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

Outline Flow Sheeting Energy Sinks/Loads and Streams Equipment Sizing Costing

Degumming Bleaching Removal FFA Deodorization Centrifuge Crude SBO Citric Acid Gum Water Citric Acid Acid Activated Clay Enzyme Water Acid Activate Clay Interesterification Hardfat SBO EmulsificationPasteurization Water Sea Salt Lecithin Diacetyl Mono/Diglycerides B-Carotenes Sorbic Acid Ergocaliferols Sodium Hydroxide Citric Acid Water Sodium Hydroxide Citric Acid Water Scraped Surface Heat Exchanger Packaging Refrigerant To Wholesaler Dissolved Air Floatation FermentationCentrifuge CO 2 Lysing Glucose Beer Still Bottom Antifoam Water Algae Glucanex Steam Cooling Water Sterile air Vent Water Air CO 2 LHO- Biomass Water NaOH Steam Salt CIP System

Fermentor PFD

DAF PFD Rxn tank A Rxn tank B P-01 P-02 P Fermented Algae Fermented Algae Fermented Algae Sterilized Air Vented Air Conc. Algae Waste Water Conc. Algae 18 Sterilized Air

Baffle tray Tower Lysed CO2 Holding tank CO2 Lysing PFD Conc. Algae Sterilized CO2 CO2 Absorbed Algae Lysed Algae & CO2 Vented CO2 Lysed Algae Throttle Valve

3 Main Centrifuge PFD Centrifuge Lysed Algae Biomass Algae Oil

TK- 01 Crude SBO Storage P N 2 Gas 1 6 TK-02 45% Citric Acid Storage P P-03P-04P-05 TK-03 4% NaOH Storage TK-04 Water Storage TK-05 10% Enzyme Refrigerated Storage N 2 Gas Cooling Heating HLO - Gums 19 TK-06 Batch Reactor P-06P-07 TK-07 Surge Tank N 2 Gas TK-08 Degummed SBO Storage Heating HX-1 HX-3 LLO HX-2 Cent-01 Degumming PFD

24 N 2 Gas TK-08 Degummed SBO Storage 2827 HX TK-09 50% Citric Acid Storage 29 P-08 P TK-10 Acid Activated Clay Tank P P-11 TK-11 Water Storage P-12 HX P-13 VP-1 TK-12 Mixer N 2 Gas TK-13 Surge Tank 44 P MX-2MX-1 49 VP Steam To MX-1 P N 2 Gas 61 TK-14 Refined SBO Storage HX-6 HX-7 HX-8 HX-9 Filter Vacuum Vessel 3837 Refining PFD

64 N 2 Gas TK-14 Refined SBO Storage 65 N 2 Gas TK-15 SBO Hardfat Storage 67 N 2 Gas TK-16 SBO Hardfat Heating Tank P-17 P-18 HX-10 HX VP P-19 TK-17 CH 3 ONa Storage 82 TK-19 Mixing Tank P P-21 Filter TK-20 Soft Water Storage HX-12 HLO P-22 P-23P HLO 96 Cent-03Cent-02 TK-18 20% Citric Acid Storage TK-21 Dryer P-25 2A1A A N 2 Gas TK-22 SBO Storage HX-13 MX-3MX-4 Water Softener Interesterification PFD

E Algae Oil Storage Refined SBO Storage Lecithin Storage Beta Carotene Storage Diacetyl Storage Sorbic Acid Storage Mono- di glycerides Storage Ergo- califerol Storage Water Storage Oil Pasteurizatio n CIP Warm Water Aqueou s Phase Prep. 10 TK-01 TK-02 TK-03 TK-04 CIP TK-05 TK-06 TK-07 TK-08 TK-11 TK-12 TK-13 Oil Phase Prep. Tank 1 CIP P-01 P-02 P-03 P-04 Warm Water Oil Oil Phase Prep. Tank 1 CIP Sea Salt Storage TK-10 P TK CIP Margarine PFD Warm Water

High Pressure Pump P-06 Ammonia Compressor Pin Rotor Machine Scraped Surface Heat Exchanger Packaging P-07 CIP Plate HX 01 Pasteurization CIP Margarine PFD 21

Overall Mass Balance for Oil Algae Oil Produced In Fermentation –127,606 kg / year Refined SBO Produced –3,424,720 kg / year Margarine Produced –117,520 kg / year Algae Oil –3,424,720 kg / year refined SBO

