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From Algae to a Functional Food
Project Team MembersTravis DallasEric Graves
Joaquin MartinezChristopher McNinch
Ramune Otterson-MeskyteCharu Saini
MentorsDan Rusinak, PE, Middough Inc.Dr. Jeffery Perl, PhD, PE, CHMM
Table of Contents
Executive Summary 3Discussion 4-5Conclusions and Recommendations 6Appendix 1 Design Basis 7Appendix 2 Chemistry of DHA 8-10Appendix 3 Block Flow 11-13Appendix 4 PFDs 14-38Appendix 5 Stream Information 39-53Appendix 6 Material and Energy Balance 54-55Appendix 7 Calculations 56-59Appendix 8 Annotated Equipment List 60-62Appendix 9 Economic Evaluation Factored from Equipment Costs
63-67
Appendix 10 Utilities 68-70Appendix 11 Conceptual Control Scheme 72-92Appendix 12 General Arrangement – Major Equipment Layout
92-95
Appendix 13 Distribution and End Use Review 96-97Appendix 14 Constraints Review 98-99Appendix 15 Applicable Standards 100-103Appendix 16 Project Communications 104-113Appendix 17 Information Sources and References 111-114
2
Executive Summary
AlphaAlgae has designed a plant that will produce a margarine fortified with a popular
omega-3 fatty acid, docosahexaenoic acid (DHA), from growing and cultivating a
specific algae species, Crypthecodinium Cohnii. The plant design incorporates all
aspects of functional food production, from growing the algae, to refining raw soybean
oil (SBO), to making the margarine, with each branch of the food production complying
with strict sanitary design guidelines. The final product, Golden Premium Spread, will be
the only margarine fortified with DHA available at mainstream health food markets in the
United States, allowing the product to obtain a large percentage of the market share
rapidly. 10.4 million tubs of margarine per year will be produced, with each tub having
426 grams of margarine. This means that the plant will produce about 2.3 million
kilograms of product in the first year.
This plant will be located in Cedar Rapids, IA, giving the facility easy access to a Cargill
ethanol plant. The Cargill ethanol plant will be utilized for margarine ingredients, food
for the algae, and waste disposal. AlphaAlgae’s Premium Golden Spread production
facility will cost $ 42 million to build and will cost $ 15 million per year in operating
costs. The payback period for this proposed facility is 5.7 years, and the net present
value of the project is $ 84,727,200 million.
3
Discussion
The health food market has exploded recently, from relatively niche corner stores to
mainstream grocery markets like Whole Foods. Along with the growth in the health food
market, the public’s knowledge and interest in having a healthy lifestyle has also
increased. Golden Premium Spread will fulfill the daily requirements for omega-3 fatty
acids and will be of interest to many consumers who shop regularly at health food
markets. Our ideal consumer population, people who are invested in healthy eating
habits and lifestyle, is increasing and very well informed of any new healthy eating
products.
The table spread market enjoys $ 5.2 billion in sales per year. It is a mature market that
has decreased slightly in the last decade due to concerns with the health of eating table
margarine. A new margarine product advertised as a healthy product will then be able to
obtain consumers who do not usually purchase table spread and capture consumers who
usually purchase other brands. Premium Golden Spread will enjoy $ 18.4 million per
year if it takes 1 % of the table spread market.
Healthy eating is a rapidly growing industry in the 21st century, with more consumers
becoming aware of the need for a balanced and nutritious diet. Omega-3 fatty acids are
becoming a more integral part of this healthy diet. One specifically, docosahexaenoic
acid (DHA) is linked to the healthy development of infants, and the lack of DHA is
affiliated with Alzheimer’s disease. DHA in the past has come from fish oils, but there is
potential for mercury or dioxins contamination as well as a fishy odor and taste.
4
Recently, it has been found that DHA can be extracted from algae instead of fish oils.
Specific algae strains with high concentrations of DHA can be grown in a controlled
environment and then processed, providing an uncontaminated, highly concentrated, and
completely vegetarian source of DHA. Once extracted, the DHA-rich oils can then be
utilized to create a healthy margarine. About $5.4 billion worth of margarines and table
spreads are sold every year, however a DHA-fortified margarine is not currently sold in
the United States. As word about the benefits of DHA spreads, it is apparent that the
desire for foods fortified with this omega-3 fatty acid will grow. A margarine that is
fortified in DHA will be both profitable in industry and beneficial to a public hungry for a
healthy diet.
DHA is generally regarded as safe (GRAS) by the Food and Drug Administration, so the
product will not need to go through any extra tests or vetting. Sanitation at the facility is
of the highest importance, and the production plant has been carefully designed with
sanitation kept firmly at the forefront of consideration. Each piece of equipment in the
food processing section of the facility is built with polished stainless steel, and each
section of the plant will be cleaned regularly with a clean in place (CIP) system, ensuring
that no microbes will exist in the final product. It is vital that the company enter into the
health food market as soon as possible in order to take advantage of the fractured table
spread market, in which many different companies vie for a small piece of the overall
market, to create and control the niche of healthy table spread. Our product would be the
first of its type easily available, and it is thought that our product would make a large
impression on the table spread market.
5
Conclusions and Recommendations
It is believed that this product will perform extraordinarily well in the marketplace. The
rise of healthy eating awareness has created a huge demand for healthier versions of
common foods, and a healthy table spread would interest a huge percentage of
consumers. The payback period of 5 years is then a conservative estimate. It is
recommended that production of the plant begin as soon as possible in order to ensure
that Golden Premium Spread be the first margarine in the market that can offer the
amount of DHA. The table spread market, though large, is a fractured market. This
means that there are many different companies that each control a very small percentage
of the overall sales. It is relatively easy, then, for a new product, especially one marketed
as having health benefits, to break into the market. In conclusion, a product of this type
would be very successful in the market and would attract a very large consumer base
extremely quickly. It is recommended that the plant be built.
6
Appendix 1
Design Basis
The size of all equipment and the economic evaluations are based on a 1 % market share
in the $ 5.2 billion table spread market. This equates to $ 52 million retail. The product
will sell at the market for $ 5, so selling the tubs wholesale will net $ 1.75. In order to
satisfy the 1 % market share, 18.4 million tubs of margarine will be produced every year.
However, much of the equipment is not running at full capacity, making increased
production if the market share increases easy.
7
Appendix 2
Chemistry and Biology of Omega-3 Fatty Acids
Lipids are molecules used by the body for energy storage, for cell membrane structural
building, and for signaling. Lipids include many different categories, and one kind of
lipid is the fatty acid. Fatty acids are long chains of hydrocarbons which terminate at a
carboxylic acid group. A carboxylic acid is a carbon double bonded to an oxygen
molecule and an alcohol, and it creates a hydrophilic end to the fatty acid molecule. The
other end, the hydrocarbon chain, is hydrophobic, which allows for the lipid to create cell
walls and other structures. The hydrophobic hydrocarbon chain can be saturated or
unsaturated. An unsaturated chain includes one or more double bonds while the saturated
chain has only single bonds. The term saturated refers to the hydrogens attached to the
carbons, and a saturated fatty acid then has the maximum amount of hydrogens bonded to
the carbons. For unsaturated fatty acids, the double bond or bonds occur in either cis or
trans formation, with cis being the primary form found in nature. Trans bonds in the
fatty acid form mostly as a result of processing techniques like partial hydrogenation,
though a very small amount does exist naturally as well. A cis double bond has the
adjacent hydrogen molecules on the same side of the bond and creates a kink in the
hydrocarbon chain. Trans formation, then, is just the opposite, with the adjacent
hydrogens appearing on opposite sides of the bond and maintaining the chain’s linear
shape. It has been found that trans-fatty acids, primarily because these kind of bonds in
fatty acids do not naturally occur, are unhealthy to consume, difficult for the body to
process, and lead to such things as coronary heart disease and obesity. Since the
8
discovery of the health risks of trans fats, the public has become very invested in excising
these fats from all processed food products, leading to the need for new techniques to
replace things like partial hydrogenation.
The body is unable to synthesize double bonds in the fatty acid beyond carbons 9 and 10,
so fatty acids like linoleic acid (LA) and alpha-linoleic acid (ALA) are essential. Though
omega-3 polyunsaturated fatty acids (PUFA) can be synthesized from LA and ALA, it is
a slow and energy intensive process. Therefore, it is much easier and more beneficial to
acquire long chain omega-3 fatty acids, which are used in a variety of bodily functions
and processes, through the diet. Omega-3 fatty acids are named for the double bond that
exists in the third bond from the methyl end of the carbon chain. Some examples of
omega-3 fatty acids are Eicosapentaenoic acid (EPA), Docosapentaenoic acid (DPA), and
Docosahexaenoic acid (DHA). Marine oils in particular contain a large amount of these
omega-3 fatty acids, but fish, like humans, are unable to synthesize these fatty acids
directly. Instead, the fish acquire these fatty acids from consuming algae, and humans
acquire the fatty acids from the fish.
This is the DHA molecule. The omega-3 bond at the methyl end of the carbon chain is depicted. The methyl end is denoted as the omega end of the molecule since it is considered the terminal end. Since there are multiple double bonds, DHA is considered a PUFA, and these double bonds are naturally in the cis formation. In cis formation, the hydrogens bonded to adjacent carbons in double bonds are situated on the same side of the bond. This makes the molecule bend or kink, making it easier for the body to
9
process. The figure also depicts the carboxylic acid that is on the other terminal end of the molecule.
Omega-3 fatty acids have been found to be an extremely beneficial part of the diet, with
many health benefits that come from consuming an adequate amount of these fatty acids.
Some examples of health benefits from consuming omega-3 fatty acids are heart health,
cancer prevention, and brain growth and health. DHA in particular has been singled out
as a very healthy and beneficial omega-3 fatty acid. DHA, like other omega-3 fatty acids,
can be found in various food products, but is found most concentrated in fish oils. These
fish oils are highly concentrated in DHA not because the fish can synthesize omega-3
fatty acids, but because the fish consume these fatty acids from microalgae that do
produce omega-3 fatty acids.
10
Appendix 3
Block Flow Diagram
DegummingBleaching
Removal FFADeodorization
CentrifugeCrude SBO
Citric AcidGumWater
Citric Acid
Citric AcidAcid Activated Clay
EnzymeWater
Acid ActivateClay
Interesterification
Hardfat SBO
Emulsification Pasteurization
WaterSea SaltLecithinDiacetyl
Mono/DiglyceridesB-Carotenes
Sorbic AcidErgocaliferols
Sodium Hydroxide
Citric AcidWater
Sodium HydroxideCitric AcidWater
ScrapedSurface HeatExchanger
Packaging
Refrigerant
To Wholesaler
DissolvedAir
FloatationFermentation CentrifugeCO2
LysingGlucose
Beer StillBottom
Antifoam
Water
Algae
Glucanex
SteamCoolingWater
Sterile air
Vent
Water
Air CO2
LHO-BiomassWater
NaOH
Steam
Steam
Salt
CIPSystem
Block Flow Description
11
Algae is grown in the fermentation stage, and C. Cohnii is the algae type that will be
grown in the fermentation stage. This species of algae has been chosen because of the
high concentration of DHA that exists in its lipids. After the algae is grown, the algae
bodies are separated from the liquid using dissolved air floatation. This process uses air
to push the algae to the top of the broth. After the algae is concentrated at the top of the
broth, it is separated from the bulk fluid by a scraper. This next step of the process is cell
lysing. This step is necessary because the DHA is inside the cell and the cell must be
broken in order to extract the oil. This process uses CO2 to pop open the cells using a
pressure differential. A centrifuge will then separate the oil from the water, leaving the
algae oil that will be used in the margarine process.
