1

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

2

DegummingBleaching

Removal FFADeodorization

CentrifugeCrude SBO

Citric Acid

GumWater

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 methoxide

Citric Acid

Water

Sodium methoxideCitric AcidWater

ScrapedSurface HeatExchanger

Packaging

Refrigerant

To Wholesaler

DissolvedAir

FloatationFermentation Centrifuge

CO2

Lysing

Glucose

Beer Still Bottom

Antifoam

Water

Algae

Glucanex

SteamCoolingWater

Sterile air

Vent

Water

Air CO2

BiomassWaterHexane

NaOH

Steam

Steam

Salt

CIPSystem

HexaneExtraction

3

Key Points

1. Plant Layout2. Controls3. Sanitation Design4. Calculations5. Economics6. Changes7. Future Endeavors8. PFD9. Report

4

Otis Rd

Cargill

A

B

C

D

E

F

A. Storage/BoilersB. FermentationC. Offices/Labs/Miscellaneous SpaceD. Water Cooling TowerE. SBO RefiningF. Margarine Processing

Wind DirectionGate

General Plant LayoutAlpha Algae Plant1928 SE Otis RdCedar Rapids, IA 52401

5

S2

Seed 1

S1

S4

S3

Seed 2

Seed 3

Seed 4

Mix Tank

Fermenter 1

Fermenter 2

Fermenter 3

Fermenter 4

Harvest Tank

DAF

RXN 1

RXN 2

Absorption

Lysed Tank

Lipid Storage

Centrifuge 1 Centrifuge 2

C3 C4Dryer

Glucose Storage

Ethanol Bottoms

Glucanex Antifoam

Salt Boiler

Cooling Tower

Electrical Room

85 ft

35 ft

115 ft

Fermentation Layout

Silo

6

HardfatSBO

Storage

CrudeSBO

Storage

WaterSoftener

SoftWater

Storage

Batch Rx

DegumSBO

Storage

Mixers

Cent-5Vacuum

Mixer

VacuumVessel

RefinedSBO

Storage

ElectricalRoom

ProcessingTank

InteresterSBO

Storage

InteresterificationTank

CA

Cent-6Cent-7

Mixers

SurgeTank

SurgeTank

Refining Layout

72ft x 34ft

7

SSHE

AmmoniaCompressor

Filling,Packing

Margarine Plant First Floor Layout

= 4 feet

CIP system

Emulsion Tanks

Ingredient PreparationTanks

HPP

50’ x 66’