Energy Sinks/Loads and Streams Steam Boiler Q = 2,035,547 BTU / hr Fermentor Heat Exchanger Silicone Antifoam Direct Steam Rejector Paratherm Boiler Q = BTU / hr Water Cooler 48.9 °C – 29.4 °C Q = 482,348.6 BTU / hr Emulsification 25 °C – °C Q = 28,600 BTU / hr Pasteurization °C – 43.3 °C Q = 9,500 BTU / hr Crystallization 43.3 °C – 10 °C Q = - 57,200 BTU/ hr

Equipment Sizing For Fermentation Process EquipmentSize (gal) TK-111,000 TK-240,000 TK-31,200 TK-4300 TK-5300 MT-122,000 10L Seed Fermenter L Seed Fermenter265 10% Seed Fermenter3,500 Main Fermenter35,000 CO 2 Lysing Tank12,000 DAF Tank24,000

Equipment for SBO Refining Component Sizing TK gal TK-0225 gal TK gal TK gal TK-0515 gal TK gal TK gal TK gal TK-0935 gal TK gal TK gal Component Sizing TK gal TK gal TK gal TK gal TK gal TK gal TK gal TK gal TK gal TK gal TK gal MX-1100 gal MX-2100 gal MX-3500 gal MX-4500 gal Component Sizing HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr HX BTU/hr TanksHeat Exchangers

Margarine Equipment Sizing ComponentSize P GPM P GPM P-031 GPM P-041 GPM P GPM P GPM P GPM Emulsion Tank L Emulsion Tank L High Pressure Pump2475 L / hr Plate Heat Exchanger6 ft^2 Scraped Surface Heat Exchanger2150 L / hr Pin Rotor Machine2000 L/hr Tub Filling Machine2740 L/hr Ammonia Compressor18 ton ComponentSize TK L TK L TK-0320 L TK-042 L TK-052 L TK-065 L TK-0710 L TK-082 L TK L TK L TK L TK L TK L

Costing Capitol Costs -Refining $ Million - Algae Oil Production $ Million - Margarine Production $ 1.8 Million - Chemicals and Ingredients $.22 Million Operating Costs - Refining $ 2.64 Million - Algae Oil Production $ 6.10 Million - Margarine Process $ 0.24 Million - Chemicals and Ingredients $ 4.7 Million Capital Costs -Refining $ Million - Algae Oil Production $ Million - Margarine Production $ 1.8 Million - Chemicals and Ingredients $.22 Million

ChemicalUnit PriceAmt. RequiredYearly Price Total Crude SBO$867.40/ton3, tons$2,773, SBO Hardfat$0.46/lb1,544, lb$710,652,04 50% Citric Acid$8.51/gal9, gal$77, Acid Activated Clay$209/ton tons$3, % Sodium Methoxide$14/kg6, kg$96, Nitrogen$7.7825/m³ m³$ Paratherm NF *$21.21/gal10,000 gal$ % Sodium Hydroxide$4.39/L L$2, Enzyme$576/L L$34, Sea Salt (Fermentation)$600/ton tons$403, Ethanol bottoms$140/ton tons$27, CO 2 Free1,096,000 kg- Lecithin$0.81/lb19,534.7 lb$15, Sea Salt (Margarine Process)$600/ton tons$443, Ergocaliferol$18234/kg lb$3, Mono/Di Glycerides$0.1/kg48,836.8 lb$10, Beta-Carotene$1250/kg193.8 lb$109, Diacetyl$2.5/kg24.42 lb$27.69 Ammonia *$500/ton18 tons$9, Sorbic Acid$8250/ton9,767.36$40, * Only capitol costs Chemical Costs

Questions ?

TK-3 Acidic Solution TK-4 Alkaline Solution TK-5 Reclaim Water TK-6 Fresh Water TK-1 Alkaline Storage TK-2 Acidic Storage 2 1 CIP Returning Liquid Water Steam HX-1 17 CIP Supplying Liquid Drain Filter CIP System

Drying Process Biomass + Water InBiomassWater Out 22, , , Liquid 19,146 3,829 15,317 2,011 1, , , Dry BiomassEvaporated Water 2, , SolidLiquid Centrifuge 2Dryer