Device and method for extracting astaxanthin

Abstract

The embodiment of the specification provides an astaxanthin extraction device, the device comprises a mixing tank, a cavitator, a static mixer, a three-phase centrifuge and a precision filter, the mixing tank is configured to mix haematococcus pluvialis, water and phospholipase to form uniform algae slurry; the cavitator is configured to receive the algae slurry and perform wall breaking on the algae slurry by utilizing hydrodynamic cavitation to obtain wall-broken algae slurry; the static mixer is configured to mix the wall-broken algae slurry and an extraction agent to form mixed algae slurry; the three-phase centrifugal machine is configured to receive the mixed algae slurry and perform three-phase separation on the mixed algae slurry to obtain an astaxanthin oil phase, a water phase and algae residues; the precision filter is configured to filter the astaxanthin oil phase so as to remove residual algae residues, and the astaxanthin oleoresin is obtained.

Description

Technical Field

[0001] This specification relates to the field of oil extraction, and in particular to an astaxanthin extraction device and method. Background Art

[0002] Astaxanthin is a natural carotenoid with strong antioxidant activity, widely used in food, health supplements, cosmetics, and pharmaceuticals. Currently, Haematococcus pluvialis is considered one of the highest-quality sources of natural astaxanthin. However, the thick-walled spores formed during the growth of Haematococcus pluvialis are highly stable, making the extraction of astaxanthin a significant technical challenge.

[0003] Existing methods for disrupting the algae wall include acid-heat, enzymatic, and mechanical methods, often combined with organic solvents or supercritical fluid technology for astaxanthin extraction. However, these methods suffer from drawbacks such as high energy consumption, high equipment costs, easy degradation of astaxanthin, and complex processes. Furthermore, the extraction process is often accompanied by residual solvents and environmental pollution, making them difficult to meet the requirements of food-grade applications and industrial production.

[0004] Therefore, it is necessary to propose an astaxanthin extraction device and method to improve the extraction efficiency and purity of astaxanthin and reduce energy consumption and environmental burden. Summary of the Invention

[0005] One or more embodiments of the present specification provide an astaxanthin extraction device. The device includes: a mixing tank, a cavitator, a static mixer, a three-phase centrifuge, and a precision filter, wherein: the mixing tank is configured to mix Haematococcus pluvialis, water, and phospholipase to form a uniform algae slurry; the cavitator is configured to receive the algae slurry and use hydraulic cavitation to break the algae wall to obtain a broken algae slurry; the static mixer is configured to mix the broken algae slurry and an extractant to form a mixed algae slurry; the three-phase centrifuge is configured to receive the mixed algae slurry and perform three-phase separation on the mixed algae slurry to obtain an astaxanthin oil phase, an aqueous phase, and an algae residue; the precision filter is configured to filter the astaxanthin oil phase to remove the residual algae residue and obtain astaxanthin oleoresin.

[0006] One or more embodiments of the present specification provide an astaxanthin extraction method. The method comprises: placing Haematococcus pluvialis, water, and phospholipase into a mixing tank for mixing to form a uniform algae slurry; conveying the algae slurry to a cavitator via a mixing feed pump, and performing a cyclic wall-breaking treatment on the algae slurry using hydraulic cavitation to obtain a wall-broken algae slurry; conveying the wall-broken algae slurry into a cooler for cooling; in response to the duration and wall-breaking rate of the cyclic wall-breaking reaching predetermined requirements, conveying the wall-broken algae slurry together with an extractant into a static mixer for mixing to form a mixed algae slurry; conveying the mixed algae slurry into a three-phase centrifuge for separation to obtain an astaxanthin oil phase, an aqueous phase, and algae residue; filtering the astaxanthin oil phase through a precision filter to remove residual algae residue and obtain astaxanthin oleoresin. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] This specification will be further described in the form of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting, and in these embodiments, like numbers represent like structures, wherein:

[0008] Figure 1 is a schematic diagram of an astaxanthin extraction device according to some embodiments of this specification;

[0009] Figure 2 is an exemplary flow chart of the astaxanthin extraction method according to some embodiments of the present specification. DETAILED DESCRIPTION

[0010] To more clearly illustrate the technical solutions of the embodiments of this specification, the following briefly describes the drawings required for describing the embodiments. Obviously, the drawings described below are merely examples or embodiments of this specification. Those skilled in the art can apply this specification to other similar scenarios based on these drawings without inventive effort. Unless otherwise apparent from the context or otherwise noted, the same reference numerals in the figures represent the same structure or operation.

[0011] It should be understood that the terms "system," "device," "unit," and / or "module" used herein are a method for distinguishing different components, elements, parts, portions, or assemblies at different levels. However, if other terms can achieve the same purpose, the terms may be replaced by other expressions.

[0012] As used in this specification and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" do not refer to the singular but also include the plural. Generally speaking, the terms "comprises" and "include" only indicate the inclusion of the steps and elements specifically identified, and these steps and elements do not constitute an exclusive list. A method or apparatus may also include other steps or elements.

