An astaxanthin extraction device and method

Abstract

The embodiment of the specification provides a kind of astaxanthin extraction device, the device includes mixing tank, cavitation device, static mixer, three-phase centrifuge, precision filter, cooler, multiple power pumps and multiple storage tanks, wherein: mixing tank is configured to mix haematococcus pluvialis, water and phospholipase to form uniform algal slurry;Cavitation device is configured to receive algal slurry, and after wall breaking of algal slurry is carried out using hydrodynamic cavitation, obtain broken algal slurry;Static mixer is configured to mix broken algal slurry and extractant to form mixed algal slurry;Three-phase centrifuge is configured to receive mixed algal slurry, and three-phase separation is carried out on mixed algal slurry to obtain astaxanthin oil phase, water phase and algal residue;Precision filter is configured to filter astaxanthin oil phase to remove residual algal residue and obtain astaxanthin oil resin.

Description

Technical Field

[0001] This manual relates to the field of oil extraction, and in particular to an astaxanthin extraction apparatus and method. Background Technology

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

[0003] In existing technologies, the cell wall disruption methods for Haematococcus pluvialis mainly include acid-thermal methods, enzymatic hydrolysis, and mechanical cell wall disruption, which are usually combined with organic solvents or supercritical fluid technology for astaxanthin extraction. However, the above methods generally suffer from drawbacks such as high energy consumption, high equipment costs, easy degradation of astaxanthin, and complex processes. Moreover, the extraction process is often accompanied by solvent residues or environmental pollution, making it difficult to meet the needs of food-grade applications and industrial production.

[0004] Therefore, there is a need to propose an astaxanthin extraction device and method to improve extraction efficiency and astaxanthin purity, while reducing energy consumption and environmental burden. Summary of the Invention

[0005] This specification provides an astaxanthin extraction apparatus according to one or more embodiments. The apparatus includes: a mixing tank, a cavitation generator, a static mixer, a three-phase centrifuge, a precision filter, a cooler, multiple power pumps, and multiple storage tanks, wherein: the mixing tank is configured to mix Haematococcus pluvialis, water, and phospholipase to form a homogeneous algal slurry; the cavitation generator is configured to receive the algal slurry and, using hydraulic cavitation, break down the algal cell walls to obtain a broken-cell algal slurry; the static mixer is configured to mix the broken-cell algal slurry with an extractant to form a mixed algal slurry; the three-phase centrifuge is configured to receive the mixed algal slurry and perform three-phase separation on the mixed algal slurry to obtain an astaxanthin oil phase, an aqueous phase, and algal residue; the precision filter is configured to filter the astaxanthin oil phase to remove residual algal residue and obtain astaxanthin oleoresin; the cooler is configured to receive the broken-cell algal slurry from the cavitation generator and, using hydraulic cavitation, break down the algal cell walls to obtain a broken-cell algal slurry. The cell-wall-broken algae slurry is cooled and then transported to the static mixer. The plurality of power pumps include: a mixing feed pump configured to provide power to the algae slurry to transport it from the mixing tank to the cavitation unit; a cell-wall-broken algae slurry feed pump configured to provide power to the cell-wall-broken algae slurry to transport it from the cavitation unit to the cooler; and an extractant feed pump configured to provide power to the extractant to transport it to the static mixer. The plurality of storage tanks include: a cell-wall-broken algae slurry storage tank configured to store the cell-wall-broken algae slurry; 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; and a waste residue receiving tank configured to store the algae residue separated during the three-phase separation process.

[0006] This specification provides one or more embodiments of an astaxanthin extraction method. The method includes: mixing Haematococcus pluvialis, water, and phospholipase in a mixing tank to form a homogeneous algal slurry; conveying the algal slurry to a cavitation unit via a mixing feed pump and using hydraulic cavitation to circulate and break down the algal slurry to obtain a broken-cell algal slurry; sending the broken-cell algal slurry to a cooler for cooling; after the duration and rate of the circulating breaking down reach predetermined requirements, conveying the broken-cell algal slurry and an extractant together to a static mixer for mixing to form a mixed algal slurry; conveying the mixed algal slurry to a three-phase centrifuge for separation to obtain an astaxanthin oil phase, an aqueous phase, and algal residue; filtering the astaxanthin oil phase through a precision filter to remove residual algal residue and obtain astaxanthin oleoresin. Attached Figure Description

[0007] This specification will be further described by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting; in these embodiments, the same reference numerals denote the same structures, wherein: Figure 1 This is a schematic diagram of an astaxanthin extraction apparatus according to some embodiments of this specification; Figure 2 This is an exemplary flowchart of an astaxanthin extraction method according to some embodiments of this specification. Detailed Implementation

[0008] To more clearly illustrate the technical solutions of the embodiments in this specification, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are merely some examples or embodiments of this specification. For those skilled in the art, these drawings can be applied to other similar scenarios without creative effort. Unless obvious from the context or otherwise specified, the same reference numerals in the drawings represent the same structures or operations.

