harvesting algae to form a neutraceutical, specifically creating a functional food
DESCRIPTION
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. Beer Still Bottom. Water. Glucanex. Biomass Water Hexane. Glucose. - PowerPoint PPT PresentationTRANSCRIPT
1
Harvesting Algae to Form a Neutraceutical, Specifically Creating a Functional Food
Team Alpha
Travis DallasEric Graves
Joaquin MartinezChris McNinch
Ramune Otterson MeskyteCharu Saini
Crypthecodinium Cohnii
2
DegummingBleaching
Removal FFADeodorization
CentrifugeCrude SBO
Citric Acid
GumWater
Citric Acid
Citric AcidAcid Activated Clay
Enzyme
Water
Acid ActivateClay
Interesterification
Hardfat SBO
Emulsification Pasteurization
Water
Sea Salt
Lecithin
Diacetyl
Mono/Diglycerides
B-Carotenes
Sorbic Acid
Ergocaliferols
Sodium methoxide
Citric Acid
Water
Sodium methoxideCitric AcidWater
ScrapedSurface HeatExchanger
Packaging
Refrigerant
To Wholesaler
DissolvedAir
FloatationFermentation Centrifuge
CO2
Lysing
Glucose
Beer Still Bottom
Antifoam
Water
Algae
Glucanex
SteamCoolingWater
Sterile air
Vent
Water
Air CO2
BiomassWaterHexane
NaOH
Steam
Steam
Salt
CIPSystem
HexaneExtraction
3
Key Points
1. Plant Layout2. Controls3. Sanitation Design4. Calculations5. Economics6. Changes7. Future Endeavors8. PFD9. Report
4
Otis Rd
Cargill
A
B
C
D
E
F
A. Storage/BoilersB. FermentationC. Offices/Labs/Miscellaneous SpaceD. Water Cooling TowerE. SBO RefiningF. Margarine Processing
Wind DirectionGate
General Plant LayoutAlpha Algae Plant1928 SE Otis RdCedar Rapids, IA 52401
5
S2
Seed 1
S1
S4
S3
Seed 2
Seed 3
Seed 4
Mix Tank
Fermenter 1
Fermenter 2
Fermenter 3
Fermenter 4
Harvest Tank
DAF
RXN 1
RXN 2
Absorption
Lysed Tank
Lipid Storage
Centrifuge 1 Centrifuge 2
C3 C4Dryer
Glucose Storage
Ethanol Bottoms
Glucanex Antifoam
Salt Boiler
Cooling Tower
Electrical Room
85 ft
35 ft
115 ft
Fermentation Layout
Silo
6
HardfatSBO
Storage
CrudeSBO
Storage
WaterSoftener
SoftWater
Storage
Batch Rx
DegumSBO
Storage
Mixers
Cent-5Vacuum
Mixer
VacuumVessel
RefinedSBO
Storage
ElectricalRoom
ProcessingTank
InteresterSBO
Storage
InteresterificationTank
CA
Cent-6Cent-7
Mixers
SurgeTank
SurgeTank
Refining Layout
72ft x 34ft
7
SSHE
AmmoniaCompressor
Filling,Packing
Margarine Plant First Floor Layout
= 4 feet
CIP system
Emulsion Tanks
Ingredient PreparationTanks
HPP
50’ x 66’
8
Margarine Plant Mezzanine Layout
ElectricalRoom
Ingredient Storage Tank Area
= 4 feet
9
Main Fermenter
Cooling Water
Sparged Steam
Vented Air 13
14
Sterile Air
10% Seed Fermenter
Cooling Water
Sparged Steam
Vent
9
Sterile Air
1000 L Seed Fermenter
10 L Seed Fermenter
250 mL Shake Flasks
Water Water
Direct Steam Injection
MT-1
Salt
Ethanol Bottoms
Glucose
Sterile Glucanex
Sterile Anti-foam
1
2
3
4 5
7
8
11
10
12Compressor 1 Filter 1
1Air
Filter 2
TK-1 TK-2 TK-3
TK-4 TK-5
STEX-1
Steam 4a
P- 1
P- 2
P- 3
P- 5 P- 6
P- 7 P- 8
Filter 3
To DAF
15
P- 9
Harvest Tank
PIC
QIC
QIC FIC
FIC
TIC
TIC
TIC
TICCompressor 1Air
PIC
Filter
