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

Harvesting Algae to Form a Neutraceutical, Specifically
Creating a Functional Food
Team Alpha
Travis Dallas
Eric Graves
Joaquin Martinez
Chris McNinch
Ramune Otterson Meskyte
Charu Saini
Crypthecodinium Cohnii
1
Beer Still
Bottom
Water
Glucanex
Glucose
Biomass
Water
Hexane
Water
Antifoam
Vent
Sterile air
Algae
Fermentation
Salt
Steam
Cooling
Water
Dissolved
Air
Floatation
CO2
Lysing
Air
CO2
Hexane
Extraction
Centrifuge
CIP
System
Sodium methoxide
Citric Acid
Water
Gum
Water
Citric Acid
Acid Activated Clay
Interesterification
Refrigerant
Emulsification
Pasteurization
Scraped
Surface Heat
Exchanger
Water
Crude SBO
Degumming
Bleaching
Removal FFA
Deodorization
Centrifuge
Sea Salt
Hardfat SBO
Sodium methoxide
Steam
Citric Acid
Citric Acid
Enzyme
Acid Activate
Clay
Water
NaOH
Citric Acid
Water
Lecithin
Steam
Packaging
Diacetyl
Mono/Diglycerides
B-Carotenes
To Wholesaler
Sorbic Acid
Ergocaliferols
2
Key Points
1.
2.
3.
4.
5.
6.
7.
8.
9.
Plant Layout
Controls
Sanitation Design
Calculations
Economics
Changes
Future Endeavors
PFD
Report
3
Wind Direction
Gate
D
A
Fencing
B
C
E
F
A.
B.
C.
D.
E.
F.
General Plant Layout
Alpha Algae Plant
1928 SE Otis Rd
Cedar Rapids, IA 52401
Storage/Boilers
Fermentation
Offices/Labs/Miscellaneous Space
Water Cooling Tower
SBO Refining
Margarine Processing
Otis Rd
Cargill
4
Fermentation Layout
115 ft
35 ft
Ethanol
Bottom
s
Glucose
Storage
Electrical
Room
Salt
Boiler
Cooling
Tower
Glucanex Antifoam
Seed 1
Fermenter 1
Harvest
Tank
S1
RXN 1
RXN 2
Seed 2
Fermenter 2
S2
DAF
85 ft
Mix
Tank
Absorption
Fermenter 3
Lipid
Storage
Lysed
Tank
Seed 3
S3
Fermenter 4
Seed 4
Centrifuge 1 Centrifuge 2
S4
C3
C4
Dryer
Silo
5
Refining Layout
Soft
Water
Storage
Degum
SBO
Storage
Crude
SBO
Storage
Surge
Tank
Batch
Rx
Mixers
Cent-5
Water
Softener
Vacuum
Mixer
Surge
Tank
Vacuum
Vessel
Electrical
Room
Refined
SBO
Storage
Mixers
Interester
SBO
Storage
Interesterification
Tank
Cent-7
Cent-6
Hardfat
SBO
Storage
C
A
Processing
Tank
72ft x 34ft
6
Margarine Plant First Floor Layout
CIP system
Ingredient
Preparation
Tanks
Emulsion Tanks
Filling,
Packing
HPP
SSHE
= 4 feet
Ammonia
Compressor
7
50’ x 66’
Margarine Plant Mezzanine Layout
Ingredient Storage
Tank Area
Electrical
Room
= 4 feet
8
TK-2
TK-1
TK-3
Fermentor Controls
TK-4
P- 10
Glucose
QIC
Salt
QIC
P- 1
1
2
Ethanol Bottoms
P- 11
Water
TK-5
QIC
P- 2
Direct
Steam
Injection
4
P- 5
3
MT-1
P- 6
STEX-1
Filter 3
QIC
11 Sterile Glucanex
Water
P- 3
10
5
Sterile Anti-foam
TIC
TIC
Steam
7
4a
PIC
Vented
Air
13
QIC
Filter 2
PIC
250 mL
Shake
Flasks
1000 L Seed
Fermenter
10 L Seed
Fermenter
10% Seed
Fermenter
Vent
P- 8
P- 7
9
Sparged
Steam
Air
QIC
TIC
Sparged
Steam
8
Filter
PIC
FIC
Air
P- 9
Filter 1 Sterile
1
Air
12
Compressor
1
To DAF
15
14
Cooling
Water
Sterile
Air
Compressor
1
Harvest Tank
Main
Fermenter
QIC
FIC
Cooling
Water
TIC
PIC
FIC