The margarine uses refined soybean oil (SBO) that is specially made in a process that
leaves zero trans fatty acids. Crude SBO is bought from Cargill in order to be processed
in our refining plant. The crude SBO is first degummed because the gums contained in
the SBO interfere with the rest of the process. A centrifuge then separates the SBO from
the gums. After the gums are separated, the SBO is bleached and deodorized so that the
final margarine process has a quality taste. Also in this process, free fatty acids are taken
out of the SBO so that the margarine has the correct “mouth feel.” Finally, the last block
of the SBO refining process is interesterification. This is a chemical reaction by which
the glycerides contained in the SBO are randomly reordered in the triglyceride. This
helps the SBO have the right form at the right temperature. If the SBO is too hard, the
margarine would not melt at mouth temperature, creating an unpleasant sensation when
eaten. If the SBO is too soft, then the margarine would liquefy inside the refrigerator,
12
making it very difficult to spread. The interesterification is used because the more classic
method to create margarine that melts and hardens at the right temperatures utilized
partial hydrogenation. This created trans fatty acids inside the margarine, which are
unhealthy and are avoided in this process.
After these ingredients have been prepared, they are mixed together in the margarine
production process. First the ingredients are emulsified, which is just an intense mixing,
creating a creamy mixture of water suspended within the oil. This resulting emulsion is
then pasteurized in order to ensure that no microbes are still living inside the emulsion.
This is required for a food product so that the consumer is not made ill eating the product.
In the scraped surface heat exchanger, the emulsion is crystallized, after which it is sent
to packaging. All of these systems are cleaned with a clean in place (CIP) system, which
keeps all the equipment clean and free of microbes.
Appendix 4
13
Process Flow Diagrams
Fermentation PFD
14
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
Rxn tank A
Rxn tank B
P-01
FermentedAlgae
FermentedAlgae Sterilized Air
Sterilize Air
Vented Air
Conc. Algae
Water
45
18
16
15
17
Dissolved Air Flotation PFD
12
Sterilized Air
Sterilized Air18
18
20
19
22 23
21
46Water
1
2
P10
P11P12
Water to Cargill treatment
Tk-6
Tk-7
DAF Tk-7
15
3
Baffle trayTowerTk- 8
CO2 Lysing PFD
Conc. Algae
Sterilized CO2
CO2 AbsorbedAlgae
LysedAlgae&CO2
Vented CO2
LysedAlgae
Throttle Valve
23
28
24
Filter 2
CO 2
Compressor 2
25 26
27
Stir tank
P13
P14
29
Lysed Algae TowerTk- 9
16
Main Centrifuge PFD
Disc Centrifuge
Wet Biomass Slurry
Algae Oil3130
Oil settling tankTK-20
P15
Algae OilCv-32
Lysed Algae29
35
36Water
17
Separation Process PFD
42
Dynamic Cross Flow Filtration
Wet Biomass
P19
40
Wet Biomass TankTk-12
41Wet Biomass
Wet Biomass
39 Water
Cv-37
P21
18
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
Cv-38
Cv-39
44
45
46
47
48
Air Vapor
Water Vapor
19
Extraction PFD
Oil
Settling Tank
Tk-11
Water
33
Disc Centrifuge
Lysed Algae P16
40
30 34
38
32 Lysed Algae
Biomass
39
P18
P17
Water
45
Water
Degumming PFD
20
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
135134
139
141140
143
144
145147146
148 149
151152
21
Refining PFD
N2 Gas
TK-56Degummed
SBOStorage
HX-8
TK-5750% Citric
AcidStorage
P-57
P-58
TK-58Acid
ActivatedClay Tank
P-59
P-60
TK-67Soft Water
Storage
P-61HX-9
P-62
VP-1
VacuumMixer
N2 Gas
TK-60SurgeTank
P-63
MX-1MX-1
VP-2
Steam
To MX-1
P-64N2 Gas
TK-61Refined
SBOStorage
HX-10
HX-11
CLR-2
CLR-3
Filter
VacuumVessel
RP-1
153
155 159154
158
162
160
161
156157
164
163
165
166
169168
188187
170
167
188187
184
185
189
192
175
173
174
172
171
180
182183
181
190191
179
178
177
176
22
Interesterification PFD
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-73HLO
Cent-7Cent-6
TK-6520% Citric
AcidStorage
N2 GasTK-68SBO
Storage
CLR-4
MX-3 MX-4
WaterSoftener
P-65
193
195194
196197
198 199 209 210
201200
213211
208207
228
221220 223
222219
216215
218
217
214
225
224
205204
203202
192
227226
212
N2 Gas
206
23
E
Algae OilStorage
Refined SBO Storage
LecithinStorage
Beta CaroteneStorage
DiacetylStorage
SorbicAcidStorage
Mono- diglyceridesStorage
Ergo-califerolStorage
WaterStorage
Oil
Pasteurization
CIP
Warm Water
Aqueous PhasePrep.69
TK-20
TK-21
TK-22
TK-23
CIPCIP
TK-24
TK-25
TK-26
TK-27
TK-30
TK-32
TK-31
Oil Phase Prep.Tank 1
CIP
P-30
P-31
P-32
P-33
Warm Water
Oil Oil Phase Prep.Tank 1
CIP
68
70
67
66
65
64
62 63
60 61
71Sea SaltStorage
TK-29
P-34
73
74
TK-28
75
72
72
76
CIP
79
77
75
79
77
80
Margarine PFD 1
Warm Water
78
P-35
P-35
78
24
High Pressure Pump
AmmoniaCompressor
Pin Rotor MachineScraped
Surface Heat Exchanger
Packaging
P-37
CIP
80
84
8586
CIP
87
89
90
Margarine PFD 2
83
88
Plate HX
8182
P-36
25
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
218208206
211
210
209
Strainer
CIP PFD
Process Flow Description
26
Fermentation
The fermentation of Crypthecodinium cohnii takes place at an ideal temperature of 81°F.
The fermentation process was chosen to be a batch process over a fed-batch process or a
continuous process. The fed-batch process showed no significant benefit to a batch
process, using a glucose substrate, either in final cell density or in fermentation time.
This is likely due to the loss of an unknown growth factor in the ethanol bottoms nutrient
during sterilization. Continuous processes for algae fermentation are untested and can
potentially compromise the sterility of the fermentation. The batch fermentations are to
take place in 35,000 gallon fermentors. Four of these fermentors, operating at 60%
volume capacity, are required to achieve the amount of lipid products specified in our
economic basis.
The fermentation is to take place on a carbon substrate of glucose. Glucose was chosen as
the substrate over acetic acid and ethanol, which could have attained higher cell
concentrations. However, higher concentrations of acetic acid or ethanol are required to
conduct such a fermentation, and both substrates have corrosive qualities that would
cause damage to the fermentors over time. The time period required for acetic acid
fermentations is also longer, at 400 hours, compared to 71 hours per fermentation with
glucose substrate. Ethanol is a fire hazard, especially at the high concentrations required
to ferment C. cohnii.
27
The fermentation of C. cohnii requires a nitrogen source. The nitrogen source for this
fermentation comes from the dead yeast that collects at the bottoms of ethanol stills.
These ethanol bottoms will act as the nitrogen source and the source of any growth
factors that are not included in other feed components. The concentration of ethanol
bottoms used will be limited to 8-10% of the concentration of glucose used as it is
important that nitrogen be consumed by the end of the growth phase of our C. cohnii.
The lack of a nitrogen source will cause the algae to enter a stationary phase in which
growth no longer occurs, but the algae begin to produce excess lipids.
The growth phase of our algae fermentation was calculated using the Arrhenius equation,
, and was calculated to be 70.15 hours. The growth rate used was calculated
from data taken from de Swaaf, et al, 1998 and was found to be 0.0371 h-1. The
maximum final concentration of algae was found to be 27.7 g dw/l and was assumed to
be 27.0 for the purposes of our fermentor. The stationary phase was assumed from
literature to be optimal at 20 hours. The lipid concentration resulting from the combined
90.15 hour fermentation time was taken to be 5.54 g/l. The fermentation schedule
accounts for a 12 hour maintenance period after each batch, which can be reduced to
increase productivity.
At 60% capacity, a single fermentor will hold 79,500 liters of fluid volume. That volume
will produce 971 pounds of lipids and 4,855 pounds of algae biomass per batch. Each
fermentation will require 7.02 short tons of glucose, 0.65 short tons of ethanol bottoms,
and 2.19 tons of sea salt to achieve a salinity of 25 g/l. The glucose, ethanol bottoms, and
28
sea salt will be mixed with 60,617 liters of water, in a 27,000 liter tank at 140°F prior to
their transfer to the fermentor. Sterilization takes place in the fermentor using sparged
steam until the broth reaches 250°F and is held at that temperature for 1 hour. The
volume of sparged steam required is 15,926 pounds of steam at 293 °F and 3 barg. The
broth is then cooled with cooling water until the temperature reaches 81°F. A seed batch
of broth, fermented in a 10% seed fermentor, is then added to the main fermentor.
During the fermentation we will add 350 pounds of glucanex and 31 pounds of silicone
anti-foam per batch as needed.
Glucanex is an enzyme complex consisting of β-glucanase, chitinase, and pectinase
manufactured by Novo Nordisk and it will be used to reduce the viscosity of the
fermentation. It is available as a freeze dried powder and will be mixed into a 100g/l
solution with water. Glucanex is a polysaccharide hydrolase, which will fold the long
chain polysaccharides produced by the algae as it consumes glucose. The byproduct
polysaccharides increase viscosity, which reduces mixing efficiency and reduces aeration
rate of the broth. The glucanex solution will preferably be added at 50% of the
fermentation time to minimize the impact on growth. Thermal sterilization would
deactivate the enzymes in the glucanex solution. The solution will be filter sterilized
using 0.22 micron pore cross flow filtration and the solution will be 100g/l in water.
The anti-foam solution that will be used is an oil with the active ingredient of
polydimethylsiloxane and it is produced by Dow Corning. The oil will be retained in our
final product and its concentration must be minimized to meet FDA standards of less than
29
10 ppm. The anti-foam will be heat sterilized with a steam heat exchanger at 250°F as it
is added to the fermentor.
The fermentation broth must be aerated with filter sterilized air sparged at 157.9
Nm3/minute at 26 psi. The air will be compressed with a centrifugal compressor and will
be sterilized with a 0.22 micron filter. A dissolved oxygen saturation of 20% is desired
for the fermentation, which is 1.359 mg oxygen/ l, for optimal growth.
Degumming
The crude SBO is stored in an agitated tank with a volume of 20,000 gallons. There is a
5 psig nitrogen blanket maintained on the tank. The crude SBO is pumped from the tank
at 720gallons per batch through a heat exchanger to raise the temperature from 77 °F to
176 °F. The heating medium is Paratherm NF being pumped at 500 gph at a temperature
of 617°F and exiting at 528.3°F. 45% citric acid is pumped into the crude SBO stream at
0.07gallon per batch giving a pH of 4.06. Citric acid is stored in a 25 gallon tank. The
citric acid and crude SBO are mixed for 30 minutes prior to the temperature being
dropped to 122 °F by cooling water at a flow rate of 500 gph and an inlet temperature of
85 °F. The cooling water outlet temperature is 113.8 °F. The addition of 4% sodium
hydroxide is a controlled process in order to maintain a constant pH of 4.90 (±0.10) in the
batch reactor. 14.4 gallons of water is added to the batch reactor. The final additive to
the 1200 gallon batch reactor is 10% enzyme solution. The enzyme is Lecitase Ultra,
manufactured by Novozyme. The Lecitase Ultra is stored in a refrigerated storage tank at
30
41 °F. The mixing in the batch reactor continues for 6 hours, and then the solution is
pumped to a 1200 gallon surge tank with a 5 psig nitrogen blanket and a 50 rpm agitation
system. The surge tank is emptied over a 6 hour period with a 120 gallon per hour pump.
Out of the surge tank the solution is heated up from 122 °F to 158 °F by the Paratherm
NF. The Paratherm cools from 617 °F to 611.6 °F. After going through the heat
exchanger the solution is directed to a centrifuge. The centrifuge sends HLO to a storage
tank which will then be sent off to Cargill in order for the gums to be processed. From
the centrifuge, the crude SBO is sent to a cooler to bring the temperature down to 122°F
prior to entering a 4,000 gallon storage tank with a 5 psig nitrogen blanket and a 50 rpm
agitation system.