PIC
PIC
QIC
P- 10
P- 11
QIC
QIC
QIC
QIC
FIC
Fermentor Controls
10
Main Fermenter
Cooling WaterSparged
Steam
Vented Air 13
Sterile Air
Sterile Glucanex
Sterile Anti-foam
7
8
11
Filter 1
Filter 2
P- 8
Filter 3
TIC
14
Compressor 1Air
PIC
PIC
FIC
QIC
QIC
9
P- 3
TIC
10QIC
Visc
Foam
QIC
P- 6
Turbidity
QIC
QIC
Fermentor Controls
11
Rxn tank A
Rxn tank B
P-01
FermentedAlgae
FermentedAlgae
Sterilized AirSterilize Air
Vented Air
Conc. Algae
Water
45
18
16
15
17
Dissolved Air Flotation Controls
12
Sterilized Air
Sterilized Air
20
19
22 23
21
46Water
1
2
P10
P11
P12
Water to Cargill treatment
Tk-6
Tk-7
DAF Tk-7
PIC
Cv-21
Cv-23
PIC
FIC
Cv-20
FIC
18 18
Cv-22
FIC
FICFIC
Cv-24
Cv-25
FIC
Cv-26
12
3
Baffle trayTowerTk- 8
CO2 Lysing Controls
Conc. Algae
Sterilized CO2
CO2 AbsorbedAlgae
LysedAlgae&CO2
Vented CO2
LysedAlgae
Throttle Valve
23
24
Filter 4
CO 2
Compressor 2
25 26
27
Stir tank
P13
P1429
Lysed Algae TowerTk- 9
Cv-30
FIC
28
FIC
Cv-27
Cv-29
Cv-28FIC
Cv-30
4748
Steam in & out
TIC
Cv-31
PIC
13
Main Centrifuge Controls
Disc Centrifuge
Algae Wet Biomass
Algae Oil3130
Algae Oil Holding tank
TK-20
P15Algae Oil
FICCv-32
Lysed Algae29
35
14
Separation Process Controls
42
Dynamic Cross Flow Filtration
Wet Biomass
P19
40
Wet Biomass TankTk-12
41Wet Biomass
Biomass
FICCv-36
39 Water
Cv-37
P21
FIC
15
Rotary
Dryer43Dry Biomass
49Steam in
TIC
50Steam out
Conveyor Belt
Collection Hopper
Conveyor Belt
Dried Algae DistributorShipping container
37
Purge
42
Dryer Process Controls
Exhauster
Air seal dust valveFume controller
Filter
RecyclePIC
16
TK- 51Crude SBO
Storage
P-51
N2 Gas
TK-5245% Citric
Acid Storage
P-52
P-53P-54
TK-534% NaOHStorage
TK-5410% EnzymeRefrigerated
Storage
N2 Gas
HLO - Gums
BatchReactor
P-55
P-56
TK-55SurgeTank
N2 Gas
TK-56Degummed
SBOStorage
HX-5
CLR-1LLO
HX-6
Cent-5
TIC
TIC
FIC
PIC
PIC
PIC
TIC
pHC
QIC
QIC LIC
TC
FIC
LIC
LIC
Degumming Controls
17
N2 Gas
TK-56Degummed
SBOStorage
HX-8
TK-5750% Citric
AcidStorage
P-57
P-58
TK-58Acid
ActivatedClay Tank
P-59
P-60
TK-59Water
Storage
P-61
HX-9
P-62
VP-1
VacuumMixer
N2 Gas
TK-60SurgeTank
P-63
MX-1MX-1
VP-2
Steam
To MX-101
P-64
N2 Gas
TK-61Refined
SBOStorage
HX-10
HX-11
CLR-2
CLR-3
Filter
VacuumVessel
RP-1
TIC
TIC
TIC
FIC
FIC
PIC
PIC
PIC
PIC
PIC
FIC
To VacuumMixer
LIC
FIC
FIC
LIC
LIC
Refining Controls
18
N2 Gas
TK-61Refined
SBOStorage
N2 Gas
TK-62SBO
HardfatStorage
N2 Gas
TK-63SBO
HardfatHeating
Tank
P-66
P-67
HX-14
HX-15
P-68
TK-64CH3ONaStorage
TK-66MixingTank
P-69
P-70
Filter
TK-67Soft
WaterStorage
HX-16
HLO
P-71
P-72 P-73
HLO
Cent-7Cent-6
TK-6520% Citric
AcidStorage
N2 Gas
TK-68SBO
Storage
CLR-4
MX-3 MX-4
WaterSoftener
P-65
TIC
TIC
TIC
TIC
PIC
PIC
PIC
PIC
FIC
TIC
FIC
QIC
FIC
FIC
LIC
QIC
TC
FIC
LIC
TC
TC
N2 Gas
PIC
FIC
QICLIC
Interesterification Controls
19
E
Algae OilStorage
Refined SBO Storage
Lecithin Storage
Beta CaroteneStorage
DiacetylStorage
Sorbic AcidStorage
Mono- di glyceridesStorage
Ergo-califerolStorage
WaterStorage
Oil
CIP
Aqueous PhasePrep.