[0009] It should be understood that the terms “system,” “device,” “unit,” and / or “module” used herein are one way to distinguish different components, elements, parts, sections, or assemblies at different levels. However, if other terms can achieve the same purpose, they may be replaced by other expressions.

[0010] As indicated in this specification and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of expressly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0011] Flowcharts are used in this specification to illustrate the operations performed by the system according to embodiments of this specification. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, the steps can be processed in reverse order or simultaneously. Furthermore, other operations can be added to these processes, or one or more steps can be removed from them.

[0012] Figure 1 This is a schematic diagram of an astaxanthin extraction apparatus according to some embodiments of this specification. For example... Figure 1 As shown, the astaxanthin extraction device 100 includes a mixing tank 110, a cooler 120, a cavitation device 130, a mixing feed pump 140, a three-phase centrifuge 150, an oleoresin 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 cell-wall-broken algae slurry storage tank 1110, a cell-wall-broken algae slurry feed pump 1120, a static mixer 1130, and a precision filter 1140.

[0013] Mixing tank 110 refers to a storage tank structure used for premixing raw materials. For example, the raw materials include Haematococcus pluvialis, water, and phospholipase.

[0014] In some embodiments, the mixing tank 110 is configured to mix Haematococcus pluvialis, water, and phospholipase to form a homogeneous algal slurry.

[0015] Cavitation device 130 refers to a device for hydraulic cavitation cell disruption treatment of algal slurry. In some embodiments, cavitation device 130 is configured to receive algal slurry and disrupt its cell walls using hydraulic cavitation to obtain disrupted algal slurry. More information on hydraulic cavitation can be found at [link to relevant documentation]. Figure 2 And its explanation.

[0016] The static mixer 1130 refers to a device for mixing the cell-wall-broken algae slurry with the extractant. The static mixer 1130 can achieve mixing of the cell-wall-broken algae slurry and the extractant by relying on the flow state of the two without relying on mechanical drive.

[0017] In some embodiments, the static mixer 1130 is configured to mix the cell wall-breaking algal slurry and the extractant to form a mixed algal slurry.

[0018] Three-phase centrifuge 150 refers to a device for separating the three-phase components in a mixed algae slurry. The three-phase components refer to the astaxanthin oil phase, aqueous phase, and algae residue in the mixed algae slurry, respectively corresponding to the oily component, aqueous component, and solid residue in the mixed algae slurry. 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 a precision filter 1140, a wastewater receiving tank 170, and a waste residue receiving tank 180, respectively.

[0019] In some embodiments, the three-phase centrifuge 150 is configured to receive the mixed algal slurry and perform three-phase separation on the mixed algal slurry to obtain an astaxanthin oil phase, an aqueous phase, and algal residue.

[0020] Precision filter 1140 refers to an apparatus for deep filtration of the astaxanthin oil phase. In some embodiments, precision filter 1140 is configured to filter the astaxanthin oil phase to remove residual algal residue and obtain astaxanthin oleoresin. For more information on precision filter 1140, please refer to [link to relevant documentation]. Figure 2 And related explanations.

[0021] In some embodiments, the astaxanthin extraction apparatus 100 further includes a cooler 120; the cooler 120 is configured to receive the cell-wall broken algae slurry from the cavitation unit 130, cool the cell-wall broken algae slurry, and convey the cooled cell-wall broken algae slurry to the static mixer 1130.

[0022] In some embodiments, the astaxanthin extraction apparatus 100 further includes a plurality of power pumps. A power pump is a pumping device that provides power for the flow of materials. The plurality of power pumps include: a mixing feed pump 140, a cell-wall-breaking algae slurry feed pump 1120, and an extractant feed pump 1100.

[0023] In some embodiments, the mixing feed pump 140 is configured to provide conveying power to the algae slurry to deliver the algae slurry from the mixing tank 110 to the cavitation unit 130.