[0013] Flowcharts are used throughout this specification to illustrate the operations performed by systems according to embodiments of this specification. It should be understood that preceding or following operations do not necessarily need to be performed in exact order. Instead, the steps may be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

[0014] Figure 1 Schematic diagram of an astaxanthin extraction device according to some embodiments of this specification. Figure 1 As shown, the astaxanthin extraction device 100 includes a mixing tank 110, a cooler 120, a cavitator 130, a mixing feed pump 140, a three-phase centrifuge 150, an oil resin receiving tank 160, a wastewater receiving tank 170, a waste residue receiving tank 180, an extractant storage tank 190, an extractant feed pump 1100, a broken wall algae slurry storage tank 1110, a broken wall algae slurry feed pump 1120, a static mixer 1130, and a precision filter 1140.

[0015] The mixing tank 110 is a storage tank structure for pre-mixing raw materials, such as Haematococcus pluvialis, water, and phospholipase.

[0016] In some embodiments, the mixing tank 110 is configured to mix the Haematococcus pluvialis, water, and phospholipase to form a homogeneous algal slurry.

[0017] The cavitator 130 is a device that performs hydrodynamic cavitation wall breaking on algae slurry. In some embodiments, the cavitator 130 is configured to receive algae slurry and use hydrodynamic cavitation to break the algae slurry wall to obtain broken algae slurry. For more information about hydrodynamic cavitation, please refer to Figure 2 and its description.

[0018] The static mixer 1130 is a device for mixing the broken algae pulp and the extractant. The static mixer 1130 can achieve mixing of the broken algae pulp and the extractant by relying on the flow state of the two without relying on mechanical drive.

[0019] In some embodiments, the static mixer 1130 is configured to mix the broken algal slurry and the extractant to form a mixed algal slurry.

[0020] The three-phase centrifuge 150 is a device for separating the three phases of the mixed algae slurry. These three phases are the astaxanthin oil phase, the aqueous phase, and the algae residue in the mixed algae slurry, corresponding to the oily component, aqueous component, and solid residue in the mixed algae slurry, respectively. The three-phase centrifuge 150 also includes an oil phase outlet, an aqueous phase outlet, and a solid phase outlet, which can be connected to the precision filter 1140, the wastewater receiving tank 170, and the waste residue receiving tank 180, respectively.

[0021] In some embodiments, the three-phase centrifuge 150 is configured to receive the mixed algae slurry and perform three-phase separation on the mixed algae slurry to obtain an astaxanthin oil phase, an aqueous phase, and an algae residue.

[0022] The precision filter 1140 is a device for deep filtering the astaxanthin oil phase. In some embodiments, the precision filter 1140 is configured to filter the astaxanthin oil phase to remove residual algae residue and obtain astaxanthin oleoresin. For more information about the precision filter 1140, please refer to Figure 2 and related instructions.

[0023] In some embodiments, the astaxanthin extraction device 100 further includes a cooler 120 ; the cooler 120 is configured to receive the broken algae slurry from the cavitator 130 , cool the broken algae slurry, and transport the cooled broken algae slurry to the static mixer 1130 .

[0024] In some embodiments, the astaxanthin extraction apparatus 100 further includes multiple power pumps. A power pump is a pump device that provides power for material flow. The multiple power pumps include a mixing feed pump 140, a wall-broken algae slurry feed pump 1120, and an extractant feed pump 1100.

[0025] In some embodiments, the mixing feed pump 140 is configured to provide conveying power to the mixed algae slurry to convey the mixed algae slurry from the mixing tank 110 to the cavitator 130 .

[0026] In some embodiments, the broken-wall algae slurry feed pump 1120 is configured to provide conveying power to the broken-wall algae slurry to convey the broken-wall algae slurry in the broken-wall algae slurry storage tank 1110 from the cavitator 130 to the cooler 120 .

[0027] In some embodiments, the extractant feed pump 1100 is configured to provide a delivery force to the extractant, so as to deliver the extractant in the extractant storage tank 190 to the static mixer 1130 .

[0028] In some embodiments, the astaxanthin extraction apparatus 100 further includes a plurality of storage tanks for storing materials during or after astaxanthin extraction. For example, the plurality of storage tanks include a cracked algae pulp storage tank 1110, an oleoresin receiving tank 160, a wastewater receiving tank 170, a waste residue receiving tank 180, and an extractant storage tank 190.

[0029] In some embodiments, the broken-wall algae slurry storage tank 1110 is configured to store the broken-wall algae slurry.

[0030] In some embodiments, the oleoresin receiving tank 160 is configured to store the astaxanthin oleoresin separated during the three-phase separation process.

[0031] In some embodiments, the wastewater receiving tank 170 is configured to store the water phase separated during the three-phase separation process.

[0032] In some embodiments, the waste receiving tank 180 is configured to store the algal residue separated during the three-phase separation process.

[0033] In some embodiments, extractant storage tank 190 is configured to store extractant.

[0034] In some embodiments, as Figure 1 As shown, the astaxanthin extraction device 100 also includes a pipeline valve 1150. The pipeline valve 1150 refers to a control device for controlling the delivery direction of the algae pulp, which is used to switch the delivery direction of the algae pulp during the cyclic wall-breaking process. For example, the pipeline valve 1150 can be a gate valve. When the cyclic wall-breaking process is completed, the pipeline valve 1150 can be switched to control the algae pulp to enter the broken wall algae pulp storage tank 1110 to terminate the circulation process. For more information about the cyclic wall-breaking process, please refer to Figure 2 and its description.