TK-20
TK-21
TK-22
TK-23
CIPCIP
TK-24
TK-25
TK-26
TK-27
TK-30
TK-31
TK-32
Oil Phase Prep.Tank 1
CIP
P-30
P-31
P-32
P-33
Warm Water
Oil Oil Phase Prep.Tank 1
CIP
Sea SaltStorage
TK-29
P-34
TK-28
CIP
Margarine Controls 1
Warm Water
QIC
QIC
QIC
QIC
QIC
QIC
QIC
QIC
QIC
QIC
QIC
QIC
P-35
P-35TIC
TIC
20
High Pressure Pump
AmmoniaCompressor
Pin Rotor MachineScraped
Surface Heat Exchanger
Tub Filling and Packaging
P-37
CIPCIP
Margarine Controls 2
Plate HX
P-36
TIC
TICVIC
PICPIC
21
TK-41Acidic Solution
TK-42Alkaline Solution
TK-43Reclaim Water
TK-44FreshWater
Alkaline Storage
Acidic Storage
CIP Returning Liquid
Water
HX-41
CIP Supplying Liquid
Drain
P-41
P-42
PP
LIC
LIC
LIC
LIC
LIC
LIC
LIC
LIC
FIC
TICFIC Strainer
CS
CIP Controls
22
Sanitary Design
Equipment Design• Cleanable to microbial level• Made of compatible materials• Accessible for inspection, maintenance and cleaning• No liquid collection and no niches• Equipment must perform as designed• Hygienic compatibility with other plant systems• Validated cleaning procedures
23
Sanitary Design (cont)
Facility Design• Physical separation of distinct hygienic zones• Material flow and personnel movement control • Prevent water accumulation inside building materials• Temperature and humidity control• Air flow and air quality control• Building envelope sanitary conditions• Interior spatial design that enables cleaning• Sanitation integrated into facility design
24
Calculations – Fermentation Process
Fermentation Time Requirement (hours/batch)= Lag Phase + Growth Phase + Stationary Phase + Maintenance= 0 + [ln(27.7 g/L)-ln(2 g/L)] / 0.03747 hr-1 + 20 + 12= 102.14 hours
Algae Production (tons/batch)= Final Concentration (g/L) x Broth Volume (L) / (1000 g/kg) x (2.2046lb/kg) / (2000lb/ton)= 27.7 x 79,500 / 1000 * 2.2045 / 2000= 2.427 tons/batch
Annual Amount of Algae Produced (tons)= Oil needed (tons) / 0.2 (g lipids / g dw cells)= 133 / 0.2= 665.0 tons
Annual Amount of Batches Required= 665.0 tons / (2.427 tons/batch)= 274.0 batches
Plant Operating Time (hours/year)= Time per batch (hours) * Batches per year / Number of fermentors = 102.14 hours * 274.0 / 4= 6,996.6 ~ 7,000 hours/year
25
Plant Economics
Total Project Capital Cost 37,328,232.77 USD
Operating Costs 18,962,032.85 USD/Year Raw Materials 6,031,280.00 USD/Year Utilities 3,532,157.83 USD/Year Maintenance 2,030,000.00 USD/Year Operating Labor Costs 2,828,000.00 USD/Year Operating Charges 707,000.00 USD/Year Plant Overhead 2,429,000.00 USD/Year G and A Costs 1,404,594.96 USD/Year
Total Product Sales 25,963,238.43 USD/Year
Payback Period 5.7 Years