[0024] In some embodiments, the cell wall-breaking algae slurry feed pump 1120 is configured to provide conveying power to the cell wall-breaking algae slurry to convey the cell wall-breaking algae slurry in the cell wall-breaking algae slurry storage tank 1110 from the cavitation unit 130 to the cooler 120.

[0025] In some embodiments, the extractant feed pump 1100 is configured to provide delivery power to the extractant to deliver the extractant from the extractant tank 190 to the static mixer 1130.

[0026] In some embodiments, the astaxanthin extraction apparatus 100 further includes a plurality of storage tanks for storing materials during or after the astaxanthin extraction process. For example, the plurality of storage tanks include: a cell-wall broken algae slurry 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.

[0027] In some embodiments, the cell wall-broken algae slurry storage tank 1110 is configured to store cell wall-broken algae slurry.

[0028] In some embodiments, the oleoresin receiving tank 160 is configured to store astaxanthin oleoresin separated during the three-phase separation process.

[0029] In some embodiments, wastewater receiving tank 170 is configured to store the aqueous phase separated during the three-phase separation process.

[0030] In some embodiments, the waste receiving tank 180 is configured to store algal residue separated during the three-phase separation process.

[0031] In some embodiments, the extractant storage tank 190 is configured to store extractant.

[0032] In some embodiments, such as Figure 1 As shown, the astaxanthin extraction device 100 also includes a pipeline valve 1150. The pipeline valve 1150 is a control device for controlling the conveying direction of the algal slurry, used to switch the conveying direction of the algal slurry during the circulating cell-wall breaking process. For example, the pipeline valve 1150 can be a gate valve. After the circulating cell-wall breaking process is completed, the algal slurry can be controlled to enter the cell-wall broken algal slurry storage tank 1110 by switching the pipeline valve 1150, thus terminating the circulation process. For more information on circulating cell-wall breaking processes, please refer to [link to relevant documentation]. Figure 2 And its explanation.

[0033] 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 in the astaxanthin extraction apparatus 100 and / or external data sources. In some embodiments, the processing device 1160 can execute program instructions based on this data, information, and / or processing results, thereby performing one or more functions described in this specification. For example, the processing device 1160 can perform one or more steps in process 200.

[0034] In some embodiments, the processing device 1160 may be a single server or a group of servers. The server group may be centralized or distributed. In some embodiments, the processing device 1160 may be local or remote. In some embodiments, the processing device 1160 may be implemented on a cloud platform. By way of example only, the cloud platform may include private cloud, public cloud, hybrid cloud, community cloud, distributed cloud, internal cloud, multi-tiered cloud, etc., or any combination thereof. In some embodiments, the processing device 1160 may be a field-programmable gate array (FPGA) or a digital signal processor (DSP). In some embodiments, the processing device 1160 may be integrated into or installed on the astaxanthin extraction device 100.

[0035] In some embodiments of this invention, modular equipment such as mixing tanks, cavitation devices, static mixers, three-phase centrifuges, and precision filters are integrated to achieve continuous flow operation throughout the astaxanthin extraction process. This significantly improves the extraction efficiency and product quality of astaxanthin oleoresin. Furthermore, each modular piece of equipment is a conventional and mature device, resulting in low procurement and maintenance costs, facilitating system integration and large-scale industrial application. Specifically, using hydraulic cavitation instead of traditional cell-wall breaking technology significantly reduces the energy consumption of the astaxanthin extraction device. Combined with a cooler, thermal degradation of the active astaxanthin components during cell-wall breaking and extraction is effectively avoided, improving the astaxanthin extraction rate and product stability. High-precision purification of the astaxanthin oil phase using a precision filter yields astaxanthin oleoresin with high purity and low residue content.

[0036] Figure 2 This is an exemplary flowchart of an astaxanthin extraction method according to some embodiments of this specification. In some embodiments, process 200 may be performed by processing equipment in an astaxanthin extraction apparatus. Figure 2 As shown, process 200 includes the following steps.

[0037] Step 210: Add Haematococcus pluvialis, water and phospholipase to a mixing tank and mix to form a uniform algal slurry.

[0038] Phospholipase is an enzyme added to the mixing tank to break down the phospholipids and glycolipids emulsions within Haematococcus pluvialis cells.

[0039] Haematococcus pluvialis is a single-celled freshwater alga belonging to the phylum Chlorophyta, class Chlorophyta, and family Haematococcus.