The degummed SBO is pumped at 120 gph through a heat exchanger to ensure the outlet
temperature is 122 °F. 50% citric acid is stored in a 35 gallon tank and added to the SBO
to achieve a pH of 3.41. The solution goes into a 100 gallon mixer where it is continually
mixed at 150 rpm for 15 minutes. From the outlet of the mixer the solution is pumped at
120 gph to a mixer where a 0.5 wt% oil of acid activated clay is added to the mixer by a
rotary feeder. Water is also added to the second mixer at a 0.05 wt% of the oil. The
solution is mixed for 15 minutes before being pumped through an economizer to raise the
temperature from 122 °F to 176 °F. The solution then enters a vacuum mixer and is
heated up to 250 °F by use of heating coils. It is continually mixed at 250 rpm for 15
minutes. The mixing is maintained at a vacuum of 10 mmHg. The solution exits the
31
mixer and is cooled by the previous economizer to 196° F. At 120 gph, the liquid flows
through a rotary disk filter to remove clay. The clay is discarded to a landfill. As it exits
the filter the liquid goes into a 1,500 gallon surge. The tank is continuously stirred at 50
rpm and utilizes a nitrogen blanket that is kept at 5 psig. The solution is pumped from
the surge tank at 120 gph to a second economizer to raise the temperature to 284° F prior
to it entering a heat exchanger where the temperature is again increased to 500 °F. The
heat exchanger heating medium is Paratherm NF, which cools from 617°F to 568.4°F.
The crude SBO enters the vacuum vessel where it is steam sparged on 4 trays at a
vacuum of 10 mmHg. The oil is maintained on each tray for 15 minutes before it falls
down to the next tray where it is sparged with additional steam. The amount of steam
from top to bottom is 0.1, 0.7, 1.5, 1.5 wt%, respective to the amount of oil. The steam,
FFA, citric acid, and water exit from the top of the vacuum vessel and are sent to Cargill
for processing. The refined oil leaves the vacuum vessel via a 120 gph pump through the
second economizer which lowers its temperature from 482 °F to 415.4 °F. At the outlet
of the economizer the oil goes through the heating coils of the vacuum mixer where its
temperature is decreased to 356 °F. The oil must be cooled down to 122 °F by cooling
water at 85° F entering the cooler and exiting at 108.4 °F. The refined oil enters the
4,000 gallon storage tank with a 5 psig nitrogen blanket and 50 rpm mixing.
Interesterification
32
The refined SBO is pumped from the storage to tank at 350 gph through a heat exchanger
to raise the temperature from 122 °F to 230 °F. The heating medium is Paratherm NF
which has a resulting temperature change of 617 °F to 542 °F. The refined SBO then
enters the interesterification mixing tank.
The hardfat SBO is stored in a 10,000 gallon tank with a nitrogen blanket at 5 psig and
continually stirred at 50 rpm. The hardfat SBO is pumped at 175 gph to a 1,000 gallon
processing tank where the hardfat SBO is heated from 77 °F to 122 °F while being mixed
at 50 rpm with a 5 psig nitrogen blanket on the tank. The tank is heated with Paratherm
NF entering at 500 gph at a temperature of 617 °F to maintain the temperature of the
hardfat SBO. The SBO is then pumped at 100 gph through a heat exchanger to raise the
temperature to 230 °F. The hardfat SBO then enters the interesterification mixing tank.
The hardfat and refined SBO are mixed and maintained at 230° F at 37.5 mmHg for 40
minutes. Cooling water is used to cool the tank to 194 °F, while still maintaining
vacuum. 99.8% sodium methoxide is added to the tank at 0.5 wt% of the oil in the
interesterification tank. Mixing is continued at 500 rpm for 30 minutes. Cooling water
cools the SBO down to 176 °F. The process is inactivated by 2 wt% addition of 20%
citric acid to the tank. Stirring is continued for an additional 15 minutes. When the
process is complete, the SBO is pumped at 500 gph through a rotary disk filter to remove
the sodium methoxide, which is sent to the landfill.
33
Water washing is done with soft water from a 7,500 gallon storage tank. The soft water
is used for two washing procedures. Each wash with soft water is done with 5 wt% oil in
a 500 gallon mixer, stirring at 150rpm. The mixing lasts for 10 minutes in each mixer.
At the outlet of each mixer is a centrifuge to handle the 500 gph oil and water mixture.
The waste from the centrifuge will need to be neutralized and disposed of. The washed
SBO leaves the second centrifuge to enter a 500 gallon atmospheric pan dryer. The
temperature is then increased to 230 °F for 30 minutes. The SBO is then pumped at 500
gph from the dryer to cooler to bring the temperature to 122 °F, using cooling water as
the medium utilized for the cooling. The SBO then enters a 5000 gallon storage tank
with a 5 psig nitrogen blanket and is mixed at 50 rpm.
Margarine Process
The margarine process is fairly straightforward, with no major chemical reactions or
exotic pieces of equipment. The ingredients are placed into two categories: the oil phase
and the water phase. The oil phase consists of the oils and the oil-soluble ingredients.
These are 669 kg / hr of the refined soybean oil gathered from the soybean refining
process, 22.9511 kg / hr of the DHA-rich algae oil taken from the harvested algae, 1.8
kg / hr of lecithin, 4.3 kg / hr of the mono and diglycerides, .00007 kg / hr of
ergocaliferol, .02 kg / hr of the beta-carotene, .002 kg / hr of the diacetyl, and .9 kg / hr
sorbic acid. These ingredients are prepared in an 1500 L oil phase preparation tank.
There are two of these tanks in order for the process to fun semi-continuously because
two tanks can be prepared at the same time. The water phase phase consists of the
34
potable, clean water and the sea salt. The water runs into the water preparation tanks at
154 kg / hr and the salt is added to the preparation at 12 kg / hr. These are prepared
together in a water phase preparation tank. There is only one of these tanks because the
ingredients are quickly and easily mixed together. After one batch is sent through,
another batch is quickly prepared. The water tank for this process is small, at 1000 L
because it is connected to the city water supply and is refilled as the water is used.
After these initial preparations, the oil phase is sent to one of the two 2000 L
emulsification tanks where it is heated with a warm water jacket over the tank. As it is
being mixed, the water phase is then slowly added, creating a water in oil emulsion. This
emulsion is heated to around 100 °F to allow for better mixing, and the emulsion tank
agitators stir the mixture with about 8 hp. After the emulsion is well-mixed, it is sent
forward to a plate heat exchanger which heats the emulsion to 110 °F. Pasteurization is
needed for two major reasons. First, it kills any remaining microbes which may still be
living inside the emulsion. Obviously, for sanitary reasons, these microbes must be
killed. Secondly, the pasteurization stage heats the emulsion to a consistent temperature,
which may not have occurred in the emulsification tanks. After pasteurization, the
emulsion is transferred to a high pressure, plunger type pump or homogenizer. This
pump pressurizes the emulsion to 75 bar, causing a slight temperature increase of 10 °F.
This high pressure keeps the emulsion from separating further down the line. After this
pressurization, the emulsion travels through a long section of insulated pipe. This part of
the process is used for pasteurization, keeping the emulsion at around 120 °F for ten
35
minutes to ensure that any microbes are completely killed. The length of this tube is 330
ft and the pipe will be wrapped around the entire plant as is common practice.
The next stage of the margarine process is considered the heart of the production line.
Here, using a scraped heat exchanger, the emulsion is crystallized to 50 °F using an
ammonia based refrigeration system. An external ammonia compressor is utilized in this
refrigeration system, with an ammonia circulation of 18 tons. The crystallized margarine
is scraped from the walls of the SSHE by mechanical means. After crystallizing, the
margarine is then kneaded in a pin rotor machine which ensures that the final margarine
project has the correct viscosity. Then the margarine is sent through a tub filling and
packaging machine, ready to be sent out the door.
CIP Process
Cleaning and sanitizing equipment is critical in the food processing industry. The
cleaning in place (CIP) system is an integral part of all modern margarine production
facilities, preventing bacteria growth and assuring sanitary equipment conditions. The
CIP system involves the recirculation of the cleaning fluids through assembled food
processing equipment in a continuous circuit with rinse and detergent solutions at the
proper concentrations, temperatures, pressures and times. For a traditional margarine
products the normal equipment cleaning interval is once a week. However, the cleaning
interval is shorter for the products with a high water content, a low fat content, or a high
protein content.
36
The CIP tanks can vary in size depending on the design and the necessary duty of the
system, but they should hold enough liquid to completely fill the largest cleaning circuit
plus a 25% reserve. The usual lay out for CIP set is to have three tanks, one that contains
fresh water, one that contains detergent, and one that contains reclaimed water. A fourth
tank with secondary detergents is found in some systems. The four CIP tank set is usually
used for margarine facilities. The tanks are usually round with a conical bottom, and
made with stainless steel.
CIP pumps fall into roughly three groups: delivery pumps, mixing pumps and return
pumps. Delivery pumps are usually centrifugal, offering high flow at relatively low
pressures and are designed to work best with a flooded suction. These are used to deliver
the cleaning solution to the portion of the plant that is being cleaned. Mixing pumps are
usually of the same design as delivery pumps, but have smaller capacities. These are used
to ensure adequate mixing of the detergents. Return pumps are used to return the cleaning
solution from the portions of the plant that are being cleaned back to the CIP tanks. They
should be designated to pump well even without a flooded suction; this allows them to
cope with the large quantities of air that become entrained in the cleaning solutions
during CIP.
Generally the most effective CIP process incorporates five steps:
1. An initial rinse;
Rinse with water at ambient temperature to remove any residues. 10 to 15 minutes
are usually sufficient for this part of the cycle.
37
2. Rinse with alkaline detergent;
Rinse with an alkaline detergent, typically a 2-2.5% solution of Caustic Soda
(NaOH) at about 70˚C for a time period of 20-30 minutes. This phase should
remove any organic matter.
3. Intermediate rinse with water;
Rinse with water at ambient temperature for a time period of 5 to 10 minutes. This
step should remove any residual detergents
4. Rinse with acidic detergent;
Rinse it with an acidic detergent, typically a 2.5% or lower concentration of Nitric
Acid (HNO₃) solution at ambient temperature for a time period of 10-15 minutes.
This phase should remove mineral salts, proteins, lime and other deposits.
5. Final rinse with clean water.
Rinse with clean water at ambient temperature to remove all traces of the cleaning
detergents. 10 to 15 minutes are usually sufficient for this part of the cycle.
During the CIP cycle it is important to keep the detergent concentrations constant; a
significant increase in concentrations can damage the system equipment, while a
significant decrease in concentration can negatively affect the detergents cleaning
efficiency.