Tax Rate is 40% Straight Line Depreciation over 10 years 2,986,258.62 USD/Year
26
Changes
27
Separation Process PFD
42
Dynamic Cross Flow Filtration
Wet Biomass
P19
40
Wet Biomass TankTk-12
41Wet Biomass
Biomass
39 WaterP21
28
Rotary
Dryer43Dry Biomass
49Steam in
50Steam out
Conveyor Belt
Collection Hopper
Conveyor Belt
Dried Algae DistributorShipping container
37
Purge
42
Dryer Process PFD
Exhauster
Air seal dust valveFume controller
Filter
Recycle
29
TK- 51Crude SBO
Storage
P-51
N2 GasTK-52
45% CitricAcid Storage
P-52
P-53 P-54
TK-534% NaOHStorage
TK-5410% EnzymeRefrigerated
Storage
N2 Gas
HLO - Gums
BatchReactor
P-55 P-56
TK-55SurgeTank
N2 GasTK-56
DegummedSBO
Storage
HX-5
CLR-1LLO
150
HX-6
Cent-5
153
131
132 133 137 142
138
136
135
134
139
141140
143
144
145147
146
148 149
151
152
Degumming (Changes)
30
N2 Gas
TK-61Refined
SBOStorage
N2 Gas
TK-62SBO
HardfatStorage
N2 Gas
TK-63SBO
HardfatHeating
Tank
P-66
P-67
HX-14
HX-15
P-68
TK-64CH3ONaStorage
TK-66MixingTank
P-69
P-70
Filter
TK-67Soft
WaterStorage
HX-16
HLO
P-71
P-72 P-73
HLO
Cent-7Cent-6
TK-6520% Citric
AcidStorage
N2 GasTK-68SBO
Storage
CLR-4
MX-3 MX-4
WaterSoftener
P-65
193
195
194
196
197
198 199 209 210
201
200
213
211
208
207
228
221220 223
222219
216215
218
217
214
225
224
205
204
203202
192
227
226
212
N2 Gas
206
Interesterification (Changes)
31
High Pressure Pump
AmmoniaCompressor
Pin Rotor MachineScraped
Surface Heat Exchanger
Packaging
P-37
CIP
80
84
8586
CIP
87
89
90
Margarine PFD 2 (Changes)
83
88
Plate HX
8182
P-36
32
Calculation - Margarine
Length of Pasteurization Piping needed
Volumetric Flow rate/(Area of pipe) = velocity of fluid
.0155 m3/min/(π * .022252) = 9.966 m/min
9.966 m/min * 10 min = 99.66 m needed for pasteurization time
99.66 m (3.28 ft / 1 m) = 326.885 ft
Or 330 ft of insulated pipe needed for pasteurization
33
TK-41Acidic Solution
TK-42Alkaline Solution
TK-43Reclaim Water
TK-44FreshWater
Alkaline Storage
Acidic Storage
CIP Returning Liquid
Water
HX-41
CIP Supplying Liquid
Drain
P-41
P-42
PP
213
203201
216215 207
205
217
212
204202
214
218
208206
211
210
209
Strainer
CIP PFD
34
Future Endeavors
• Within next 5 years take over 2% of the market
– Need to add 3 fermentors, remainder of plant can be operated at higher capacity
• Degumming and Deacidifiction byproducts streams
– Lecithin profitable byproduct
– FFA high in protein into animal feed
• Margarine Flavoring – cinnamon, garlic, honey
• Strictly selling DHA as vitamin supplement at GNC
35
Margarine Nutritional Label
36
Summary
1. Plant Layout2. Controls3. Sanitation Design4. Calculations5. Economics6. Changes7. Future Endeavors8. PFD9. Report
37
Questions?