8

Margarine Plant Mezzanine Layout

ElectricalRoom

Ingredient Storage Tank Area

= 4 feet

9

Main Fermenter

Cooling Water

Sparged Steam

Vented Air 13

14

Sterile Air

10% Seed Fermenter

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

12Compressor 1 Filter 1

1Air

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

To DAF

15

P- 9

Harvest Tank

PIC

QIC

QIC FIC

FIC

TIC

TIC

TIC

TICCompressor 1Air

PIC

Filter

PIC

PIC

QIC

P- 10

P- 11

QIC

QIC

QIC

QIC

FIC

Fermentor Controls

10

Main Fermenter

Cooling WaterSparged

Steam

Vented Air 13

Sterile Air

Sterile Glucanex

Sterile Anti-foam

7

8

11

Filter 1

Filter 2

P- 8

Filter 3

TIC

14

Compressor 1Air

PIC

PIC

FIC

QIC

QIC

9

P- 3

TIC

10QIC

Visc

Foam

QIC

P- 6

Turbidity

QIC

QIC

Fermentor Controls

11

Rxn tank A

Rxn tank B

P-01

FermentedAlgae

FermentedAlgae

Sterilized AirSterilize Air

Vented Air

Conc. Algae

Water

45

18

16

15

17

Dissolved Air Flotation Controls

12

Sterilized Air

Sterilized Air

20

19

22 23

21

46Water

1

2

P10

P11

P12

Water to Cargill treatment

Tk-6

Tk-7

DAF Tk-7

PIC

Cv-21

Cv-23

PIC

FIC

Cv-20

FIC

18 18

Cv-22

FIC

FICFIC

Cv-24

Cv-25

FIC

Cv-26

12

3

Baffle trayTowerTk- 8

CO2 Lysing Controls

Conc. Algae

Sterilized CO2

CO2 AbsorbedAlgae

LysedAlgae&CO2

Vented CO2

LysedAlgae

Throttle Valve

23

24

Filter 4

CO 2

Compressor 2

25 26

27

Stir tank

P13

P1429

Lysed Algae TowerTk- 9

Cv-30

FIC

28

FIC

Cv-27

Cv-29

Cv-28FIC

Cv-30

4748

Steam in & out

TIC

Cv-31

PIC

13

Main Centrifuge Controls

Disc Centrifuge

Algae Wet Biomass

Algae Oil3130

Algae Oil Holding tank

TK-20

P15Algae Oil

FICCv-32

Lysed Algae29

35

14

Separation Process Controls

42

Dynamic Cross Flow Filtration

Wet Biomass

P19

40

Wet Biomass TankTk-12

41Wet Biomass

Biomass

FICCv-36

39 Water

Cv-37

P21

FIC

15

Rotary

Dryer43Dry Biomass

49Steam in

TIC

50Steam out

Conveyor Belt

Collection Hopper

Conveyor Belt

Dried Algae DistributorShipping container

37

Purge

42

Dryer Process Controls

Exhauster

Air seal dust valveFume controller

Filter

RecyclePIC

16

TK- 51Crude SBO

Storage

P-51

N2 Gas

TK-5245% Citric

Acid Storage

P-52

P-53P-54

TK-534% NaOHStorage

TK-5410% EnzymeRefrigerated

Storage

N2 Gas

HLO - Gums

BatchReactor

P-55

P-56

TK-55SurgeTank

N2 Gas

TK-56Degummed

SBOStorage

HX-5

CLR-1LLO

HX-6

Cent-5

TIC

TIC

FIC

PIC

PIC

PIC

TIC

pHC

QIC

QIC LIC

TC

FIC

LIC

LIC

Degumming Controls

17

N2 Gas

TK-56Degummed

SBOStorage

HX-8

TK-5750% Citric

AcidStorage

P-57

P-58

TK-58Acid

ActivatedClay Tank

P-59

P-60

TK-59Water

Storage

P-61

HX-9

P-62

VP-1

VacuumMixer

N2 Gas

TK-60SurgeTank

P-63

MX-1MX-1

VP-2

Steam

To MX-101

P-64

N2 Gas

TK-61Refined

SBOStorage

HX-10

HX-11

CLR-2

CLR-3

Filter

VacuumVessel

RP-1

TIC

TIC

TIC

FIC

FIC

PIC

PIC

PIC

PIC

PIC

FIC

To VacuumMixer

LIC

FIC

FIC

LIC

LIC

Refining Controls

18

N2 Gas

TK-61Refined

SBOStorage

N2 Gas

TK-62SBO

HardfatStorage

N2 Gas

TK-63SBO

HardfatHeating

Tank

P-66

P-67

HX-14

HX-15

P-68

TK-64CH3ONaStorage

TK-66MixingTank

P-69

P-70

Filter

TK-67Soft

WaterStorage

HX-16

HLO

P-71

P-72 P-73

HLO

Cent-7Cent-6

TK-6520% Citric

AcidStorage

N2 Gas

TK-68SBO

Storage

CLR-4

MX-3 MX-4

WaterSoftener

P-65

TIC

TIC

TIC

TIC

PIC

PIC

PIC

PIC

FIC

TIC

FIC

QIC

FIC

FIC

LIC

QIC

TC

FIC

LIC

TC

TC

N2 Gas

PIC

FIC

QICLIC

Interesterification Controls

19

E

Algae OilStorage

Refined SBO Storage

Lecithin Storage

Beta CaroteneStorage

DiacetylStorage

Sorbic AcidStorage

Mono- di glyceridesStorage

Ergo-califerolStorage

WaterStorage

Oil

CIP

Aqueous PhasePrep.

TK-20

TK-21

TK-22

TK-23

CIPCIP

TK-24

TK-25

TK-26

TK-27

TK-30

TK-31

TK-32

Oil Phase Prep.Tank 1

CIP

P-30

P-31

P-32

P-33

Warm Water

Oil Oil Phase Prep.Tank 1

CIP

Sea SaltStorage

TK-29

P-34

TK-28

CIP

Margarine Controls 1

Warm Water

QIC

QIC

QIC

QIC

QIC

QIC

QIC

QIC

QIC

QIC

QIC

QIC

P-35

P-35TIC

TIC

20

High Pressure Pump

AmmoniaCompressor

Pin Rotor MachineScraped

Surface Heat Exchanger

Tub Filling and Packaging

P-37

CIPCIP

Margarine Controls 2

Plate HX

P-36

TIC

TICVIC

PICPIC

21

TK-41Acidic Solution

TK-42Alkaline Solution

TK-43Reclaim Water

TK-44FreshWater

Alkaline Storage

Acidic Storage

CIP Returning Liquid

Water

HX-41

CIP Supplying Liquid

Drain

P-41

P-42

PP

LIC

LIC

LIC

LIC

LIC

LIC

LIC

LIC

FIC

TICFIC Strainer

CS

CIP Controls

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

Plant Operating Time (hours/year)= Time per batch (hours) * Batches per year / Number of fermentors = 102.14 hours * 274.0 / 4= 6,996.6 ~ 7,000 hours/year

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% Straight Line Depreciation over 10 years 2,986,258.62 USD/Year

26

Changes

27

Separation Process PFD

42

Dynamic Cross Flow Filtration

Wet Biomass

P19

40

Wet Biomass TankTk-12

41Wet Biomass

Biomass

39 WaterP21

28

Rotary

Dryer43Dry Biomass

49Steam in

50Steam out

Conveyor Belt

Collection Hopper

Conveyor Belt

Dried Algae DistributorShipping container

37

Purge

42

Dryer Process PFD

Exhauster

Air seal dust valveFume controller

Filter

Recycle

29

TK- 51Crude SBO

Storage

P-51

N2 GasTK-52

45% CitricAcid Storage

P-52

P-53 P-54

TK-534% NaOHStorage

TK-5410% EnzymeRefrigerated

Storage

N2 Gas

HLO - Gums

BatchReactor

P-55 P-56

TK-55SurgeTank

N2 GasTK-56

DegummedSBO

Storage

HX-5

CLR-1LLO

150

HX-6

Cent-5

153

131

132 133 137 142

138

136

135

134

139

141140

143

144

145147

146

148 149

151

152

Degumming (Changes)