9
Fermentor Controls
Sterile
Filter 3 Glucanex
11
QIC
Sterile
Antifoam
P- 6
10
QIC
QIC
P- 3
PIC
7
Foam
Vented
Air
13
Filter 2
Main
Fermenter
Visc
Turbidity
QIC
P- 8
QIC
14
9
QIC
TIC
Sparged
Steam
Air
Compressor 1
PIC
FIC
Filter 1
Cooling
Water
8
Sterile Air
TIC
10
Dissolved Air Flotation Controls
20
Vented Air
DAF Tk-7
1
Fermented
Algae
Tk-6
16
P11
Cv-23
Cv-25
FIC
FIC
Rxn tank B
22
FIC
23
P12
Cv-20
15
Conc. Algae
18
P-01
19
FIC
2
FIC
Tk-7
Cv-22
Fermented
Algae
17
Rxn tank A
Sterilized Air
Cv-26
FIC
P10
21
Water
45
PIC
PIC
12
Sterilized Air
46
18
18
Cv-21
Sterilize Air
Cv-24
Water
Water to Cargill treatment
Sterilized Air
11
CO2 Lysing Controls
Cv-30
.
Conc Algae
CO 2
23
27
Compressor 2
Vented CO2
3
Stir tank
Filter 4
Baffle
tray
Tower
Tk- 8
24
Cv-29
PIC
Sterilized CO2
FIC
FIC
28
P13
Cv-27
Lysed
Algae
Tower
Tk- 9
FIC
Cv-30
Cv-28
25
26
CO2 Absorbed
Algae
Lysed
Algae
&
CO2
29
Throttle
Valve
P14
TIC
Lysed
Algae
Cv-31
48
47
Steam in & out
12
Main Centrifuge Controls
Lysed Algae
Algae Oil
Holding tank
TK-20
29
30
Algae Wet
Biomass
Algae Oil
31
Disc Centrifuge
Cv-32
FIC
35
Algae Oil
P15
13
Separation Process Controls
FIC
Wet Biomass
Cv-36
40
Wet Biomass
41
Wet Biomass Tank
Tk-12
P19
Biomass
Cv-37
FIC
Dynamic Cross Flow
Filtration
39
42
Water
P21
14
Dryer Process Controls
Exhauster
Purge
Air seal dust valve
Fume controller
37
42
PIC
Recycle
Filter
Dry Biomass
Conveyor Belt
Rotary
Dryer
43
49
Steam
in
Steam
50 out
TIC
Collection Hopper
Shipping container
Dried Algae Distributor
Conveyor Belt
15
Degumming Controls
TK-53
4% NaOH
Storage
PIC
TK-54
10% Enzyme
Refrigerated
Storage
N2 Gas
TK-52
45% Citric
Acid Storage
P-53
TK- 51
Crude SBO
Storage
Batch
Reactor
QIC
QIC
HX-5
TC
P-52
pHC
LIC
TIC
PIC
FIC
LIC
P-51
P-54
TK-55
Surge
Tank
N2 Gas
P-56
HX-6
PIC
P-55
N2 Gas
LIC
TIC
TIC
HLO - Gums
LLO
CLR-1
FIC
Cent-5
TK-56
Degummed
SBO
Storage
16
Refining Controls
TK-58
Acid
Activated
Clay Tank
PIC
TK-59
Water
Storage
VP-1
TK-57
50% Citric
Acid
Storage
N2 Gas
TK-56
Degummed
SBO
Storage
FIC
PIC
RP-1
FIC
PIC
CLR-2
P-58
TIC
HX-9
HX-8
P-59
MX-1
TIC
P-62
LIC
TIC
VP-2
P-60
FIC
P-57
Vacuum
Vessel
Vacuum
Mixer
HX-11
Filter
P-61
PIC
MX-1
FIC
N2 Gas
Steam
TK-60
Surge
Tank
To MX-101
LIC
P-64
PIC
N2 Gas
LIC
P-63
FIC
HX-10
CLR-3
To Vacuum
Mixer
TK-61
Refined
SBO
Storage
17
PIC
Interesterification Controls
N2 Gas
TK-62
SBO
Hardfat
Storage
LIC
TK-67
Soft
Water
Storage
Water
Softener
QIC
P-71
FIC
P-65
PIC
HX-16
N2 Gas
FIC
TIC
TK-63
SBO
Hardfat
Heating
Tank
TK-64
CH3ONa
Storage
TK-65
20% Citric
Acid
Storage
FIC
MX-3
P-68
TIC
P-66
HX-14
TC
PIC
LIC
QIC FIC
PIC
N2 Gas
TIC
N2 Gas
P-72
HLO
P-73
HLO
TK-66
Mixing
Tank
TC
LIC
TK-61
Refined
SBO
Storage
MX-4
P-69
Cent-6
QIC
Cent-7
PIC
P-67
TK-68
SBO
Storage
N2 Gas
HX-15
TC
TIC
P-70
TIC
CLR-4
FIC
Filter
FIC
18
Margarine Controls 1
QIC
TK-20
TK-21
Algae
Oil
Storage
P-30
CIP
QIC
Refined
SBO
Storage
P-31
CIP
QIC
OilOil
Phase
Prep.