[0035] In some embodiments, the astaxanthin extraction apparatus 100 further includes a processing device 1160. The processing device 1160 can process data and / or information from various components of the astaxanthin extraction apparatus 100 and / or external data sources. In some embodiments, the processing device 1160 can execute program instructions based on the data, information, and / or processing results, thereby performing one or more functions described herein. For example, the processing device 1160 can perform one or more steps in process 200.

[0036] In some embodiments, the processing device 1160 can be a single server or a server group. The server group can be centralized or distributed. In some embodiments, the processing device 1160 can be local or remote. In some embodiments, the processing device 1160 can be implemented on a cloud platform. As an example only, the cloud platform can include a private cloud, a public cloud, a hybrid cloud, a community cloud, a distributed cloud, an internal cloud, a multi-layer cloud, etc. or any combination thereof. In some embodiments, the processing device 1160 can be a field programmable gate array (FPGA) or a digital signal processor (DSP). In some embodiments, the processing device 1160 can be integrated or installed on the astaxanthin extraction device 100.

[0037] Some embodiments of the present invention integrate modular equipment such as a mixing tank, a cavitator, a static mixer, a three-phase centrifuge, and a precision filter to achieve continuous flow operation throughout the astaxanthin extraction process, significantly improving the extraction efficiency and product quality of astaxanthin oleoresin. At the same time, each modular device is conventional and mature, with low procurement and maintenance costs, facilitating system integration and large-scale industrial application. The use of hydraulic cavitation instead of traditional cell wall breaking technology can significantly reduce the energy consumption of the astaxanthin extraction device; combined with a cooler, it effectively avoids thermal degradation of the astaxanthin active ingredient during cell wall breaking and extraction, improving the astaxanthin extraction rate and product stability; and by using a precision filter to purify the astaxanthin oil phase with high precision, astaxanthin oleoresin with high purity and low residue content is obtained.

[0038] Figure 2 is an exemplary flow chart of the astaxanthin extraction method according to some embodiments of this specification. In some embodiments, process 200 can be performed by a processing device in an astaxanthin extraction device. Figure 2 As shown, the process 200 includes the following steps.

[0039] In step 210, Haematococcus pluvialis, water and phospholipase are put into a mixing tank for mixing to form a uniform algae slurry.

[0040] Phospholipase refers to an enzyme substance added to the mixing tank to decompose the phospholipids and glycolipids emulsifying components in the cells of Haematococcus pluvialis.

[0041] Haematococcus pluvialis is a unicellular freshwater algae belonging to the Chlorophyta, Chlorophyceae, and Haematococcus family.

[0042] Algal slurry refers to a fluid mixture formed by mixing Haematococcus pluvialis, water and phospholipase.

[0043] In some embodiments, the Haematococcus pluvialis, water, and phospholipase can be added to a mixing tank in a mass ratio and mixed to form a uniform algae slurry. Mixing can be achieved by fluid circulation, stirring, or other methods that help to evenly disperse the Haematococcus pluvialis, water, and phospholipase.

[0044] In some embodiments, the mass ratio of Haematococcus pluvialis to water is 1:4 to 1:11. In order to ensure good fluidity and stability of the algae slurry during mixing and wall breaking, to facilitate the subsequent wall breaking of the algae slurry, to avoid difficulties in transporting the algae slurry due to excessive concentration, and to avoid the situation where the astaxanthin concentration is reduced due to excessive dilution, preferably, the mass ratio of Haematococcus pluvialis to water is 1:3 to 1:10. Preferably, the mass ratio of Haematococcus pluvialis to water is 1:5 to 1:10.

[0045] In some embodiments, the amount of phospholipase added is 0.5% to 5.5% of the mass of Haematococcus pluvialis. This effectively decomposes emulsifying components such as phospholipids and glycolipids in Haematococcus pluvialis cells, significantly promotes the oil-water separation process, and improves the purity and extraction efficiency of the astaxanthin oil phase. Preferably, the amount of phospholipase added is 1% to 5% of the mass of Haematococcus pluvialis. More preferably, the amount of phospholipase added is 2% to 5% of the mass of Haematococcus pluvialis.

[0046] In some embodiments of the present specification, controlling the mass ratio range of Haematococcus pluvialis and water (for example, 1:3 to 1:10) can ensure good fluidity and stability of the algae slurry during the mixing and wall-breaking process, which is beneficial to the subsequent wall-breaking of the algae slurry, avoids difficulties in transporting the algae slurry due to excessive concentration, and avoids the situation where the astaxanthin concentration is reduced due to excessive dilution; controlling the addition amount of phospholipase within a certain range (for example, the addition amount of phospholipase is 1% to 5% of the mass of Haematococcus pluvialis) can effectively decompose emulsified components such as phospholipids and glycolipids in Haematococcus pluvialis cells, significantly promote the oil-water separation process, and improve the purity and extraction efficiency of the astaxanthin oil phase.