38
Appendix 5
Stream Data
Stream No
Stream Name
Stream DataFlow rate, kg/batchFlow rate, kg/hrTemperature, °CPressure, bargPhaseSp grBulk density, kg/m3
Water, kgDry solids, kgSolvent, kgpHAir, Nm3/min
1 2 3 4 4a 5
Glucose Sea SaltEthanol Bottoms
Water to Water Heater
Steam to Water Heater
Water to Mix Tank #1
6,371.2
1,989.1
592.1
56,827.4
3,790.0
60,617.3
17 17 17 17 145 60
1 1 2 3 2Liquid Solid Liquid Liquid Gas Liquid
1.54 1.00 0.002 1.00
7 8 9 10 11 12
39
Medium to Fermenter
Steam Sparged Seed Batch
Sterile Anti-foam
Sterile Glucanex Sterile Air
69,569.7
7,224.3
8,277.2 14
1,590
14,168
7,222
7,224.3
0.20
202.01
60 145 121 27 -
- 3 2.0 2.0 0.8 Liquid Gas Liquid Liquid Liquid Gas 1.20
1.20 -
- - 60,617
7,224.3
7,305.7
1,431 -
592
215.6
159 -
8,360
755.9 -
7.0 7.0 - - 156.32
13 14 15 16 17 18
Vented AirInlet from
Harvest Tank Rxn tank A Rxn tank BSterile Air In Sterile Air In
14,168
86,663
43,332
43,332
202.01
14,444
7,222
7,222 1,000 1,000
27 27 0.5 7 7 Gas Liquid Liquid Liquid Gas Gas
- 1.20
1.60
-
- 76,583
38,292
38,292
- 3,095
1,548
1,548
- 6,985
3,492
3,492
-
156.32 13 13
19 20 21 22 23 24
40
inlet DAF
Waste Water
Conc Algae
Vented air
Inlet from daf tk Sterlized CO2 In
86,663 63,295
23,368 23,368
14,444
30,162 10,882 1,000
27 27
27
27 27
3 10.3422 Liquid Liquid Gas Liquid Gas 1 2
1,600 1,600
76,583 57,437
19,146 19,146
3,095 619
2,476 - 2,476
6,985 5,239
1,746 - 1,746
26
25 26 27 28 30 31Absorbed
CO2 Algae
Throttled Algae
Vented CO2
Lysed Algae Ctfg. Inlet lipids
23,368 23,368 466
6,581 27 3 1.01353 0 Liquid Liquid gas Liquid Liquid
18,787 18,787
19,146 19,146 -
624 2319 2,476 2,476 466
2,319 2,319 1,746 1,746 -
32 33 34 35 36 37
41
biomass
Biomass + Water In Biomass Water Out Dry Biomass Evaporated Water
22,903
22,902.52
6,168.82
16,733.71 2,339.66 3,829.16
31,360 Liquid Liquid Liquid Solid Liquid 19,146
19,146
3,829
15,317
2,011 2,011
1,990.42 20.11
1,746 1,746
349 1,397
60 61 62 63 64 65
Alg. Oil In 1 Alg. Oil In 2 SBO In 1 SBO In 2 Lecithin In
B-Carotene In
22.9511 22.9511 668.831 668.831 1.73047 0.01716870 70 70 70 70 70
Liquid Liquid Semi-Solid Semi-Solid Liquid Solid
0.9 900 900 900 900 1078.2 941
- - - - - -- - - - - -- - - - - -- - - - - -- - - - - -
42
66 67 68 69Diaceyl In Sorbic Acid In Mono- Di Glycerides In Ergocaliferol
0.002163 0.865236 4.32618 7.52E-05
70 70 70 70 Liquid Liquid Solid
990 1200 - - - -- - - -- - - -- - - -- - - -
70 71 72Potable Water in 1 Potable Water In 2 Oil Phase prep. 1
153.803 153.803 698.72370 70 70
liquid Liquid Liquid
1000 1000 933153.803 153.803 -
- - -- - -- - -- - -
73 74 75 76
43
Sea Salt In Aqueous Phase 1 Aqueous Phase 2 Oil Phase 2
12.3042 166.1072 166.1072 698.72370 70 70 70
Solid Liquid Liquid Semi-Solid
920 980 980 933- 153.803 153.803 -- - - -- - - -- - - -- - - -
77 78 79Heating Water In Heating Water In 2 Heating Water Out
22712.5 22712.5 22712.5120 120 119
Liquid Liquid Liquid
1000 1000 100022712.5 22712.5 22712.5
- - - -
80 81 82 83 84Emulsion Out Plate Hot Plate Hot Water PHX Out HPP Out
44
Water In Out
864.8305922 22712.5 22712.5 864.8305922 864.8305922100 120 119 110 120
75Liquid Liquid Liquid Liquid
933 1000 1000 933 933153.803 22712.5 22712.5 153.803 153.803
- - -- - -
5.3 5.3 5.3- - -
85 86 87 88Ref. In Ref. Out SSHE Out SSHE Out 2 - - 864.8305922 864.8305922
-20 50 50 Liquid Vapor Semi-Solid Semi-Solid
20 - 933 933- 153.803 153.803- - -- - -- - -- - -
89 90Pin Rotor Out To Wholesaler
45
864.8305922 864.830592250 50
Semi-Solid Semi-Solid
933 933153.803 153.8
- -- -- -- -
131 132 133 134 135
Nitrogen Blanket
Crude SBO Inlet HX-5
Crude SBO Outlet HX-5
Heating Medium Inlet
HX-5
Heating Medium Outlet
HX-5 720.00 720.00 500.00 500.00 77 176 617 528.3
0.5 psi Gas Liquid Liquid Liquid Liquid
0.92 0.89 7.00 7.00
136 137 138 139 140From 45% Citric Acid
Tank
Inlet Batch Reactor
From 4% NaOH Tank
From Enzyme Tank
Cooling Water Inlet
0.07 720.00 0.11 0.50 500.00
77 176 77 77 85
Liquid Liquid Liquid Liquid Liquid1.24 0.92 1.00 1.00
1.75 4.06 12.60 7.00
141 142 143 144 145Cooling Water
OutletBatch Reactor
OutletNitrogen Blanket
Surge Tank Outlet
Centrifuge Inlet 5
720.00 500.00 120.00 120.00113.8 122 122 158
0.5 psi
46
Liquid Liquid Gas Liquid Liquid 0.92 0.92 0.92 4.90 4.90 4.90
146 147 148 149 150Heating
Medium Inlet HX-6
Heating Medium Outlet
HX-6HLO - Gums
LLO - Degummed
SBO
Inlet Degummed
SBO Storage
500.00 500.00 3.63 120.00 120.00617 611.6 158 158 122
Liquid Liquid Liquid Liquid Liquid
0.92 4.90 7.00 7.00
151 152 153Cooling Water
Inlet CLR-1Cooling Water Outlet CLR-1
Nitrogen Blanket
500.00 500.00
85 88 0.5 psi
Liquid Liquid Gas
153 154 155 156 157
Nitrogen Blanket
Degummed SBO Storage Tank Outlet
Outlet HX-8
Heating Medium Inlet
HX-8 Paratherm
Heating Medium Outlet
HX-8 Paratherm
120.00 120.00 500.00 500.00 122(77 S/U) 122 617 610.4
0.5 psi Gas Liquid Liquid Liquid Liquid
47
0.92 0.92 7.00 7.00
158 160 161 162 163From 50% Citric Acid
Tank
Acid Activated Clay Inlet MX-2
Water Inlet MX-2 Outlet MX-2 Inlet Vacuum
Mixer
0.07 4.61 lb/hr 0.11 120.00 120.0077 77 122 176
Liquid Solid Liquid Liquid Liquid1.24
1.72 3.41 3.41
164 165 166 167 168
Vacuum Pump 1
Outlet Vacuum Mixer Inlet Filter Waste Outlet
FilterInlet Surge
Tank
120.00 120.00 0.35 120.00 249.8 195.8 195.8 195.8
10.00 Gas Liquid Liquid Solid Liquid
3.41 3.41 3.41 3.41
169 170 171 172 173
Nitrogen Blanket
Outlet Surge Tank Inlet HX-11 Outlet HX-11
Heating Medium Inlet
HX-11 120.00 120.00 120.00 500.00 195.8 284 500 617
0.5 psi Gas Liquid Liquid Liquid Liquid
48
3.41 3.41 3.41
174 175 176 177 178Heating
Medium Outlet HX-11
Vacuum Pump 2
Tray 1 Sparging Steam
Tray 2 Sparging Steam
Tray 3 Sparging Steam
500.00 0.13 0.93 1.99568.4 224.6 224.6 224.6
6.00 Liquid Gas Gas Gas Gas
179 180 181 182 183Tray 4
Sparging Steam
Waste Outlet Vacuum Vessel
Outlet CLR-2 Cooling Water Inlet CLR-2
Cooling Water Outlet CLR-2
1.99 6.46 6.46 500.00 500.00
224.6 374 140 85 94.5
Gas Gas Liquid Liquid Liquid 1.72 1.72
184 185 187 188 189
Recycle to MX-1
Outlet Vacuum Vessel Outlet HX-10 Outlet Vacuum
Mixer Heater
Inlet Refined SBO Storage
Tank 120.00 120.00 120.00 120.00 482 415.4 356 122
Liquid Liquid Liquid Liquid Liquid
7.00 7.00 7.00 7.00
49
190 191 192
Cooling Water Inlet CLR-3
Cooling Water Outlet CLR-3
Nitrogen Blanket
500.00 500.00
85 108.40 0.5 psi
Liquid Liquid Gas
193 194 195 196 197
Nitrogen Blanket
SBO Hardfat to Heating Tank
Nitrogen Blanket
Heating Medium Inlet Heating Tank
Heating Medium Outlet Heating Tank
175.00 500.00 500.00 77 617 551.7
0.5 psi 0.5 psi Gas Liquid Gas Liquid Liquid
7.00
198 199 200 201 202
Inlet HX-14 Outlet HX-14Heating
Medium Inlet HX-14
Heating Medium Outlet
HX-14Inlet HX-15
100.00 100.00 350.00 500.00 500.00
122 230 617 595 122
Liquid Liquid Liquid Liquid Liquid
7.00 7.00 7.00
203 204 205 206 207
50
Outlet HX-15Heating
Medium Inlet HX-15
Heating Medium Outlet
HX-15
Nitrogen Blanket
Cooling Medium Inlet Mixing Tank
350.00 500.00 500.00 500.00
230 617 542.3 85 0.5 psi
Liquid Liquid Liquid Gas Liquid
7.00
208 209 210 211 212Cooling
Medium Outlet Mixing Tank
Outlet CH3ONa Storage Tank
Outlet 20% Citric Acid
Storage Tank Inlet Filter Outlet Filter
1.00 10.00 500.00 500.00500.00
97.6 77 77 176 176
Liquid Solid Liquid Liquid Liquid 1.93 4.50 4.50
213 214 215 216 217
Waste Outlet Filter
Outlet Soft Water Storage
TankInlet MX-3 Inlet MX-4
Heating Medium Inlet
HX-161.63 100.00 50.00 50.00
500.00176 77 190 190 617
Solid Liquid Liquid Liquid Liquid
4.50 7.00 7.00 7.00
218 219 220 221 222
51
Heating Medium Outlet
HX-16
Inlet Centrifuge 6
HLO Centrifuge 6
Soaps
LLO Centrifuge 6
Inlet Centrifuge 7
500.00 32.79 500.00 500.00500.00 573.9 178.5 178.5 178.5 180.5
Liquid Liquid Liquid Liquid Liquid
4.50 4.50 7.00 7.00
223 224 225 226 227HLO
Centrifuge 7 Soaps
LLO Centrifuge 7
Inlet SBO Storage Tank
Cooling Medium Inlet
HX-13
Cooling Medium Outlet
HX-1332.36 500.00 500.00
500.00 500.00180.5 180.5 122 85 123.5
Liquid Liquid Liquid Liquid Liquid
7.00
228Nitrogen
Blanket SBO Storage Tank
0.5 psiGas
52
Appendix 6
Material and Energy Balance
Refining Mass Balance on Yearly Basis
Centrifuge 1Inlet HLO LLO
Crude SBO 2856361.3 kg Crude SBO 17401.3 kg Crude SBO 2838960.0 kg
53
FFA 43503.3 kg Phospholipids 323.3 kg Phospholipids 29.0 kgPhospholipids 352.4 kg Citric Acid 380.5 kg FFA 43503.3 kgCitric Acid 380.5 kg Water 12305.0 kgWater 12305.0 kg NaOH 486.0 kgNaOH 486.0 kg Enzyme 60.0kgEnzyme 60.0 kg
2913448.5 – 30956.2 – 2882492.3 = 0Filter
Inlet Waste OutletCrude SBO 2838960.0 kg Crude SBO 8516.9 kg Crude SBO 2830443.2 kgPhospholipids 29.0 kg Phospholipids 20.4 kg Phospholipids 8.7 kgFFA 43503.3 kg Clay 14412.3 kg FFA 43503.3 kgCitric Acid 2331.8 kg Citric Acid 2331.8 kgClay 14412.3 kg Water 4762.7 kgWater 4762.7 kg
2903999.3 – 22949.6 – 2881049.7 = 0Sparging
Inlet Waste OutletCrude SBO 2830443.2 kg Crude SBO 28304.4 kg Crude SBO 2787986.5 kgPhospholipids 8.7 kg Phospholipids 5.8 kg Phospholipids 2.9 kgFFA 43503.3 kg FFA 42633.3 kg FFA 870.0 kgCitric Acid 2331.8 kg Citric Acid 2331.8 kg Mono/
Diglycerides14152.3 kg
Water 4762.7 kg Water 4762.7 kgSteam 109533.3 kg Steam 109533.3 kg
2990582.0 – 187571.3 – 2803011.7 = 0Interesterification
Inlet OutletCrude SBO 2787986.5 kg SBO 3488739.4 kgPhospholipids 2.9 kg Phospholipids 2.9 kgFFA 870.0 kg FFA 870.0 kgMono/Diglycerides
14152.2 kg Mono/Diglycerides
14152.2 kg
SBO Hardfat 700752.9 kg Citric Acid 18688.7 kgCitric Acid 18688.7 kg CH3ONa 6863.4 kgCH3ONa 6863.4 kg Soft Water 60359.0 kgSoft Water 60359.0 kg
3589675.6 - 3589675.6 = 0Filter
Inlet Waste OutletSBO 3488739.4 kg SBO 13955.0 kg SBO 3474784.5 kgPhospholipids 2.9 kg CH3ONa 5998.7 kg Phospholipids 2.9 kgFFA 870.0 kg FFA 870.0 kgMono/Diglycerides
14152.2 kg Mono/Diglycerides
14152.2 kg
Citric Acid 18688.7 kg Citric Acid 18688.7 kgCH3ONa 6863.4 kg CH3ONa 864.7 kg
54
Soft Water 60359.0 kg Soft Water 60359.0 kg3589675.7 – 19953.7 – 3569722.0 = 0
Centrifuge 2Inlet HLO LLO
SBO 3474784.5 kg SBO 20848.7 kg SBO 3453935.8 kgPhospholipids 2.9 kg FFA 435.0 kg Phospholipids 2.9 kgFFA 870.0 kg Citric Acid 18688.7 kg FFA 435.0 kgMono/Diglycerides
14152.2 kg CH3ONa 432.4 kg Mono/Diglycerides
14152.2 kg
Citric Acid 18688.7 kg Soft Water 199413.0 kg CH3ONa 432.4 kgCH3ONa 864.7 kg Soft Water 34685.3 kgSoft Water 234098.2 kg
3743461.4 – 239817.8 – 3503643.6 = 0Centrifuge 3
Inlet HLO LLOSBO 3453935.8 kg SBO 20723.6 kg SBO 3433212.1 kgPhospholipids 2.9 kg FFA 435.0 kg Phospholipids 2.9 kgFFA 435.0 kg CH3ONa 432.4 kg Mono/
Diglycerides14152.2 kg
Mono/Diglycerides
14152.2 kg Soft Water 173287.4 kg Soft Water 34473.7 kg
CH3ONa 432.4 kgSoft Water 208111.6 kg
3677069.9 – 195228.4 – 3481840.9 = 0
(3447367.2 kg) * 99.3% = 3424720 kg
Appendix 7
Calculations
For the fermentation process, an algae Monad growth rate was assumed.