Tank 1
Warm Water
QIC
Lecithin
TK-22
Storage
TK-23
Beta
CaroteneSt
orage
TIC
P-35
TK-31
QIC
TK-24
QIC
Diacetyl
Storage
CIP
QIC
TK-25
TK-26
TK-27
P-34
Sorbic
AcidE
Storage
Mono- di
glycerides
Storage
OilOil
Phase
Prep.
Tank 1
QIC
TK-32
QIC
Ergocaliferol
Storage
Aqueous
Phase
Prep.
QIC
TK-28
CIP
QIC
P-33
TK-30
P-35
Water
Storage
QIC
P-32
Sea Salt
Storage
TIC
Warm Water
TK-29
19
Margarine Controls 2
P-36
Plate HX
TIC
CIP
CIP
High
Pressure
Pump
PIC
PIC
Scraped
Surface Heat
Exchanger
Pin Rotor
Machine
P-37
VIC
TIC
Ammonia
Compressor
Tub Filling and
Packaging
20
CIP Controls
Water
CIP Returning Liquid
P-42
FIC
P
CIP Supplying Liquid
Strainer
TIC
P
LIC
LIC
LIC
LIC
LIC
LIC
LIC
LIC
CS
HX-41
FIC
TK-41
Acidic
Solution
Alkaline
Storage
TK-42
Alkaline
Solution
TK-43
Reclaim
Water
TK-44
Fresh
Water
P-41
Acidic
Storage
Drain
21
Sanitary Design
Equipment Design
•
•
•
•
•
•
•
Cleanable to microbial level
Made of compatible materials
Accessible for inspection, maintenance and cleaning
No liquid collection and no niches
Equipment must perform as designed
Hygienic compatibility with other plant systems
Validated cleaning procedures
22
Sanitary Design (cont)
Facility Design
•
•
•
•
•
•
•
•
Physical separation of distinct hygienic zones
Material flow and personnel movement control
Prevent water accumulation inside building materials
Temperature and humidity control
Air flow and air quality control
Building envelope sanitary conditions
Interior spatial design that enables cleaning
Sanitation integrated into facility design
23
Calculations – Fermentation Process
Fermentation Time Requirement (hours/batch)
= Lag Phase + Growth Phase + Stationary Phase + Maintenance
= 0 + [ln(27.7 g/L)-ln(2 g/L)] / 0.03747 hr-1 + 20 + 12
= 102.14 hours
Algae Production (tons/batch)
= Final Concentration (g/L) x Broth Volume (L) / (1000 g/kg) x (2.2046lb/kg) / (2000lb/ton)
= 27.7 x 79,500 / 1000 * 2.2045 / 2000
= 2.427 tons/batch
Annual Amount of Algae Produced (tons)
= Oil needed (tons) / 0.2 (g lipids / g dw cells)
= 133 / 0.2
= 665.0 tons
Annual Amount of Batches Required
= 665.0 tons / (2.427 tons/batch)
= 274.0 batches
Plant Operating Time (hours/year)
= Time per batch (hours) * Batches per year / Number of fermentors
= 102.14 hours * 274.0 / 4
= 6,996.6 ~ 7,000 hours/year
24
Plant Economics
Total Project Capital Cost
37,328,232.77
Operating Costs







Raw Materials
Utilities
Maintenance
Operating Labor Costs
Operating Charges
Plant Overhead
G and A Costs
USD
18,962,032.85
USD/Year
6,031,280.00
3,532,157.83
2,030,000.00
2,828,000.00
707,000.00
2,429,000.00
1,404,594.96
USD/Year
USD/Year
USD/Year
USD/Year
USD/Year
USD/Year
USD/Year
25,963,238.43
USD/Year
Total Product Sales
Payback Period
5.7



Years