[0047] In some embodiments, the phospholipase is one or a combination of two or more of phospholipase A1, phospholipase A2, and phospholipase B. Technicians can adjust the ratio of Haematococcus pluvialis to water and the amount of phospholipase added based on the type of phospholipase used to achieve optimal emulsification and demulsification. For example, when using phospholipase B, the mass ratio of Haematococcus pluvialis to water can be 1:5, and the amount of phospholipase B added can be 2% to 4% of the mass of the Haematococcus pluvialis. When using phospholipase A1 and A2 in combination, the mass ratio of Haematococcus pluvialis to water can be 1:10, and the amount of phospholipase added can be approximately 2% of the mass of the Haematococcus pluvialis. Under different phospholipase usage conditions, by appropriately adjusting the mass ratio of Haematococcus pluvialis to water, the efficiency of phospholipase in decomposing algal cell components can be optimized. Furthermore, by adjusting the amount of phospholipase added, the subsequent algal cell wall breaking efficiency and astaxanthin extraction rate can be synergistically improved.

[0048] In some embodiments of the present specification, by using one or a combination of two or more of phospholipase A1, phospholipase A2, and phospholipase B, the above three types of phospholipases show stronger adaptability and stability in the decomposition process of the emulsified structure of Haematococcus pluvialis cells compared to other types of phospholipases, and can achieve efficient degradation of phospholipid and glycolipid emulsifying components at a lower addition amount, thereby promoting the release of astaxanthin and the effective separation of the oil phase and the water phase.

[0049] In step 220, the algae slurry is transported to the cavitator through a mixing feed pump, and the algae slurry is subjected to a circulating wall-breaking treatment by using hydraulic cavitation.

[0050] In some embodiments, a mixing feed pump can be connected to the outlet of the mixing tank and the inlet of the cavitator through pipelines. After the algae slurry is formed in the mixing tank, it can be transported to the cavitator by the transport power provided by the mixing feed pump.

[0051] Hydraulic cavitation refers to the liquid cavitation phenomenon caused by local high flow velocity and low pressure when algae slurry flows through the cavitator.

[0052] In some embodiments, the algae slurry is subjected to a wall-breaking treatment, comprising: utilizing the mechanical shear force and energy shock generated by hydraulic cavitation to destroy the cell walls of Haematococcus pluvialis in the algae slurry. Specifically, the algae slurry is driven into the cavitator by a mixing feed pump. When the algae slurry flows through a structural mutation region (e.g., a contraction section or a nozzle) inside the cavitator, a large number of cavitation bubbles are formed due to a significant increase in the local flow velocity and a rapid drop in pressure. As the pressure recovers, the bubbles rapidly disintegrate, generating strong mechanical shear force and energy shock waves that can act on the Haematococcus pluvialis in the algae slurry, destroying its cell walls and releasing fat-soluble active substances such as astaxanthin.

[0053] In some embodiments, the processing equipment can perform a cyclic cell wall-breaking process on the algae slurry. This cyclic cell wall-breaking process includes circulating the algae slurry through a cavitator for hydraulic cavitation and cooling it through a cooler. During each cycle, the algae slurry is driven by a mixing feed pump into the cavitator, where cavitation bubbles are formed to break down the cell walls of the Haematococcus pluvialis algae in the slurry. The slurry is then cooled in a cooler to prevent thermal degradation of the astaxanthin. The cooled algae slurry then flows back to the mixing tank, ready for the next cycle.

[0054] Step 230: In response to the duration of the cyclic wall breaking and the wall breaking rate reaching a preset standard, the cyclic wall breaking is stopped to obtain the broken wall algae pulp.

[0055] In some embodiments, the processing equipment can stop the circulating wall breaking treatment by switching the pipeline valve after the circulating wall breaking treatment is completed, and transport the broken wall algae slurry to the broken wall algae slurry storage tank for subsequent transportation to the static mixer together with the extractant for mixing treatment.

[0056] The preset standards include a circulation wall breaking time of 0.5 hours to 3 hours, and a wall breaking rate of more than 90% of the sampled algae slurry.

[0057] In some embodiments, the cyclic cell disruption process lasts for less than four hours. To achieve sufficient cell disruption and ensure extraction efficiency and product stability, the cyclic cell disruption process preferably lasts for 0.5 to 3 hours. More preferably, the cyclic cell disruption process lasts for 2 to 3 hours.

[0058] Circulating water refers to the water used as cooling medium in the cooler. Figure 1As shown, the circulating water can be condensed water. The circulating water can be indirectly heat-exchanged with the algae slurry to reduce the temperature rise of the algae slurry during the circulating wall-breaking process. In some embodiments, the circulating water temperature of the cooler (i.e., the condensed water temperature) is not higher than 20°C. In order to suppress the degradation of astaxanthin caused by temperature increase while releasing fat-soluble active substances such as astaxanthin, and to ensure extraction efficiency and product stability, preferably, the circulating water temperature of the cooler is in the range of 5 to 15°C. Preferably, the circulating water temperature of the cooler is in the range of 8 to 10°C.

[0059] In some embodiments of the present specification, by controlling the circulation cell-breaking time within a certain range (e.g., between 0.5 hours and 3 hours) and the circulating water temperature of the cooler within a certain range (e.g., not higher than 20°C), it is possible to fully break the cell walls of the algae, release fat-soluble active substances such as astaxanthin, and inhibit the degradation of astaxanthin caused by increased temperature, thereby ensuring extraction efficiency and product stability.

[0060] In step 240, the broken algae pulp and the extractant are conveyed to a static mixer for mixing to form a mixed algae pulp.

[0061] Extraction agents are oily materials used to extract fat-soluble active ingredients such as astaxanthin from cracked algae pulp. The extraction agents can be pre-stored in extraction agent storage tanks.