38
Specification on Rotary Dryer (Heyl & Patterson)
• Dryer Type = Direct Rotary• Process Type = Batch Mode• Dryer Size = 90" Diameter x 60 ft. O/A Length• Air Flow Rate = 5430 lb/hr• Steam Heat Exchanger Duty = 271,065 BTU/hr Max.• Dryer Duty = 101,650 BTU/hr Max.• Dryer Inlet/Outlet Air Temperature = 268/190 Deg F• Dryer Evaporative Load = 3829 lb/hr• System Price = $400,000-$660,000 USD
39
Calculations – Fermentation Process
Steam Sparged into Fermentor to Sterilize, 60 to 121°C (kg steam)(Steam at 145°C and 3 barg)
mbroth (kg)*cp(kJ/kg*K)*ΔT (K) = msteam(kg)*Hvap (kJ/kg) + msteam (kg)*cp (kJ/kg*K)*ΔT (K)
17,300,000 kJ = msteam *[2,163.47 (kJ/kg) + 0.5*4.187*(144-120)+0.5*4.187*(144-60)]
msteam = 7,240 kg steam
Steam Used to Heat Mix Water from 17 to 60°C (kg steam)(Steam at 145°C and 3 barg)
mbroth (kg)*cp(kJ/kg*K)*ΔT (K) = msteam(kg)*Hvap (kJ/kg) + msteam (kg)*cp (kJ/kg*K)*ΔT (K)
9,873,628 kJ = msteam *[2,163.47 (kJ/kg) + 0.5*4.187*(144-17)+0.5*4.187*(144-60)]
msteam = 3,719.7 kg steam
Heat Evolved from Cell Growth (kcal)
= 0.12 * Oxygen Uptake Rate (mmol/(h)) * Fermentation Time (h)
= 0.12 * 295.35 mmol/h * 70.14 h
= 2,485.88 kcal
40
Calculations - Separations
Centrifuge #2Mass Balance:ΣMass = Mass in – Mass out = 00 = 22,902.52 (kg/batch of lysed algae) – 6,168.82 (kg/batch of algae) – 16,733.71 9 (kg/batch of waste water)Energy Balance:Q = MCp(∆T) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = 100HP x 2545 = 244,500 BTU/ Hr
Centrifuge #3Mass Balance:ΣMass = Mass in – Mass out = 0
Energy Balance:Q = MCp(∆T) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = ? HP x 2545 = 381, 845 BTU/ Hr
41
Calculations - Separations
Co 2 absorption and LysingMass Balance:ΣMass = Mass in – Mass out = 0 0 = 86,663 (kg/batch of algae) + 1000 (kg/hr of air) – 63,295 (kg/batch waste water) -23,368 (kg/batch of conc. algae) - 1000 (kg/hr of air) Energy Balance:Q = MCp(∆T) + Qin Q = throttling process is adiabatic, so Qin is the steam jacket to tankQ = 12,700.6 kg/hr of steam
Centrifuge #1Mass Balance:ΣMass = Mass in – Mass out = 00 = 23,368 (kg/batch of conc. Algae) - 466 (kg/batch of lipids) - 22, 902 (kg/batch of lysed algae)Energy Balance:Q = MCp(∆T) + QinQ = assumption of no temperature change , Qin HP supplied to centrifugeQ = 150 HP x 2545 = 381, 845 BTU/ Hr
42
Calculations - Refining
Vacuum VesselSparging Steam flow designTray1- 715.59/6/3785.412*0.092/1000*0.001 = 0.42 gal/hrTray2- 715.59/6/3785.412*0.092/1000*0.007 = 2.91 gal/hrTray3- 715.59/6/3785.412*0.092/1000*0.015 = 6.23 gal/hrTray4- 715.59/6/3785.412*0.092/1000*0.015 = 6.23 gal/hr
HX-11 Oil into the Vacuum VesselQoil = mcp(∆T)Qoil = 921.33*0.55*(500-284)Qoil = 109454 BTU/hr
QPoil = mcp(∆T)T = 617- (109454/2900/.79)T = 569.2°F
∆Tlm = [(T1 – t2) – (T2 – t1)]/ln[(T1 – t2)/ (T2 – t1)]∆Tlm = [(617-500) – (569.2-284)]/ln[(617-500)/(569.2-284)]∆Tlm = 188.8°F
Q = UA ∆Tlm A = 109454/60/188.8A = 9.68 ft2