Tax Rate is 40%
Straight Line Depreciation over 10 years
2,986,258.62 USD/Year
25
Changes
26
Separation Process PFD
Wet Biomass
40
Wet Biomass
41
Wet Biomass Tank
Tk-12
P19
Biomass
Dynamic Cross Flow
Filtration
39
42
Water
P21
27
Dryer Process PFD
Exhauster
Purge
Air seal dust valve
Fume controller
37
42
Recycle
Filter
Dry Biomass
Conveyor Belt
Rotary
Dryer
43
49
Steam
in
Steam
50 out
Collection Hopper
Shipping container
Dried Algae Distributor
Conveyor Belt
28
Degumming (Changes)
TK-53
4% NaOH
Storage
N2 Gas
TK-52
45% Citric
Acid Storage
131
TK- 51
Crude SBO
Storage
P-53
P-54
138
132
135
134
TK-55
Surge
Tank
136
133
N2 Gas
139
Batch
Reactor
P-52
HX-5
P-51
TK-54
10% Enzyme
Refrigerated
Storage
137
143
HX-6
142
P-55
141
144
P-56
147
146
TK-56
Degummed
SBO
Storage
145
140
HLO - Gums
LLO
148
CLR-1
149
150
152
151
Cent-5
29
N2 Gas
153
N2 Gas
Interesterification (Changes)
193
TK-67
Soft
Water
Storage
Water
Softener
TK-62
SBO
Hardfat
Storage
P-71
P-65
214
N2 Gas
194
217
HX-16
195
218
TK-63
SBO
Hardfat
Heating
Tank
TK-64
CH3ONa
Storage
TK-65
20% Citric
Acid
Storage
215
216
196
MX-3
197
P-66
P-68
HX-14
198
199
P-69
209
N2 Gas
210
219
206
P-72
HLO 220
N2 Gas
192
MX-4
201
200
222
P-73
221
224
223
TK-66
Mixing
Tank
TK-61
Refined
SBO
Storage
Cent-6
Cent-7
N2 Gas
207
P-67
208
HX-15
202
203
205
204
HLO
P-70
213
228
CLR-4
211
212
225
Filter
227
226
30
TK-68
SBO
Storage
Margarine PFD 2 (Changes)
82
81
P-36
80
Plate HX
83
CIP
CIP
High
Pressure
Pump
84
Scraped
Surface Heat
Exchanger
87
88
Pin Rotor
Machine
P-37
86
85
Ammonia
Compressor
89
Packaging
90
31
Calculation - Margarine
Length of Pasteurization Piping needed
Volumetric Flow rate/(Area of pipe) = velocity of fluid
.0155 m3/min/(π * .022252) = 9.966 m/min
9.966 m/min * 10 min = 99.66 m needed for pasteurization time
99.66 m (3.28 ft / 1 m) = 326.885 ft
Or 330 ft of insulated pipe needed for pasteurization
32
CIP PFD
Water
214
CIP Returning Liquid
201
203
CIP Supplying Liquid
205
213
P-42
Strainer
216
215
217
207
210
211
P
TK-41
Acidic
Solution
P
TK-42
Alkaline
Solution
TK-43
Reclaim
Water
TK-44
Fresh
Water
218
202
204
206
209
212
HX-41
208
P-41
Alkaline
Storage
Acidic
Storage
Drain
33
Future Endeavors
• Within next 5 years take over 2% of the market
– Need to add 3 fermentors, remainder of plant can be
operated at higher capacity
• Degumming and Deacidifiction byproducts streams
– Lecithin profitable byproduct
– FFA high in protein into animal feed
• Margarine Flavoring – cinnamon, garlic, honey
• Strictly selling DHA as vitamin supplement at GNC
34
Margarine Nutritional Label
35
Summary
1.
2.
3.
4.
5.
6.
7.
8.
9.
Plant Layout
Controls
Sanitation Design
Calculations
Economics
Changes
Future Endeavors
PFD
Report
36
Questions?