55
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
Steam Sparged into Fermentor to Sterilize, 60 to 121°C (kg steam)
56
(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 steamHeat 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
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 steamCentrifuge #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
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
57
Centrifuge #3Mass Balance:ΣMass = Mass in – Mass out = 0Energy Balance:Q = MCp(∆T) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = HP x 2545 = 381, 845 BTU/ Hr
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/hrHX-11 Oil into the Vacuum VesselQoil = mcp(∆T)Qoil = 921.33*0.55*(500-284)Qoil = 109454 BTU/hrQPoil = 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°FQ = UA ∆Tlm A = 109454/60/188.8A = 9.68 ft2 Annual Energy Cost For 1 Fermentor Motor Power (kWh) * Cost of energy ($0.10/kWh) * # of BatchesAnnual Energy Cost = 400 hp * 0.745 kW/hp * 90.2 hours * $0.10/kWh * 272 batchesAnnual Energy Cost = $ 731,125.12
Interesterifaction Rate ConstantAssumed that the rate constant depended on a Arrhenius relationship, assumed activation energy is similar to digestion, breaking triglycerides in the bodyk=A*e^(Ea/RT)T= 353 KEa = 9 kcal/mol = 37,681.2 J/molR = 8.312 J/mol KA = 1.948 * 10^9 1/mink = 5.171 * 10^3 1/min
Heat needed for temperature change of emulsion
58
Q=w Cp ΔTAssume clean heat transfer area and an emulsion specific heat of .5(1906.2) * (.5) * (100-70)= 28,599.3 BTU / hr
Heat needed for Plate Heat ExchangerQ = w Cp ΔT= (1906.62) (.5) (110-100)= 9533.1 BTU/hr
Heat Removed by SSHEQ = w Cp ΔT= (1906.62) (.5) (50-120)= -66,731.7 BTU/ hr
Length of Pasteurization Piping needed Volumetric Flow rate/(Area of pipe) = velocity of fluid.0155 m3/min/(π * .022252) = 9.966 m/min9.966 m/min * 10 min = 99.66 m needed for pasteurization time99.66 m (3.28 ft / 1 m) = 326.885 ft
Appendix 8
Annotated Equipment List:
Equipment Size (gal)TK-01 11,000TK-02 40,000TK-03 1,200TK-04 300TK-05 300
59
MT-1 22,00010L Seed Fermenter 2.651000L Seed Fermenter 26510% Seed Fermenter 3,500Main Fermenter 35,000CO2 Lysing Tank 12,000DAF Tank 24,000
Component Sizing Component Sizing
TK-51 20000 galTK-52 25 galTK-53 400 galTK-54 15 galBatch Reactor 1500 galTK-55 1500 galTK-56 4000 galTK-57 35 galTK-58 250 galTK-59 600 galTK-60 100 galTK-61 4000 galTK-62 10000 galTK-63 1000 galTK-64 250 galTK-65 1200 galTK-66 400 galTK-67 7500 galTK-68 5000 gal
MX-1 100 galMX-2 100 galMX-3 500 galMX-4 500 gal
Component Sizing Component Sizing
HX-5 202490 BTU/hrHX-6 12604 BTU/hrCLR-1 12604 BTU/hrHX-8 15340 BTU/hrHX-9 19901 BTU/hrHX-10 36568 BTU/hrHX-11 109454 BTU/hr
60
CLR-2 39542 BTU/hrCLR-3 97016 BTU/hrHX-14 49572 BTU/hrHX-15 159621 BTU/hrHX-16 92228 BTU/hr
Component SizeP-30 0.25 GPMP-31 3.5 GPMP-32 1 GPMP-33 1 GPMP-34 3.5 GPMP-35 110 GPMP-36 4.25 GPMEmulsion Tank 1 2000 LEmulsion Tank 2 2000 LHigh Pressure Pump 2475 L / hrPlate Heat Exchanger 6 ft^2Scraped Surface Heat Exchanger 2150 L / hrPin Rotor Machine 2000 L/hrTub Filling Machine 2740 L/hrAmmonia Compressor 18 ton
Component SizeTK-20 1000 LTK-21 5000 LTK-22 20 LTK-23 2 LTK-24 2 LTK-25 5 LTK-26 10 LTK-27 2 LTK-28 500 LTK-29 1000 LTK-30 500 LTK-31 1500 LTK-32 1500 L
61
Appendix 9
Economic Evaluation Factored from Equipment Costs
All data was obtained through the use of Aspen Economic Evaluator. For this evaluation, the design basis of 1 % of the $ 5.2 billion dollar table spread market was assumed.
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
62
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
YearCumulative Cashflow 1%(1+.05)^15
NPV
IRR
1 2 3 4 5 6
-6,743,784.40-
37,526,542.44-
36,965,246.61-
26,892,098.71-
15,922,960.38-
4,000,701.501.05 1.10 1.16 1.22 1.28 1.34
8594606.905 8896573.13984,727,200.17
1.255 1.575 1.977 2.481 3.113 3.9073523334.564 3051379.281
25.5% 37,830.75
7 8 9 10 11 12
8,935,054.09 22,948,103.27 38,105,847.45 54,479,485.96 72,144,219.55 91,179,464.491.41 1.48 1.55 1.63 1.71 1.80
9193199.989 9484583.267 9770817.048 10051993.69 10328203.88 10599536.65
4.903 6.154 7.723 9.693 12.164 15.2662638066.389 2277103.861 1962641.785 1689304.503 1452198.915 1246906.129
13 14 15
111,669,077.84 133,701,594.40 157,370,476.071.89 1.98 2.08
10866079.43 11127918.04 11385136.78
63
19.159 24.044 30.1761069461.925 916330.0812 784371.5829
Cumulative Cash Flow
-$50,000,000
$0
$50,000,000
$100,000,000
$150,000,000
$200,000,000
0 2 4 6 8 10 12 14 16Year
Cum
ulat
ive
Rev
enue
(USD
)
Another evaluation was done in which the market share of Golden Premium Spread would increase to 2 % in 7 years:
Cumulative Cash Flow 1% (2% in year 7)(1+.05)^15
NPV
IRR
-6,743,784.40-
37,526,542.44-
36,965,246.61-
26,892,098.71-
15,922,960.38-
29,650,701.501.05 1.10 1.16 1.22 1.28 1.34
8594606.905 -10243851.78158,394,244.01
64
1.345 1.81 2.43 3.27 4.40 5.922491148.688 2012941.306
34.5% -3,699.31
-3,779,190.32 24,246,908.04 54,562,396.40 87,309,673.42 122,639,140.60 160,709,630.48
1.41 1.48 1.55 1.63 1.71 1.8018386399.98 18969166.53 19541634.1 20103987.38 20656407.75 21199073.29
7.97 10.72 14.41 19.39 26.08 35.083247429.924 2615327.379 2103165.333 1688999.289 1354680.215 1085259.492
201,688,857.18 245,753,890.30 293,091,653.641.89 1.98 2.08
21732158.85 22255836.08 22770273.55
47.19 63.47 85.37868468.9858 694272.6917 554484.1595
Cumulative Cash Flow
-$100,000,000
-$50,000,000
$0
$50,000,000
$100,000,000
$150,000,000
$200,000,000
$250,000,000
$300,000,000
$350,000,000
0 2 4 6 8 10 12 14 16Year
Cum
ulat
ive
Rev
enue
(USD
)
65
Another situation was examined in which Golden Premium Spread would enjoy a 2 % market share at the beginning of its life. The payback period for this situation is about 5 years:
YearCumulative Cashflow 1%(1+.05)^15
NPV
IRR
1 2 3 4 5 6
-6,743,784.40-
43,226,542.44-
42,103,950.78-
21,957,654.98 -19,378.32 23,825,139.441.05 1.10 1.16 1.22 1.28 1.34
17189213.81 17793146.28198,627,853.09
1.428 2.039 2.911 4.157 5.936 8.476-9445737.657 -36810605.43 385592.3691 4846230.113 3695843.23 2813207.6
25.5% -3,665.08
7 8 9 10 11 12
49,696,650.62 77,722,748.98 108,038,237.34 140,785,514.36 176,114,981.54 214,185,471.421.41 1.48 1.55 1.63 1.71 1.80
18386399.98 18969166.53 19541634.1 20103987.38 20656407.75 21199073.29
12.103 17.282 24.676 35.235 50.312 71.8412137653.163 1621736.506 1228526.21 929388.4216 702200.8618 529925.6511
13 14 15
255,164,698.12 299,229,731.24 346,567,494.581.89 1.98 2.08
21732158.85 22255836.08 22770273.55
102.582 146.477 209.154399477.6092 300832.6647 226329.326
66
Cumulative Cash FlowBasis: 2% Market Share from Start
-$100,000,000
-$50,000,000
$0
$50,000,000
$100,000,000
$150,000,000
$200,000,000
$250,000,000
$300,000,000
$350,000,000
$400,000,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Year
Cum
ulati
ve R
even
ue (U
SD)
Appendix 10
Utilities
Chemical and Margarine Ingredient Costs:
Chemical Unit Price Amt. Required Yearly Price TotalCrude SBO $867.40/ton 3,196.9423 tons $2,773,027.75SBO Hardfat $0.46/lb 1,528,431.473 lb $703,078.4850% Citric Acid $8.51/gal 9,118.579 gal $77,599.11Acid Activated Clay $209/ton 15.887 tons $3,320.3899% Sodium Methoxide
$14/kg 6,863.348 kg $96,086.87
Nitrogen $7.7825/m³ 1.3114 m³ $102.064% Sodium $4.39/L 484.737 L $2,128.00
67
HydroxideEnzyme $576/L 60.053 L $34,590.53Sea Salt (Fermentation)
$600/ton 672.44 tons $403,464.00
Ethanol bottoms $140/ton 199.46 tons $27,924.40CO2 Free 1,096,000 kg -Lecithin $0.81/lb 19,534.7 lb $15,823.10Sea Salt (for Margarine Production)
$600/ton 739.449 tons $443669.40
Ergocaliferol $18234/kg 0.36628 lb $3,029.43Mono/Di Glycerides $0.1/kg 48,836.8 lb $10,780.75Beta-Carotene $1250/kg 193.8 lb $109,883.00Diacetyl $2.5/kg 24.42 lb $27.69Sorbic Acid $8250/ton 9,767.36 $40,290.40Dextrose $0.3085/lb 2141 tons $1,320,997.00
Fermentation Facility:
Equipment Energy Requirements:
Fermentation Mixer x 4: 300 kWSteam Boiler: 597 kWDecanter Centrifuge x 2: 106 kWDisk Centrifuge x 2: 15 kW
Refining Process:
Heat Loads and Sink:
Heat Exchanger 5Q= 202,490 BTU/ hr
Heat Exchanger 6Q = 12,604 BTU/ hr
Cooler 1Q = 12,604 BTU / hr
Heat Exchanger 8Q = 15,340 BTU / hr
68
Heat Exchanger 9Q = 19,901 BTU / hr
Heat Exchanger 10Q = 36,568 BTU / hr
Heat Exchanger 11Q = 109454 BTU / hr
Cooler 2Q = 39542 BTU / hr
Cooler 3Q = 97016 BTU / hr
Heat Exchanger 14Q = 49,572 BTU / hr
Heat Exchanger 15Q = 159,621 BTU / hr
Heat Exchanger 16Q = 92,228 BTU / hr
Cooler 4Q = 161,694 BTU / hr
Batch Reactor Cooling CoilsQ = 119,232 BTU / hr
Vacuum Mixer Heating CoilsQ = 29,317 BTU / hr
TK-63 Heating CoilsQ = 139,588 BTU / hr
TK-66 Cooling CoilsQ = 52,261 BTU / hr
Margarine Plant:
Equipment Electrical Requirements:
Emulsion Mixer: 8 kW
69
Emulsion Mixer 8 kWHigh Pressure Pump (Homogenizer): 15 kWSSHE: 22 kWPin Rotor Machine: 28 kWAmmonia Compressor: 55 kWTub Filling and Packing: 2.75 kW
Heat Loads and Sinks:
Temperature of Margarine rises from 70 ºF to 100 °F in emulsion tanks:Q = 29,000 BTU/hr
Temperature of Margarine rises from 100 °F to 110 °F in plate heat exchanger:Q = 9,600 BTU/hr
Temperature of Margarine decreases from 120 °F to 50 °F in scraped surface heat exchanger:Q = 58,000 BTU/hr
Appendix 11
Conceptual Control Scheme
70
Main Fermenter
Cooling Water
SpargedSteam
Vented Air 13
14
Sterile Air
10% Seed Fermenter
Cooling Water
SpargedSteam
Vent
9
Sterile Air
1000 L Seed Fermenter
10 L Seed Fermenter
250 mLShake 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 11Air
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 21
