harvesting algae to form a neutraceutical, specifically creating a functional food team alpha travis...
TRANSCRIPT
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
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
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
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