37
Specification on Rotary Dryer (Heyl &
Patterson)
•
•
•
•
•
•
•
•
•
Dryer Type = Direct Rotary
Process Type = Batch Mode
Dryer Size = 90" Diameter x 60 ft. O/A Length
Air Flow Rate = 5430 lb/hr
Steam Heat Exchanger Duty = 271,065 BTU/hr Max.
Dryer Duty = 101,650 BTU/hr Max.
Dryer Inlet/Outlet Air Temperature = 268/190 Deg F
Dryer Evaporative Load = 3829 lb/hr
System Price = $400,000-$660,000 USD
38
Calculations – Fermentation Process
Steam Sparged into Fermentor to Sterilize, 60 to 121°C (kg steam)
(Steam at 145°C and 3 barg)
mbroth (kg)*cp(kJ/kg*K)*ΔT (K) = msteam(kg)*Hvap (kJ/kg) + msteam (kg)*cp (kJ/kg*K)*ΔT (K)
17,300,000 kJ = msteam *[2,163.47 (kJ/kg) + 0.5*4.187*(144-120)+0.5*4.187*(144-60)]
msteam = 7,240 kg steam
Steam Used to Heat Mix Water from 17 to 60°C (kg steam)
(Steam at 145°C and 3 barg)
mbroth (kg)*cp(kJ/kg*K)*ΔT (K) = msteam(kg)*Hvap (kJ/kg) + msteam (kg)*cp (kJ/kg*K)*ΔT (K)
9,873,628 kJ = msteam *[2,163.47 (kJ/kg) + 0.5*4.187*(144-17)+0.5*4.187*(144-60)]
msteam = 3,719.7 kg steam
Heat Evolved from Cell Growth (kcal)
= 0.12 * Oxygen Uptake Rate (mmol/(h)) * Fermentation Time (h)
= 0.12 * 295.35 mmol/h * 70.14 h
= 2,485.88 kcal
39
Calculations - Separations
Centrifuge #2
Mass Balance:
ΣMass = Mass in – Mass out = 0
0 = 22,902.52 (kg/batch of lysed algae) – 6,168.82 (kg/batch of algae) – 16,733.71 9 (kg/batch of waste water)
Energy Balance:
Q = MCp(∆T) + Qin
Q = assumption of no temperature change , Qin HP supplied to centrifuge
Q = 100HP x 2545 = 244,500 BTU/ Hr
Centrifuge #3
Mass Balance:
ΣMass = Mass in – Mass out = 0
Energy Balance:
Q = MCp(∆T) + Qin
Q = assumption of no temperature change , Qin HP supplied to centrifuge
Q = ? HP x 2545 = 381, 845 BTU/ Hr
40
Calculations - Separations
Co 2 absorption and Lysing
Mass 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 tank
Q = 12,700.6 kg/hr of steam
Centrifuge #1
Mass Balance:
ΣMass = Mass in – Mass out = 0
0 = 23,368 (kg/batch of conc. Algae) - 466 (kg/batch of lipids) - 22, 902 (kg/batch of lysed algae)
Energy Balance:
Q = MCp(∆T) + Qin
Q = assumption of no temperature change , Qin HP supplied to centrifuge
Q = 150 HP x 2545 = 381, 845 BTU/ Hr
41
Calculations - Refining
Vacuum Vessel
Sparging Steam flow design
Tray1- 715.59/6/3785.412*0.092/1000*0.001 = 0.42 gal/hr
Tray2- 715.59/6/3785.412*0.092/1000*0.007 = 2.91 gal/hr
Tray3- 715.59/6/3785.412*0.092/1000*0.015 = 6.23 gal/hr
Tray4- 715.59/6/3785.412*0.092/1000*0.015 = 6.23 gal/hr
HX-11 Oil into the Vacuum Vessel
Qoil = mcp(∆T)
Qoil = 921.33*0.55*(500-284)
Qoil = 109454 BTU/hr
QPoil = mcp(∆T)
T = 617- (109454/2900/.79)
T = 569.2°F
∆Tlm = [(T1 – t2) – (T2 – t1)]/ln[(T1 – t2)/ (T2 – t1)]
∆Tlm = [(617-500) – (569.2-284)]/ln[(617-500)/(569.2-284)]
∆Tlm = 188.8°F
Q = UA ∆Tlm
A = 109454/60/188.8
A = 9.68 ft2
42