PIC
PIC
QIC
P- 10
P- 11
QIC
QIC
QIC
QIC
FIC
Fermentor Controls
71
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
72
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
73
3
Baffle trayTowerTk- 8
CO2 Lysing Controls
Conc. Algae
Sterilized CO2
CO2 AbsorbedAlgae
LysedAlgae&CO2
Vented CO2
LysedAlgae
ThrottleValve
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
74
Main Centrifuge Controls
Disc Centrifuge
Wet Biomass Slurry
Algae Oil3130
Oil settling tankTK-20
P15
Algae OilFICCv-32
Lysed Algae29
35
36Water
75
Extraction Controls
Oil
Settling Tank
Tk-11
Water
33
Disc Centrifuge
Lysed Algae
P16
40
30
34
38
32 Lysed Algae
Biomass
39
P18
P17
Water
45Water
FICCv-33
FICCv-34
Cv-35
FIC
76
Separation and Drying Processes Controls
Rotary
Dryer
42
Dynamic Cross Flow Filtration
Biomass P19
40
43
Biomass /water tank
Tk-12
Dry Biomass
P20
37 water vapor
41
Biomass
Biomass
FICCv-36
49Steam in
TICCv-38
50 Steam out
Conveyor Belt
Collection Hopper
Conveyor Belt
Shipping container
Table Spread Distributor
Dried Algae Distributor
39Water
Cv-37
P21
FIC
Degumming Controls
77
TK- 51Crude SBO
Storage
P-51
N2 GasTK-52
45% CitricAcid 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
pHCQIC
QIC LIC
TCFIC
LIC
LIC
Refining Controls
78
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-9P-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
TICTIC
FIC
FIC
PIC
PIC
PIC
PIC
PIC
FIC
To VacuumMixer
LIC
FIC
FIC
LIC
LIC
Interesterification Controls
79
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-73HLO
Cent-7Cent-6
TK-6520% Citric
AcidStorage
N2 GasTK-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
LICQIC
TC
FIC
LICTC
TC
N2 Gas
PIC
FIC
QICLIC
80
E
Algae OilStorage
Refined SBO Storage
LecithinStorage
Beta CaroteneStorage
DiacetylStorage
SorbicAcidStorage
Mono- diglyceridesStorage
Ergo-califerolStorage
WaterStorage
Oil
Pasteurization
CIP
Warm Water
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
81
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
82
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
Control Descriptions:
83
Fermentation
P-1, 2P1 will be centrifugal pump on a quantity control switch allowing it to pump 5309.3 gal of glucose to MT-1. P2 will also a centrifugal be on a quantity control switch allowing the pump to transfer 156.4 gallons of ethanol bottoms to MT-1.
P-10P10 will be a rotary feeder an will transfer 4,385.2lb of crystalline sea salt to MT-1.
P-11P11 will pump culinary (soft) water into the mix tank and will be controlled by the quantity control switch measuring the transfer of heated water in stream 5 added to MT-1.
Valve 4aValve 4a will control the amount of steam added to the water stream in stream 4 by a temperature sensor and quantity control switch. Temperature of the water in stream 5 will be maintained at 140 °F by the addition of steam. Stream 5 will add 60617.3 liters of water to MT-1.
P-3Pump 3 will be a centrifugal pump and will be controlled by a quantity control switch to transfer 57,974.8 liters of medium to the Main Fermentor from MT-1. The switch will allow for a 2 hour mixing time in the Main Fermentor before transferring to an empty Fermenter.
Valve 8During sterilization, steam will be sparged in stream 8 and will be controlled by a temperature sensor and added in an amount, 15,926.8 lb, which will make the temperature of the broth 250 °F. The temperature will be maintained at 250°F for 1 hour after which the cooling water will be run at full flow rate.
P-7Pump 7 is a centrifugal pump and it will be controlled by a quantity control switch to transfer the seed batch volume to the main fermentor. The volume transferred will be 2100 gallons at approximately 80.6°F.
Compressor 1, Valve 12Compressor 1 is a centrifugal compressor and will be controlled by the pressure in stream 12 before the valve at a pressure of 3 barg. The valve will be controlled by a flow rate control, which will allow for a transfer of 158 normal cubic meters per minute of air.
P-5
84
Pump 5 will be controlled by a rotational viscometer transmitter monitoring a slip stream on the side of the fermentor and will transfer a volume of 420 gallons of glucanex solution to be filtered and transferred to the main fermentor batch when viscosity reaches 20cP.
P-6Pump 6 will be controlled by a rubber sheathed electrode monitoring the presence of foam in the fermentor. A maximum quantity of 3.6 gallons of silicone based anti-foam oil will be transferred to be heat sterilized and then to the Main Fermenter.
STEX-1The amount of steam transferred to the heat exchanger used to sterilize stream 10 will be controlled by a temperature sensor and a valve controlling the flow rate of steam at 293°F and 3 barg.
CW-1Cooling water flow into the cooling jacket on the main fermentor will be controlled by a valve and temperature sensor. The temperature inside the fermentor will be maintained at 80.6°F.
Valve 13Valve 13 will control stream 13, which is the vented air stream in the fermentor. The valve will be controlled by a pressure sensor in the vessel and will not allow the pressure to exceed 3 barg while steam sparging. Operating pressure will be maintained below 1.79 barg during fermentation and air sparging.
P-8Pump 8 will transfer the final volume of the fermentation broth to the harvest tank and will be controlled by a quantity control switch. The amount of liquid broth transferred will be 22,893.9 gallons when the fermentation has been completed. A turbidity sensor will monitor cell density and will determine when a batch is completed and when to transfer the broth.
Extraction and Lysing
Stream 15 (FIC)Stream 15 is divided into 2 equal streams, 16 and 17, that go into reaction tanks A and B and the feed inlet control valve (Cv-20) is a mass flow rate measurement equalizing valve that ensure that stream 16 and 17 are of equal valve and direct flow to one of the streams if they are not equal.
Reaction tanks A and BThe fermentation broth will be pumped out of each of these and controlled by mass flow meters (Cv-23 & 22) that allow the pumps to operate at specified gpm flow rate and the
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valves will open or close adjusting for a constant specified gpm. The air inlet flow rate will be controlled by an inlet pressure valve (Cv-21) and the pressure is regulated at 500 Kg per hour, the valve will open or closed if the 500 Kg per hour is not maintained.
DAF tank 7The Dissolved Air Flotation tank has a regulating valve (Cv-24) for the in air that is maintained at 1000 Kg/hour and the valve will adjust to maintain this flow rate. The waste water being pumped out the tank will be maintained at specified gallons per minute by the regulating valve (Cv-26) and this valve will open or close to adjust for the correct gpm.
CO 2 Absorption TowerThe absorption tower is maintained at 150 PSI and a pressure relief valve (Cv-30) if the pressure is higher than 150 PSI the valve will open and relieve the excess pressure. The CO 2 is pumped into the tower at 150 PSI and the control valve (Cv-29) will open and or close to maintain the appropriate pressure. The tower also has a recirculation pump that operates at set gpm and valve (Cv-27) adjusts to ensure the correct gpm is applied for recirculation.
CO 2 Throttling and lysing Tower tank 9The control valve (Cv-28) maintains the 150 psi and will adjust according to maintain the pressure going into the throttling valve. The lysing tower is maintained at a temperature of 80ºC by steam and the valve (Cv-31) and this valve is a temperature control valve that opens and closes to keep the specific temperature of 80ºC. The lysed algae is pumped from the tower and controlled by mass flow meters (Cv-30) that allow the pump to operate at specified gpm and the valve will open or close adjusting for a constant specified gpm.
Storage tank 10The algae oil is pumped from this storage tank and controlled by mass flow meters (Cv-32) that allow the pump to operate at specified gpm and the valve will open or close adjusting for a constant specified gpm.
Stream 30The lysed aglae is pumped from pumped from the first centrifuge in a second centrifuge and is controlled by a mass flow meter (Cv-33) that allow the pump to operate at specified gpm and the valve will open or close adjusting for a constant specified gpm.
Settling tank 11The waste water being pumped out the tank will be maintained at specified gallons per minute by the regulating valve (Cv-35) and this valve will open or close to adjust for the correct gpm. The oil is be pumped from this tank also and will be maintained at specified gallons per minute by the regulating valve (Cv-34) and this valve will open or close to adjust for the correct gpm.
Biomass Storage tank 12
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The Biomass and water being pumped out of this tank will be feed into a third centrifuge and will be maintained at specified gallons per minute by the regulating valve (Cv-36) and this valve will open or close to adjust for the correct gpm into the centrifuge. The water leaving the centrifuge will be pumped into a series of pipes that collects all the waste water and vavle (Cv-37) will open or close the valve to ensure the proper gpm is maintained.
Rotary DryerThe rotary dyer uses steam to dry the biomass and the steam will be regulated by valve (Cv-38) which will regulate the steam inlet by opening and or closing to maintain the correct drying temperature.