[0062] In some embodiments, the extractant is one of medium chain glycerides (MCT) or ethyl esterified vegetable oil.

[0063] In some embodiments of this specification, by using medium-chain fatty acid glycerides (MCT) or ethylated vegetable oil as an extractant, the subsequent astaxanthin extraction efficiency and the astaxanthin content in the oil phase can be significantly improved. Compared with conventional natural vegetable oils (such as coconut oil), modified low-viscosity oils as extractants (such as medium-chain fatty acid glycerides, ethylated safflower oil, ethylated sunflower oil, etc.) have lower viscosity, better fluidity, and are not easy to emulsify, which is conducive to subsequent oil-water separation, significantly improving the separation efficiency and product purity of the astaxanthin extraction process, while avoiding the problem of solvent residue, without the need for removal, and the process is simpler and more reliable. In addition, MCT and ethylated vegetable oil are both food-grade oils with good stability and safety, suitable for application fields such as food and health products, and effectively avoid the problems of incomplete emulsification or insufficient solubility caused by traditional organic solvents.

[0064] Mixed algae slurry refers to a liquid mixture formed by mixing cracked algae slurry with an extractant. In some embodiments, the mixed algae slurry is a three-phase system, comprising an oil phase, an aqueous phase, and a solid phase. The oil phase is primarily composed of medium-chain fatty acid glycerides or ethylated vegetable oils, which serve as extractants and are used to dissolve fat-soluble active ingredients such as astaxanthin in the cracked algae slurry; the aqueous phase is derived from the water in the cracked algae slurry and contains some soluble impurities; and the solid phase is the algal cell fragments remaining after the algae slurry is cracked.

[0065] In some embodiments, the broken algae pulp and the extractant can be respectively delivered to a static mixer by a broken algae pulp feed pump and an extractant feed pump for mixing to form a mixed algae pulp. Specifically, the broken algae pulp can be delivered from the broken algae pulp storage tank through the broken algae pulp feed pump, and the extractant can be delivered from the extractant storage tank through the extractant feed pump. The broken algae pulp and the extractant can be delivered to the static mixer through a pipeline according to the feed speed ratio; the static mixer can complete the mixing by relying on the fluid flow of the broken algae pulp and the extractant without mechanical power, thereby forming a mixed algae pulp. By setting the feed speed ratio, it is possible to ensure sufficient contact and mixing between the broken algae pulp and the oily extractant, thereby promoting the efficient transfer of astaxanthin and optimizing the effect of subsequent three-phase centrifugation. Among them, the feed speed ratio can be pre-set by technicians according to different materials. For example, the feed speed ratio of broken algae pulp to extractant can be 2:1. For more information about the feed speed, please refer to Table 1 and its description.

[0066] In some embodiments, the amount of the extractant added is 0.2 to 6 times the dry matter weight of the Haematococcus pluvialis. To ensure sufficient extraction of astaxanthin, reduce the amount of extractant used, reduce the burden of subsequent oil phase concentration and separation, and improve overall extraction efficiency and cost control capabilities, the amount of the extractant added is preferably 0.3 to 5 times the dry matter weight of the Haematococcus pluvialis.

[0067] In some embodiments, the broken wall algae pulp and the extraction agent can be delivered to the static mixer in a continuous feeding manner. The amount of the extraction agent added can be set by the feed rate ratio of the broken wall algae pulp to the extraction agent. For example, when the feed rate ratio of the broken wall algae pulp to the extraction agent is 2:1, the amount of the extraction agent added is 2 times the dry matter weight of the Haematococcus pluvialis; for another example, when the feed rate ratio is 11:5, the amount of the extraction agent added is 5 times the dry matter weight of the Haematococcus pluvialis.

[0068] In some embodiments of the present specification, by controlling the amount of extractant added within a certain range (for example, the amount of extractant added is between 0.3 times and 5 times the dry matter weight of Haematococcus pluvialis), the amount of extractant used can be reduced while ensuring sufficient extraction of astaxanthin, thereby reducing the burden of subsequent oil phase concentration and separation, and improving the overall extraction efficiency and cost control capabilities.

[0069] In step 250, the mixed algae slurry is conveyed to a three-phase centrifuge for separation to obtain an astaxanthin oil phase, an aqueous phase, and an algae residue.

[0070] In some embodiments, the processing equipment can transport the mixed algae slurry to a three-phase centrifuge for separation to obtain astaxanthin oil phase, water phase and algae residue. Specifically, the three-phase centrifuge can form a strong centrifugal field under high-speed rotation, and separate the mixed algae slurry into astaxanthin oil phase, water phase and algae residue according to the density difference between the oil phase, water phase and solid phase. Among them, the oil phase outlet, water phase outlet and solid phase outlet of the three-phase centrifuge can be connected to a precision filter, a wastewater receiving tank and a waste residue receiving tank respectively; the water phase and algae residue can flow into the wastewater receiving tank and the waste residue receiving tank respectively, and the astaxanthin oil phase can be filtered through a precision filter and then flow into the oil resin receiving tank to achieve independent collection and storage of the astaxanthin oil phase, water phase and algae residue.