30

N2 Gas

TK-61Refined

SBOStorage

N2 Gas

TK-62SBO

HardfatStorage

N2 Gas

TK-63SBO

HardfatHeating

Tank

P-66

P-67

HX-14

HX-15

P-68

TK-64CH3ONaStorage

TK-66MixingTank

P-69

P-70

Filter

TK-67Soft

WaterStorage

HX-16

HLO

P-71

P-72 P-73

HLO

Cent-7Cent-6

TK-6520% Citric

AcidStorage

N2 GasTK-68SBO

Storage

CLR-4

MX-3 MX-4

WaterSoftener

P-65

193

195

194

196

197

198 199 209 210

201

200

213

211

208

207

228

221220 223

222219

216215

218

217

214

225

224

205

204

203202

192

227

226

212

N2 Gas

206

Interesterification (Changes)

31

High Pressure Pump

AmmoniaCompressor

Pin Rotor MachineScraped

Surface Heat Exchanger

Packaging

P-37

CIP

80

84

8586

CIP

87

89

90

Margarine PFD 2 (Changes)

83

88

Plate HX

8182

P-36

32

Calculation - Margarine

Length of Pasteurization Piping needed

Volumetric Flow rate/(Area of pipe) = velocity of fluid

.0155 m3/min/(π * .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

TK-41Acidic Solution

TK-42Alkaline Solution

TK-43Reclaim Water

TK-44FreshWater

Alkaline Storage

Acidic Storage

CIP Returning Liquid

Water

HX-41

CIP Supplying Liquid

Drain

P-41

P-42

PP

213

203201

216215 207

205

217

212

204202

214

218

208206

211

210

209

Strainer

CIP PFD

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 Layout2. Controls3. Sanitation Design4. Calculations5. Economics6. Changes7. Future Endeavors8. PFD9. 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 121°C (kg steam)(Steam at 145°C and 3 barg)

mbroth (kg)*cp(kJ/kg*K)*ΔT (K) = msteam(kg)*Hvap (kJ/kg) + msteam (kg)*cp (kJ/kg*K)*ΔT (K)

17,300,000 kJ = msteam *[2,163.47 (kJ/kg) + 0.5*4.187*(144-120)+0.5*4.187*(144-60)]

msteam = 7,240 kg steam

Steam Used to Heat Mix Water from 17 to 60°C (kg steam)(Steam at 145°C and 3 barg)

mbroth (kg)*cp(kJ/kg*K)*ΔT (K) = msteam(kg)*Hvap (kJ/kg) + msteam (kg)*cp (kJ/kg*K)*ΔT (K)

9,873,628 kJ = msteam *[2,163.47 (kJ/kg) + 0.5*4.187*(144-17)+0.5*4.187*(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 #2Mass Balance:ΣMass = Mass in – Mass out = 00 = 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) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = 100HP x 2545 = 244,500 BTU/ Hr

Centrifuge #3Mass Balance:ΣMass = Mass in – Mass out = 0

Energy Balance:Q = MCp(∆T) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = ? HP x 2545 = 381, 845 BTU/ Hr

41

Calculations - Separations

Co 2 absorption and LysingMass Balance:ΣMass = 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 tankQ = 12,700.6 kg/hr of steam

Centrifuge #1Mass Balance:ΣMass = Mass in – Mass out = 00 = 23,368 (kg/batch of conc. Algae) - 466 (kg/batch of lipids) - 22, 902 (kg/batch of lysed algae)Energy Balance:Q = MCp(∆T) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = 150 HP x 2545 = 381, 845 BTU/ Hr

42

Calculations - Refining

Vacuum VesselSparging Steam flow designTray1- 715.59/6/3785.412*0.092/1000*0.001 = 0.42 gal/hrTray2- 715.59/6/3785.412*0.092/1000*0.007 = 2.91 gal/hrTray3- 715.59/6/3785.412*0.092/1000*0.015 = 6.23 gal/hrTray4- 715.59/6/3785.412*0.092/1000*0.015 = 6.23 gal/hr

HX-11 Oil into the Vacuum VesselQoil = mcp(∆T)Qoil = 921.33*0.55*(500-284)Qoil = 109454 BTU/hr

QPoil = mcp(∆T)T = 617- (109454/2900/.79)T = 569.2°F

∆Tlm = [(T1 – t2) – (T2 – t1)]/ln[(T1 – t2)/ (T2 – t1)]∆Tlm = [(617-500) – (569.2-284)]/ln[(617-500)/(569.2-284)]∆Tlm = 188.8°F

Q = UA ∆Tlm A = 109454/60/188.8A = 9.68 ft2