Refining
TK-51,55,56,60,61,62,63,66,68 (PIC)All SBO storage tanks will have a nitrogen blanket of 0.5psig place on them. The controllers will be dead band controller to allow the pressure to get to the required amount, and then the valve will go shut.
P-51,52 (FIC)The flow into the batch reactor will be controlled to allow only 720 gallons of crude SBO to enter the batch reactor per batch. This quantity will be sensed by the controller and match the amount of 45% citric acid flowing into the batch reactor.
HX-5,6,8,11,14,15,16, Heating Coils of TK-63 and Vacuum Mixer, Cooling Coils of TK-66 and Batch Reactor (TIC)The SBO oil will be temperature monitored on the outlet of the heat exchangers in order to control the position of a valve positioned on the outlet of the heating/cooling medium to control flow. The heating/cooling coils will have temperature monitoring of the associated tanks. The temperature sensor will adjust a valve on the return line of heating/cooling medium.
Batch Reactor (pHC)The pH of the batch reactor will be monitored in order to maintain it at 4.8-5.0. A small pump will circulate the liquid from the batch reactor through a line where the pH will be monitored. The 4% NaOH will be added accordingly to maintain the proper pH.
Batch Reactor, P-54, P-55 (LIC, TC, FIC, TC)The level in the batch reactor will be monitored to control when the impellers can begin mixing. Once mixing begins, there will be a 30 minute time delay until the addition of the enzyme. The enzyme will be monitored for flow in order to secure the pump when the proper amount has been added. The mixing will continue for 6 hours, and then the
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mixer will be secured. Once the mixer is secured P-55 will pump the contents of the batch reactor to the surge tank.
P-56 (LIC)In order to create a continuous process, there will be level control from the surge tank starting the flow of P-56. The pump will shut off when level goes below a desired level.
CLR-1,2,3 (FIC)There will be continuous flow of cooling medium through the cooler. The hot liquid flow will be monitored and will adjust the outlet flow of cooling water in order to give an adequate cooling amount.
VP-1,2 (PIC)Pressure sensors will monitor the vacuum pressure in the tank. The vacuum pump will run continuously and have a recycle valve on it to maintain the proper vacuum pressure. The valve will open more in order to cause less of an increase in vacuum.
P-57,58 (LIC,FIC)The level in the tank will control the flow of P-57. The flow through the downstream line will be monitored and will match the proper flow of 50% citric acid through P-58.
RP-1 and P-60 (FIC)The flow will be monitored to determine the amounts of acid activated clay will be added to MX-1.
P-63 (LIC)The flow of oil from the surge tank will be controlled by the level present in the tank, which will control P-63.
Steam to Vacuum Vessel (FIC)The flow of oil into the vacuum vessel will be monitored by flow control. This will control the position of each of the four tray steam sparging inlet valves. The flow of steam will be matched against the flow of oil. The flow of steam will be monitored as well to better match the amount of flow of steam going into the vacuum vessel.
P-64 (LIC)The flow of oil from the vacuum vessel will be controlled by a level control switch which will control P-64.
Hardfat SBO Storage, P-65 (LIC, QIC)The flow of liquid from the tank is not a continuous process. The flow will be controlled by a level indicator to indicate that P-65 can pump to the processing tank. There will be a quantity controller in order to control how much is sent to the processing tank.
Refined SBO and Hardfat SBO (QIC)
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The quantities of the SBOs will be monitored to maintain the 20 to 80 ratio of hardfat to refined SBO going into the interesterification tank by control valves. P-66 and P-67 will be on the quantity control switch causing the flow of liquid into the tank. When the proper amount has been sent, the pumps will secure themselves.
TK-66, P-68, P-69, P-70 (LIC, QIC, TC, FIC)The level in the mixing tank will be monitored and once the proper level is reached the impellers will begin mixing. At the proper level the sodium methoxide will be introduced to the system in order to initiate mixing. The quantity of sodium methoxide will be monitored and when the 1.7 gallons of it has been added the pump will be secured. When the P-68 is secured and time control will be set for 30 minutes at which time the 20 citric acid will be pumped into the mixing tank to secure the interesterification process. The flow rate of citric acid will be monitored and P-69 will be secured when 17.21 gallons have been added to the tank. The tank will stir for 15 additional minutes at which time the impeller will be secured, and P-70 will begin running to pump out the tank. The amount of flow out of P-70 will be monitored at the outlet of the filter in order to control the pump.
P-71 and Soft Water Flow (FIC)P-71 will turn on the sensing of flow in the line going to the washing system. The amount of soft water going into each mixer will be controlled by sensing lines monitoring the SBO flow. The amount of soft water will correspond with 5 wt% of SBO.
Margarine Plant
P-30 and P-31
These pumps are controlled by a QIC control. The controllers measure the amount of SBO and algae oil and then shut off the pumps when the correct amount of each has been transferred.
TK-22, 23, 24, 25, 26, 27
The amounts of ingredients added to the margarine are controlled by QIC controls that open and close valves added to the line. These ingredients are gravity controlled. When the right amount of ingredients have been transferred, the controller closes the valves.
P-32
This pump is controlled by the water flow. Once enough water has entered the water preparation tank for one batch, then the pump is turned off.
TK-29
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The flow of the salt as it leaves the tank is controlled by this controller. Once the right amount of salt for one batch has left the tank, then the valve is closed.
P-33 and P-34
Each of these pumps are controlled by the flow out of the preparation tanks. Once the tanks are emptied, then the pumps are shut off.
Hot water inflow valve
This valve controls the amount of hot water that flows into the jackets of the emulsion tanks. It is controlled by the temperature of the emulsion inside the tanks. The valve can be opened in different degrees, such as totally closed, 50 % open, 75 % open, et cetera. If the temperature of the emulsion inside the tanks is too low, then the valve is opened to allow for more heat to transfer to the fluid. If the emulsion is too warm, the valve is closed to compensate.
PHX Hot Water inflow Valve
The plate heat exchanger’s hot water inflow is controlled by the margarine outflow temperature. If the emulsion is leaving the plate heat exchanger too cool, then the hot water inflow is increased. If the emulsion is too warm, the valve is partially closed to lower the amount of heating.
HPP
This plunger pump is controlled by the pressure of the outflowing emulsion. The pressure of this fluid needs to be 75 bar. If the pressure isn’t high enough, then the valve increases the amount of pressurization that occurs within the pump.
SSHE
The control for this piece of equipment comes from the temperature of the crystallized margarine just as it leaves the heat exchanger. The temperature of the fluid at this part of the flow should be 50 °F. The valve controls the ammonia refrigerant. If more cooling is needed, the valve is opened more fully, allowing more ammonia to flow into the SSHE and increasing the amount of cooling.
Pin Rotor Viscosity
A separate line that splits off the main line, using a very small recirculation pump, allows for this controller to check the viscosity of the margarine as it leaves the pin rotor machine. If this value is not ideal, the controller can increase or decrease the pin rotor machine’s kneading, raising or lowering the margarine’s viscosity until it is ideal.
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Appendix 12
General Arrangement – Major Equipment Layout
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Overall Plant Layout:
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
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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 C4 Dryer
Glucose Storage
Ethanol Bottoms
Glucanex Antifoam
Salt Boiler
Cooling Tower
Electrical Room
85 ft
35 ft
115 ft
Fermentation Layout
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SSHE
AmmoniaCompressor
Filling,Packing
Margarine Plant First Floor Layout
= 4 feet
CIP system
Emulsion Tanks
Ingredient PreparationTanks
HPP
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Margarine Plant Mezzanine Layout
Electrical Room
Ingredient Storage Tank Area
= 4 feet
Appendix 13
Distribution and End-use Issues Review
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Once fully processed and packaged, Golden Premium Spread will be distributed
across the United States by a trucks owned by a wholesale company. This wholesaler
will be fully experienced in and authorized to handle and distribute food products safely
and professionally, and the these trucks will utilize refrigeration to keep the product fresh
and safe for all consumers to enjoy. Despite the professionalism of the distribution
service, problems could still arise. It has to be assumed that not every truck will reach its
destination without problem, but we assume that all of the trucks will be able to distribute
the product without issue or loss.
The product has been processed carefully in order to ensure the health of the
consumer, however contamination could possibly arise at some time in the future. If any
of our valued customers becomes sick as a result of our product, then production will
immediately cease and a recall will be issued. However, the chances for such a recall are
very slim due to the careful processing and strict sanitation standards that will be strongly
enforced in the production facility. Each margarine tub will be marked for identification
and accountability in case of any contamination instances, making the problem batch or
batches easy to find and recall. Such an issue will not occur in such a carefully designed
facility except for gross negligence from a worker in the facility, so each worker will be
trained in sanitation and cleanliness.
Some consumers will be concerned about complications that may occur as a result
of consuming too much of the product. Some studies have claimed that consuming too
much DHA could have adverse side effects like increased bleeding, increased risk of
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heart failure for people with congestive heart failure, or even hemorrhagic strokes.
However all of these possible side effects only occur with extremely large doses of
omega-3 fatty acids. In Food and Drug Administration has stated that intake of DHA and
other omega-3 fatty acids is generally regarded as safe (GRAS) in doses of up to 3000 mg
per day. In order for a consumer to reach that level, he or she would have to consume
almost an entire tub of Golden Premium Spread. Therefore, a problem in which a
customer overdoses on DHA from eating Golden Premium Spread should not occur.
Omega-3 are considered GRAS which means that the margarine product will be safe.
Appendix 14
Constraints Review
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Despite all precautions and careful design, it cannot be assumed that each
fermentation batch will be successful. Industry standard is to assume that approximately
1/1000 batches will go wrong in some way, whether through contamination or some other
flaw. Another constraint that arises in the fermentation period is the growth rate of the
algae. Our fermentation system has been designed to utilize the maximum, exponential,
growth of the algae, however, a limit is imposed on the system once the algae reach a
certain concentration. This concentration is avoided during the step-up procedure, with
the growing algae placed into larger and larger containers in order to lower the
concentration and keep the algae from approaching the stationary phase of growth, but it
is inevitable that at some point, the algae will stop growing. Also, the algae can only
make a certain amount of DHA concentrated lipids during the starvation portion of the
fermentation. There is no known way to increase the DHA content in these lipids, so
only 40 % of the lipids are DHA.
Sanitation is a constraint to this process as well. Every vessel needs to be
regularly cleaned in order to keep the final product free of any pathogenic microbes. This
means that the entire system must be continually cleaned, and it cannot run continuously.
There are enough vessels in order for cycling to occur, however. This means that while
one vessel is being used, another can be rigorously cleaned with the CIP system. A
consumer becoming sick after ingesting the product would have catastrophic results on
the market share of the product. Care must be taken in the cleaning of the system and the
entire plant, which lowers the amount of actual production that can be done.
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Another major constraint on this design is market demand. It is important to
make just enough product to meet the market demand, but not so much that some of the
product goes unsold. In order to ensure that the product just meets the market demand,
the first year of production will just meet the 1 % market share level. If too much is
made, then money will be wasted in the production while unsold tubs of Golden Premium
Spread pile up or have to be discarded. In this way, the market is the most major of the
constraints on this process.
Appendix 15
Applicable Standards
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The final margarine product must comply with FDA regulations about vitamin
content in margarines. All margarine products must replicate the nutritional content of
butter, so all margarines are fortified with Vitamin A and many are fortified with Vitamin
D as well. Golden Premium Spread is fortified with both Vitamin A and D which are
included in the list of ingredients. From the nutritional label figure, it can be seen that
our product will supply 10 % of the recommended daily dosage of Vitamin A in every
serving. It will also include 10 % of the recommended daily dosage of Vitamin D with
every serving.