[0071] In some embodiments, the rotation speed of the three-phase centrifuge is 2000 rpm to 7000 rpm. To ensure separation efficiency while avoiding excessive energy consumption and wear of the astaxanthin extraction device, reducing operating costs, and effectively preventing astaxanthin degradation due to temperature increases during the separation process, thereby improving the astaxanthin extraction rate and oil phase purity, while extending the service life of the astaxanthin extraction device, the rotation speed of the three-phase centrifuge is preferably 3000 rpm to 6000 rpm.

[0072] In some embodiments of the present specification, by controlling the rotation speed of the three-phase centrifuge within the range of 3000 rpm to 6000 rpm, it is possible to ensure separation efficiency while avoiding excessive energy consumption and wear of the astaxanthin extraction device, reducing operating costs, and effectively preventing astaxanthin degradation due to increased temperature during the separation process, thereby improving the astaxanthin extraction rate and oil phase purity, and extending the service life of the astaxanthin extraction device.

[0073] Step 260: Filter the astaxanthin oil phase through a precision filter to remove residual algae residue and obtain astaxanthin oleoresin.

[0074] In some embodiments, the astaxanthin oil phase obtained by separation in a three-phase centrifuge can be filtered through a precision filter to remove residual algal residue and obtain astaxanthin oleoresin. Specifically, the precision filter can utilize a micron-sized filter element to separate the residual algal residue from the oil phase through physical screening and interception. The filtered astaxanthin oil phase can be transferred to an oleoresin receiving tank for storage as astaxanthin oleoresin, thereby obtaining a high-purity astaxanthin oleoresin suitable for subsequent processing or direct use.

[0075] In some embodiments, the precision filter has a filtration accuracy of at least 3000 mesh. To effectively remove fine algal residue particles from the astaxanthin oil phase, preventing sedimentation, oxidation, or product quality degradation caused by residual impurities, thereby improving the purity and quality of the filtered astaxanthin oleoresin, the precision filter preferably has a filtration accuracy of at least 2000 mesh.

[0076] In some embodiments of the present specification, by controlling the filtration accuracy of the precision filter within a certain range (e.g., above 2000 mesh), algal residues with tiny particle sizes in the astaxanthin oil phase can be effectively removed, thereby avoiding sedimentation, oxidation, or product quality degradation caused by residual impurities, thereby improving the purity and quality of the filtered astaxanthin oleoresin.

[0077] In some embodiments of the present invention, the algae slurry is transported to a cavitator, and the algae slurry is subjected to a cyclic wall-breaking treatment using hydraulic cavitation, and a cooler is used to perform real-time cooling during the circulation process. Under the action of hydraulic cavitation, the mechanical energy generated can effectively destroy the structure of the algae cell wall and promote the release of fat-soluble active ingredients such as astaxanthin; the cooler can inhibit the thermal degradation of astaxanthin caused by local temperature rise during the treatment process, thereby improving the activity and stability of the product. Compared with traditional wall-breaking methods, it has the advantages of significantly reduced energy consumption, continuous flow operation, high production efficiency, and improved astaxanthin extraction rate. At the same time, the three-phase centrifuge, static mixer and other equipment used are common industrial equipment with low equipment cost, which is convenient for large-scale industrial promotion. Furthermore, the astaxanthin oil phase is separated by a three-phase centrifuge, and fine impurities are removed by a precision filter to obtain pure and stable astaxanthin oil resin, which is suitable for subsequent processing or direct application.

[0078] It should be noted that the above description of process 200 is for illustration and purpose only and does not limit the scope of application of this specification. Those skilled in the art may make various modifications and changes to the process under the guidance of this specification. However, such modifications and changes are still within the scope of this specification.

[0079] In different embodiments, parameters such as raw material ratio, phospholipase type and addition amount, cooling water temperature, wall breaking time, feed rate ratio of broken algae slurry to extractant, and centrifuge speed vary. The specific process parameters and astaxanthin extraction effect are listed in Table 1 below. For example, as shown in Example 1 in Table 1, the processing equipment can put Haematococcus pluvialis, water, and phospholipase B in a mass ratio of 1:3 into a mixing tank, add phospholipase B at a rate of 2% of the dry weight of Haematococcus pluvialis, and mix to form a uniform algae slurry. The algae slurry is transported to a cavitator by a feed pump. Under the condition of cooling water temperature of 8°C, hydrodynamic cavitation cycle wall breaking is carried out for 3 hours. After the wall breaking rate reaches more than 90%, the cycle wall breaking process is stopped to obtain a broken algae slurry; then, the broken algae slurry is fed into a static mixer with medium-chain fatty acid glycerides (MCT) at a feed rate ratio of 2:1 to obtain a mixed algae slurry; the mixed algae slurry is transported to a three-phase centrifuge for separation, and the centrifuge speed is 3000rpm. After filtering through a precision filter, astaxanthin oleoresin was obtained with an extraction rate of 85% and an astaxanthin content of 4.4%. Examples 2-8 are shown in Table 1 and are not described in detail here. Table 1

[0080] In order to further verify the superiority of the astaxanthin extraction device and method used in this specification, a control example is set up, and the process parameters of the control example and the extraction effect of astaxanthin are listed in Table 2 below. The control example is consistent with the process of the embodiment. However, the control example differs from the embodiment of the present invention in some process parameters or treatment conditions. For example, as shown in Control Example 1 in Table 2, compared with Example 1, the control example does not use phospholipase, and Haematococcus pluvialis, water and phospholipase B are put into a mixing tank at a mass ratio of 1:5, the cooling water temperature is 10°C, and the wall breaking time is 3 hours to obtain broken wall algae pulp; the broken wall algae pulp and medium-chain fatty acid glyceride (MCT) are fed into a static mixer at a feed rate ratio of 6:1 to obtain a mixed algae pulp; the mixed algae pulp is transported to a three-phase centrifuge for separation, and the centrifuge speed is 6000rpm. After filtering through a precision filter, astaxanthin oleoresin is obtained, the astaxanthin extraction rate is 61%, and the astaxanthin content is 5.4%. Table 2

