
222
219
198
199
209
210
206
P-72
P-73
N2 Gas
HLO
HLO
221
220
223
224
201
192
TK-66 Mixing Tank
200
TK-61 Refined SBO Storage
Cent-7
Cent-6
N2 Gas
TK-68 SBO Storage
207
208
228
P-67
HX-15
P-70
203
202
CLR-4
213
211
225
205
212
204
Filter
227
226
31
Margarine PFD 2 (Changes)

81
82
P-36
80
Plate HX
83
CIP
CIP
High Pressure Pump
Pin Rotor Machine
Scraped Surface Heat Exchanger
84
87
88
P-37
86
89
85
Packaging
Ammonia Compressor
90
32
Calculation - Margarine

• Length of Pasteurization Piping needed
• Volumetric Flow rate/(Area of pipe) velocity of
  fluid
• .0155 m3/min/(p .022252) 9.966 m/min
• 9.966 m/min 10 min 99.66 m needed for
  pasteurization time
• 99.66 m (3.28 ft / 1 m) 326.885 ft
• Or 330 ft of insulated pipe needed for
  pasteurization

33
CIP PFD
Water
CIP Supplying Liquid
CIP Returning Liquid
P-42
Strainer
TK-41 Acidic Solution
TK-42 Alkaline Solution
TK-43 Reclaim Water
TK-44 Fresh Water
P
P
HX-41
P-41
Alkaline Storage
Acidic Storage
Drain
34
Future Endeavors

• Within next 5 years take over 2 of the market
• Need to add 3 fermentors, remainder of plant can
  be operated at higher capacity
• Degumming and Deacidifiction byproducts streams
• Lecithin profitable byproduct
• FFA high in protein into animal feed
• Margarine Flavoring cinnamon, garlic, honey
• Strictly selling DHA as vitamin supplement at GNC

35
Margarine Nutritional Label
36
Summary

1. Plant Layout
2. Controls
3. Sanitation Design
4. Calculations
5. Economics
6. Changes
7. Future Endeavors
8. PFD
9. Report

37
Questions?
38
Specification on Rotary Dryer (Heyl Patterson)

• Dryer Type Direct Rotary
• Process Type Batch Mode
• Dryer Size 90" Diameter x 60 ft. O/A Length
• Air Flow Rate 5430 lb/hr
• Steam Heat Exchanger Duty 271,065 BTU/hr Max.
• Dryer Duty 101,650 BTU/hr Max.
• Dryer Inlet/Outlet Air Temperature 268/190 Deg
  F
• Dryer Evaporative Load 3829 lb/hr
• System Price 400,000-660,000 USD

39
Calculations Fermentation Process

• Steam Sparged into Fermentor to Sterilize, 60 to
  121C (kg steam)
• (Steam at 145C and 3 barg)
• mbroth (kg)cp(kJ/kgK)?T (K) msteam(kg)Hvap
  (kJ/kg) msteam (kg)cp (kJ/kgK)?T (K)
• 17,300,000 kJ msteam 2,163.47 (kJ/kg)
  0.54.187(144-120)0.54.187(144-60)
• msteam 7,240 kg steam
• Steam Used to Heat Mix Water from 17 to 60C (kg
  steam)
• (Steam at 145C and 3 barg)
• mbroth (kg)cp(kJ/kgK)?T (K) msteam(kg)Hvap
  (kJ/kg) msteam (kg)cp (kJ/kgK)?T (K)
• 9,873,628 kJ msteam 2,163.47 (kJ/kg)
  0.54.187(144-17)0.54.187(144-60)
• msteam 3,719.7 kg steam
• Heat Evolved from Cell Growth (kcal)
• 0.12 Oxygen Uptake Rate (mmol/(h))
  Fermentation Time (h)
• 0.12 295.35 mmol/h 70.14 h
• 2,485.88 kcal

40
Calculations - Separations

• Centrifuge 2
• Mass Balance
• SMass Mass in Mass out 0
• 0 22,902.52 (kg/batch of lysed algae)
  6,168.82 (kg/batch of algae) 16,733.71 9
  (kg/batch of waste water)
• Energy Balance
• Q MCp(?T) Qin
• Q assumption of no temperature change , Qin HP
  supplied to centrifuge
• Q 100HP x 2545 244,500 BTU/ Hr
• Centrifuge 3
• Mass Balance
• SMass Mass in Mass out 0
• Energy Balance
• Q MCp(?T) Qin
• Q assumption of no temperature change , Qin HP
  supplied to centrifuge
• Q ? HP x 2545 381, 845 BTU/ Hr

41
Calculations - Separations

• Co 2 absorption and Lysing
• Mass Balance
• SMass Mass in Mass out 0
• 0 86,663 (kg/batch of algae) 1000 (kg/hr of
  air) 63,295 (kg/batch waste water) -23,368
  (kg/batch of conc. algae) - 1000 (kg/hr of air)
• Energy Balance
• Q MCp(?T) Qin
• Q throttling process is adiabatic, so Qin is
  the steam jacket to tank
• Q 12,700.6 kg/hr of steam
• Centrifuge 1
• Mass Balance
• SMass Mass in Mass out 0
• 0 23,368 (kg/batch of conc. Algae) - 466
  (kg/batch of lipids) - 22, 902 (kg/batch of
  lysed algae)
• Energy Balance
• Q MCp(?T) Qin
• Q assumption of no temperature change , Qin HP
  supplied to centrifuge
• Q 150 HP x 2545 381, 845 BTU/ Hr

42
Calculations - Refining

• Vacuum Vessel
• Sparging Steam flow design
• Tray1- 715.59/6/3785.4120.092/10000.001 0.42
  gal/hr
• Tray2- 715.59/6/3785.4120.092/10000.007 2.91
  gal/hr
• Tray3- 715.59/6/3785.4120.092/10000.015 6.23
  gal/hr
• Tray4- 715.59/6/3785.4120.092/10000.015 6.23
  gal/hr
• HX-11 Oil into the Vacuum Vessel
• Qoil mcp(?T)
• Qoil 921.330.55(500-284)
• Qoil 109454 BTU/hr
• QPoil mcp(?T)
• T 617- (109454/2900/.79)
• T 569.2F
• ?Tlm (T1 t2) (T2 t1)/ln(T1 t2)/ (T2
  t1)
• ?Tlm (617-500) (569.2-284)/ln(617-500)/(569
  .2-284)