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Other than the vitamin requirements that the final product must have, the most
important applicable standard to which AlphaAlgae’s Golden Premium Spread facility
must conform are sanitation standards. Obviously, sanitation and immaculate cleanliness
are of great importance to a food plant. Without these standards, consumers can become
sick, which a public health issue. Both for the safety of the valued customer, and for the
company’s profit, the Golden Premium Spread plant has been carefully designed from the
bottom up to conform to these applicable sanitation standards. Most of these standards
come from the IMACE Code of Hygiene which was written in January 1999. These
codes inform the design engineer how to design a plant which will manufacture fat
spreads using good manufacturing practice. Some of these standards are as follows:
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
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
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The IMACE Code of Hygiene also describes the need for fat products to conform
to standards regarding the taste and consistency of the final product, as well as its mouth
feel. Golden Premium Spread should be a solid, but spreadable, at refrigerator
temperatures, softer but still a solid at room temperatures, and should melt at mouth
temperature. This feeling of having the table spread melt in one’s mouth, literally, is a
standard to which AlphaAlgae’s Golden Premium Spread adheres. Using industry
standards for the margarine processing and ingredients keeps the process clean and free
of contamination as well as providing a superior product that will not only attract new
customers, but will keep customers. The overall goal is to keep customers coming back
to our table spread every time the customer goes to the health food grocery store.
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Appendix 16
Projects Communication File
Middough Visit March 22- Group presented to John Micheli-Filters should have magnets-CIP is a daily process, but with evidence of good cleanliness can make it once a week, we will use 1/week-Will operate 24 hrs, with only a 2-3 workers to monitor fermenters-Want flow into dryer to have lowest possible water content-Vacuum pumps-steam boosters with 3-4 stages-SBO storage tanks have nitrogen blanket of 0.5 psig is sufficient-Use a homogenizer as the HPP-Pump out of the votator is for back pressure regulator-CIP filter should be an inline strainer-CIP alkaline and acid tanks are probably industrial 55 gal poly bottles with installed flow meters-Must have code, date for each box and tub-Have workers packing boxes with tubs-Pastuerization is a piping run of 30 minutes at the constant temperature
Meeting Notes - 3/11/2009 - by CharuPresentation Feedback:
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Strong Points: Well organized PowerPoint, maintained standard time, Handouts ( Mass balance), Q&A
Improvements: Units consistency, Give a summary before and after the presentation and mention future works
List of things we need to work on:1. Have drawing standards, Assign numbers for streams used in each process and
use same format for spreadsheets.2. Work on Instrumentation of PFD, using Icarus.3. Work on Process description: Including Equipment list and details, Chemistry
Section, Products section4. Break down the cost estimate, have estimate cost for the building, using Icarus.5. We should avoid using centrifuges just to keep our capital cost down.6. Land cost for our project is similar to cost of produce the amount of glucose we
need.7. Dan will be sending the contact information to find more about the dryers.8. For the CO2 lysing we only need 2 feet diameter column, as a continuous process
Meeting Notes - 3/4/2010 - by Travis
The following topics were discussed during a conference call: Enzymes can be stored in a kegerator at the required temperature, just label it on
the PFD and designate the temperature on the mass balance sheet Heat exchanger should assume a overall heat transfer coefficient for all heat
exchangers and go from there Cooling water inlet at 85 F and out at a maximum of 120 F Determine the duty required for heaters, boilers, cooler, ammonia system. Allow
Aspen to determine sizing and pricing required Discussed putting things into Aspen to determine the pricing Discussed the washing process of SBO For the presentation, have handouts for the mass balance and any other specifics
associated For the presentation order, have overall block flow, pfds, and whatever else Will be sending chemical list pricing to Dan by Friday Will send presentation via email to Dan 24 hours prior to Tuesday
Meeting Notes - 2/26/2010 - by Ramune
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The following topics were discussed during the phone conference: The C02 for our fermentation will come from ethanol refinery The prices of commodity chemicals can be found in the library sources Look at the different extractors GEA separators Disk centrifuge Agitation and heat transfer from biochemical engineering books Need to make overall Block Flow Diagram including hexane Need mass balance kg/batch Every 24h equipment must be cleaned - five step process CIP Fermentation vessel is sterilized Energy balance on glucose going in Respiration rate The design of the dissolved air unit can be found in engineering book Use ASPEN to generate prices of equipment Peristaltic pump for SOB process
Meeting Notes -2/23/2010 -By Ramune
Our mentor Dan came to meet with us at CEB. The following topics were discussed: Communication between group members must be improved - Dan suggested
working together and exploring all ideas Color code was used on our block flow diagram; red - add certain things, green -
take the stuff out Always have the back-up slides for the equipment or process that was not chosen
by us, but it is alternative to our process or equipment Do not take prices from the catalog (reagent grade for laboratory purposes) Chemical properties of sodium methoxide Bottoms that are used for the fermentation is not yeast In order to find the price of certain equipment or component we can look at the
alternative and estimate the price Vitamin D comes from shrimp For the incoming air use the absolute filter (about 400hp motor) Need to have drop tanks and storing capacity for our raw materials (1.5 times the
size of the truck) Our process is combination of batch and continuous Use enzyme to brake slime after CO2 lysing Use hexane after centrifuge Dry the biomass in direct dryer Cascaded CSTRs are like PFR and can be replaced by batch reactor
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Refrigeration unit will come with margarine equipment
Meeting Notes – 2/18/2010 -By Charu
1. Presentation was missing the overall mass balance2. BFD needs to improved ( It should serve as a road map of the process) and needs
specific streams name3. PFD needs to be developed from BFD4. We need to use consistent units ( lbs/hr is preferred)5. Cost Estimate on main equipments6. Utilities and waste products ( all inputs and outputs) should be in diagram7. For recovery process use the minimum antifoam8. analyze gas absorption, mix system, dissolve oxygen, power number and agitator9. How and why are we starving algae? By limiting amount of Nitrogen and to let
algae produce oil.10. Make a page on Wikispaces for all the assumptions made in the process.11. Hexane Extraction method was discussed taking account for carotene present in
the oil12. Eric will be talking to John for the IPE program13. Talked about, how nickel rainy works.14. Hardening Ratio for the Margin is 20:8015. We need refrigerated room for margin16. Look into Pesticide control, Clean up system, Sanitary design and EPA system
Phone conference 2/11/2010 - By Ramune
All group members were participating in the phone conference. The following topics were discussed during our conference call with mentor Dan:
Making margarine in our facility and shipping it off We looking to take 1% of butter/margarine market and base the rest of the process
on this number Use available recipe for margarine Show how margarine plant opperates Need to make contact with Cargill The fermentation vessel size is standard Scale-up gradually from lab to production vessel We will be using glucose for fermentation (buying from Cargill, need to figure
out the pricing) Lysing with CO2 and remaining biomass will be treated with hexane We will base our marketing on the trends of “Whole Foods” Need to make detailed block flow diagram Calculations in excel spreadsheets
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Phone Call 3 Notes - by Charu
1. Each group member talked about whatever they found through their research.2. We decided to run the batch process as compare to continuous process3. Economy Calculations – Travis needs to look for how the market for spread butter will grow? Then do the rough calculations on net present value. We also need to take in consideration that 5-10% of our process will be spoiled. Yield will be affected.4. We will have to buy 0 trans fatty acid of certain melting point to mix with our product (lipid) to make the spread. That can be purchased from Cargill or AVM , etc.5. Do we need to refine the crude oil? No, because it doesn’t contain any harmful material when compared with FDA standards. There is no strong smell in the lipid, so little favoring should work for deodorization6. Bio-reactor- How the heat will be removed from? Cooling jacket? Coils inside or out the reactor? Because increasing the surface is not the only way.7. Yeast Extract- How yeast will be used in the process?8. Extraction Processes where discussed. Volume will be reduced in order to operate the lysing process. We want to produce the lipids in liquid form after all the processes.9. Two Different separation methods were mentioned single-stage separation and Countercurrent separation.
Phone Call 2 Notes - by Dan
Team Alpha: Re On Stream factor, Yields, Pricing.
You have determined how much you want to sell. Now you have determine how many batches you need to produce.
The only commercial fermentation process is ethanol. It has many biological pressures to keep it from being contaminated. Yet only one technology provider, Volgebusch, guarantees their process. Many process that started off as continuous have switched back to batch. If a batch goes bad you have the other fermentors to continue manufacturing.
No plant operates 100% of the time.The best chemical plants operate 85% 0f the time or 7500 hr/year. Federal holidays, plant utilities shut downs, no feed stock, unschedule break downs, waiting for analytic results, batches gone bad, off spec material, acts of god etc.
Besides the actual operating time you have to allow time for discharge, cleaning, charging, sterilizing, induction time etc.
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No reactions are 100% complete nor are recoveries 100% complete. There are losses at every step. Including wash out losses when cleaning equipment. Even when shipping finished product to customers. They all effect the overall yield from raw materials to sold goods. As mentioned above some batches go bad and have to be wasted. Not only loss of reactor time but also loss of raw materials.
The selling price in the is not the price that you sell it for as it leaves the plant. Retailers typically buy goods at 50% of what they sell it for. The wholesaler that you sell it to also has to make money to cover his warehousing and distribution cost. So your selling price may only be 35% of what the supermarket sells it for. Confirm the number for table spreads.
A good deal of chemical engineering is business.
Phone Call 1 notes - By Charu• Decided as a group to go with functional food• Discussed about the economy and market of the product• Everyone discussed about what they are working on.• Tried to come up with site location ( FL, CA ?)• Specified the type of Bioreactor we will be using ( Clear tubes)• Discussed if product is in or outside the cell.• Got the reference for oilgae• Referred to look more into:Membrane Filtration, Reusing the water, Gross separation, concentrating the solution, Acrylic Chemicals, Cross flow Membrane
First Meeting Thursday Jan 21 Notes - By Charu• Start wikispace and set communication matrix of group members• Whenever emailing Dan, make sure to email at both email ids written on the business card• Importance of Fatty acids DHA , Omega 3 acid• Main Source of Fish Oil Algae• Selling Target $3-4/gallon• Open pond vs. closed pond Depends on water sources, yield, carbon dioxide utilization, sulfur dioxide extraction if used from power plant, contamination• Nutraceutical we can make functional food, use the nutrients available along with color of alage.• Yellow color Pro Vitamin A, using double bond absorption makes it saturated and color goes away.• DHA Properties , 6 Double Bonds
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• Other fatty acids zero trans fatty acid• Resources Bailey’s Books• Goal Make a flow diagram and discuss the challenges and uncertainity• How Lipids are transported? High molecular weight compounds aren’t absorbed by the body• Sanitation Big issue in Designing Nutraceutical products• Product Making Butter, supplements or just crystallize the fatty acids and sell them to food industries• Bioreactors requires enrich source of CO2• Target, Market, Money 2 acres?• Process of growing algae Use sunlight or feed glucose in dark?• Recylcing very important• Economy • Make the Block diagram of the project• Harvesting microfilteration , centrifugation• Hardening & interesterfication process• Bulk or fractional extraction?• To lower the price of butter spread, we can use soybeans to go trans fatty acids• Can DHA and carotenes be removed?
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Appendix 17
Information Sources and References
Advanced Dairy Chemistry. Volume 2: Lipids. Ed. by P.F. Fox and P.L.H. McSweeney. New York: Springer Science + Business Media, Inc., 2006
Amato, T. et al. “An integrated approach to dissolved air flotation.” Water Science & Technolgy Ed. Peter Wilderer. Germany: Technical University of Munich, 2001. 19-26. Print.
Bailey, James E. (James Edwin), 1944-. Biochemical Engineering Fundamentals / James E. Bailey, David F. Ollis. Ed. David F. Ollis joint author. New York : McGraw-Hill, 1977. Web.
Arterburn, Linda M., et al. “Bioequivalence of Docosahexaenoic Acid from Different Algal Oils in Capsules and in a DHA-Fortified Food.” Lipids (2007) 42: 1011-1024
Baker, R.W. Encyclopedia of Separations Science. Academic Press, 2000. Web 15 Feb. 2010.
Beal, R.E., Sohns, V.E., “Treatment of Soybean Oil Soapstock to Reduce Pollution.” Journal of the American Oil Chemistrys' Society (1972) 49, No.8: 447-450.
Converti, Attilio, et al. "Estimation of Viscosity of Highly Viscous Fermentation Media Containing One Or More Solutes." Biochemical engineering journal 4.1 (1999): 81-5. Web.
da Silva, Teresa Lopes, et al. "Effect of n-Dodecane on Crypthecodinium Cohnii Fermentations and DHA Production." Journal of industrial microbiology & biotechnology 33.6 (2006): 060601. /fndfed/zgw.ebscohost.com:210/aph/. Web.
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