[0081] A comparison of Example 2 and Control Example 2 shows that, while the ratio of Haematococcus pluvialis to water, the amount of phospholipase added, the cooling water temperature, the wall-breaking time, the type of extractant, the feed rate ratio, and the centrifuge speed were all kept consistent, the only difference was the type of phospholipase. Example 2 employed phospholipase B, while Control Example 2 employed alkaline protease. The results showed that the astaxanthin extraction rate in Example 2 reached 93%, with an astaxanthin content of 7.3%, while the extraction rate in Control Example 2 was only 62%, with an astaxanthin content of 5.7%. This difference indicates that phospholipase B is more effective in breaking down the phospholipid and glycolipid emulsifying components within Haematococcus pluvialis cells, significantly increasing astaxanthin release; whereas non-specific proteases (such as alkaline proteases) have limited facilitating effects on the astaxanthin extraction process. This demonstrates the significant technical advantages of using specific phospholipases (such as phospholipase A1, phospholipase A2, or phospholipase B, or a combination of two or more) in one or more embodiments of this specification for efficient astaxanthin extraction.

[0082] A comparison of Example 2 and Control Example 3 shows that, under the same conditions of the ratio of Haematococcus pluvialis to water, the type and amount of phospholipase added, the cooling water temperature, wall-breaking time, feed rate ratio, and centrifuge speed, the only difference was the type of extractant. Example 2 used medium-chain fatty acid glycerides (MCT) as the extractant, while Control Example 3 used coconut oil. The results showed that the astaxanthin extraction yield in Example 2 was 93%, with an astaxanthin content of 7.3%; the extraction yield in Control Example 3 was 87%, with an astaxanthin content of only 2.7%. This comparison indicates that MCT, due to its lower viscosity, better fat solubility, and polarity matching with astaxanthin, can more efficiently promote the transfer of astaxanthin from the aqueous phase to the oil phase in the mixed algae slurry, thereby achieving a higher astaxanthin content in the oil phase. In contrast, coconut oil, due to its higher viscosity and stronger emulsification tendency, has insufficient astaxanthin enrichment capacity in the oil phase. Therefore, in one or more embodiments of this specification, MCT or ethylated vegetable oil is used as the extractant to effectively improve the astaxanthin extraction efficiency and purity.

[0083] From the comparison of Examples 1-5 in Table 1 and Comparative Examples 1-4 in Table 2, it can be seen that the astaxanthin extraction device and method used in this specification uses medium-chain fatty acid glycerides (MCT) or ethyl esterified vegetable oil as a diluent extractant, which can achieve efficient extraction of astaxanthin under low energy consumption and temperature conditions. Compared with Comparative Examples 1-4 in which no phospholipase is used, other enzymes are used, or different ratios of broken algae pulp to extractant are used, the astaxanthin extraction rate and content obtained by the astaxanthin extraction method used in this specification are significantly improved, with better extraction effect and process stability.

[0084] While the basic concepts have been described above, it will be apparent to those skilled in the art that the detailed disclosure is merely illustrative and does not limit this specification. Although not explicitly stated herein, various modifications, improvements, and revisions to this specification may be made by those skilled in the art. Such modifications, improvements, and revisions are suggested in this specification and remain within the spirit and scope of the exemplary embodiments of this specification.

[0085] This specification also uses specific terms to describe the embodiments of this specification. For example, "one embodiment," "an embodiment," and / or "some embodiments" refer to a feature, structure, or characteristic associated with at least one embodiment of this specification. Therefore, it should be emphasized and noted that references to "one embodiment," "an embodiment," or "an alternative embodiment" two or more times in different locations in this specification do not necessarily refer to the same embodiment. Furthermore, certain features, structures, or characteristics of one or more embodiments of this specification may be appropriately combined.

[0086] In addition, unless expressly stated in the claims, the order of the processing elements and sequences, the use of alphanumeric characters, or the use of other names described in this specification are not intended to limit the order of the processes and methods of this specification. Although the above disclosure discusses some of the invention embodiments currently considered useful through various examples, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments. On the contrary, the claims are intended to cover all modifications and equivalent combinations that are consistent with the spirit and scope of the embodiments of this specification. For example, although the system components described above can be implemented by hardware devices, they can also be implemented only by software solutions, such as installing the described system on an existing server or mobile device.

[0087] Similarly, it should be noted that, in order to simplify the presentation of this specification and thus facilitate understanding of one or more embodiments of the invention, the foregoing descriptions of the embodiments of this specification sometimes combine multiple features into a single embodiment, figure, or description thereof. However, this disclosure method does not imply that the subject matter of this specification requires more features than those recited in the claims. In fact, an embodiment may have fewer features than all of the features of a single disclosed embodiment.

[0088] In some embodiments, numbers are used to describe the quantity of components and attributes. It should be understood that such numbers used in the description of the embodiments are modified by the modifiers "about", "approximately" or "substantially" in some examples. Unless otherwise stated, "about", "approximately" or "substantially" indicate that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the description and claims are approximate values, which may change according to the required characteristics of individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and adopt the general method of retaining digits. Although the numerical domains and parameters used to confirm the breadth of their range in some embodiments of this specification are approximate values, in specific embodiments, the settings of such numerical values ​​are as accurate as possible within the feasible range.

[0089] Each patent, patent application, patent application publication, and other materials, such as articles, books, specifications, publications, and documents, cited in this specification is hereby incorporated by reference in its entirety. This includes application history documents that are inconsistent with or conflict with the content of this specification, as well as documents (currently or subsequently attached to this specification) that limit the broadest scope of the claims of this specification. It should be noted that if the descriptions, definitions, and / or terminology used in the accompanying materials are inconsistent or conflicting with the content of this specification, the descriptions, definitions, and / or terminology used in this specification will control.

[0090] Finally, it should be understood that the embodiments described in this specification are intended only to illustrate the principles of the embodiments of this specification. Other variations may also fall within the scope of this specification. Therefore, by way of example and not limitation, alternative configurations of the embodiments of this specification may be considered consistent with the teachings of this specification. Accordingly, the embodiments of this specification are not limited to the embodiments explicitly described and illustrated in this specification.

Claims

1. An astaxanthin extraction device, characterized in that, The device comprises: a mixing tank, a cavitator, a static mixer, a three-phase centrifuge and a precision filter, wherein: The mixing tank is configured to mix Haematococcus pluvialis, water and phospholipase to form a uniform algae slurry; The cavitator is configured to receive the algae slurry and break the algae slurry by hydraulic cavitation to obtain broken algae slurry; The static mixer is configured to mix the wall-broken algae pulp and the extractant to form a mixed algae pulp; The three-phase centrifuge is configured to receive the mixed algae pulp and perform three-phase separation on the mixed algae pulp to obtain an astaxanthin oil phase, an aqueous phase and an algae residue; The precision filter is configured to filter the astaxanthin oil phase to remove the residual algal residue and obtain astaxanthin oleoresin.

2. The astaxanthin extraction device according to claim 1, characterized in that The device also includes a cooler; the cooler is configured to receive the broken algae slurry from the cavitator, cool the broken algae slurry, and transport the cooled broken algae slurry to the static mixer.

3. The astaxanthin extraction device according to claim 2, characterized in that The device further comprises a plurality of power pumps, the plurality of power pumps comprising: a mixing feed pump configured to provide conveying power to the mixed algae slurry, so as to convey the mixed algae slurry from the mixing tank to the cavitator; a broken-wall algae slurry feed pump, configured to provide conveying power to the broken-wall algae slurry, so as to convey the broken-wall algae slurry from the cavitator to the cooler; An extractant feed pump is configured to provide a conveying force to the extractant, so as to convey the extractant to the static mixer.

4. The astaxanthin extraction device according to claim 3, characterized in that The device further comprises a plurality of storage tanks, the plurality of storage tanks comprising: a broken-wall algae pulp storage tank, configured to store the broken-wall algae pulp; an oleoresin receiving tank configured to store the astaxanthin oleoresin; a wastewater receiving tank configured to store the aqueous phase separated during the three-phase separation process; The waste residue receiving tank is configured to store the algae residue separated in the three-phase separation process.

5. A method for extracting astaxanthin, the method being implemented based on the astaxanthin extraction device according to any one of claims 1 to 4, characterized in that: The method comprises: Putting Haematococcus pluvialis, water and phospholipase into a mixing tank and mixing them to form a uniform algae slurry; The algae slurry is transported to the cavitator through a mixing feed pump, and the algae slurry is subjected to a cyclic wall-breaking treatment, wherein the cyclic wall-breaking treatment comprises: passing the algae slurry through the cavitator for hydraulic cavitation treatment and passing through a cooler for cooling; In response to the duration and the breaking rate of the cyclic wall breaking reaching a preset standard, stopping the cyclic wall breaking to obtain the broken wall algae pulp; transporting the wall-broken algae pulp and the extractant together to a static mixer for mixing to form a mixed algae pulp; The mixed algae slurry is conveyed to a three-phase centrifuge for separation to obtain an astaxanthin oil phase, an aqueous phase and an algae residue; The astaxanthin oil phase is filtered through a precision filter to remove residual algae residue and obtain astaxanthin oleoresin.

6. The method according to claim 5, characterized in that The mass ratio of the Haematococcus pluvialis to the water is 1:3 to 1:10, and the added amount of the phospholipase is 1% to 5% of the mass of the Haematococcus pluvialis.

7. The method according to claim 5, characterized in that The duration of the circulating wall breaking is 0.5 hours to 3 hours, and the circulating water temperature of the cooler is not higher than 20°C.

8. The method according to claim 5, characterized in that The extractant is one of medium-chain fatty acid glyceride (MCT) or ethyl esterified vegetable oil.

9. The method according to claim 5, characterized in that The amount of the extractant added is 0.3 to 5 times the dry matter amount of the Haematococcus pluvialis.

10. The method according to claim 5, characterized in that The rotation speed of the three-phase centrifuge is 3000 rpm to 6000 rpm.

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