[0040] Algal slurry refers to a fluid mixture formed by Haematococcus pluvialis, water, and phospholipase.

[0041] In some embodiments, Haematococcus pluvialis, water, and phospholipase can be added to a mixing tank in a mass ratio for mixing to form a homogeneous algal slurry. Mixing can be achieved through fluid circulation, stirring, or other methods that help to uniformly disperse the Haematococcus pluvialis, water, and phospholipase.

[0042] In some embodiments, the mass ratio of Haematococcus pluvialis to water is 1:4 to 1:11. To ensure good flowability and stability of the algal slurry during mixing and cell disruption, which is beneficial for subsequent cell disruption and avoids difficulties in slurry transport due to excessive concentration, while also avoiding excessive dilution leading to a decrease in astaxanthin concentration, preferably, the mass ratio of Haematococcus pluvialis to water is 1:3 to 1:10. More preferably, the mass ratio of Haematococcus pluvialis to water is 1:5 to 1:10.

[0043] In some embodiments, the amount of phospholipase added is 0.5% to 5.5% of the mass of Haematococcus pluvialis. This effectively decomposes emulsified components such as phospholipids and glycolipids in Haematococcus pluvialis cells, significantly promoting the oil-water separation process and improving 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.

[0044] In some embodiments of this specification, controlling the mass ratio of Haematococcus pluvialis to water within a range (e.g., 1:3 to 1:10) ensures good flowability and stability of the algal slurry during mixing and cell disruption, which is beneficial for subsequent cell disruption and avoids difficulties in transporting the algal slurry due to excessive concentration. It also avoids the situation where excessive dilution reduces the astaxanthin concentration. Controlling the amount of phospholipase added within a certain range (e.g., 1% to 5% of the mass of Haematococcus pluvialis) effectively decomposes emulsified components such as phospholipids and glycolipids in Haematococcus pluvialis cells, significantly promoting the oil-water separation process and improving the purity and extraction efficiency of the astaxanthin oil phase.

[0045] 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 according to different types of phospholipase to achieve better emulsification and decomposition effects. For example, when using phospholipase B, the mass ratio of Haematococcus pluvialis to water can be selected as 1:5, and the amount of phospholipase B added is 2% to 4% of the mass of Haematococcus pluvialis; when using a combination of phospholipase A1 and A2, the mass ratio of Haematococcus pluvialis to water can be selected as 1:10, and the amount of phospholipase added is approximately 2% of the mass of Haematococcus pluvialis. Under different phospholipase usage conditions, by appropriately adjusting the mass ratio of Haematococcus pluvialis to water, the decomposition efficiency of phospholipase on algal cell components can be optimized; furthermore, by controlling the amount of phospholipase added, the subsequent cell wall breaking efficiency of algal slurry and astaxanthin extraction rate can be synergistically improved.

[0046] Some embodiments in this specification demonstrate that, by using one or more of phospholipase A1, phospholipase A2, and phospholipase B, these three types of phospholipases exhibit stronger adaptability and stability during the decomposition of Haematococcus pluvialis cell emulsion structures compared to other types of phospholipases. They can achieve efficient degradation of phospholipids and glycolipids at lower addition levels, thereby promoting the release of astaxanthin and effective stratification of the oil and aqueous phases.

[0047] Step 220: The algae slurry is transported to the cavitation unit by a mixing feed pump, and the algae slurry is circulated and broken up using hydraulic cavitation.

[0048] In some embodiments, the mixing feed pump can be connected via pipelines to the outlet of the mixing tank and the inlet of the cavitation unit, respectively. After the algae slurry is formed in the mixing tank, it can be conveyed to the cavitation unit by the conveying power provided by the mixing feed pump.

[0049] Hydraulic cavitation refers to the liquid cavitation phenomenon caused by localized high flow velocity and low pressure when algal slurry flows through a cavitator.

[0050] In some embodiments, the cell wall disruption treatment of the algal slurry includes: utilizing the mechanical shear force and energy impact generated by hydraulic cavitation to break down the cell walls of Haematococcus pluvialis in the slurry. Specifically, the algal slurry is pumped into the cavitator by a mixing feed pump. When the algal slurry flows through the structural abrupt change region (e.g., a constriction section or nozzle) inside the cavitator, a large number of cavitation bubbles are formed due to a significant increase in local flow velocity and a rapid decrease in pressure. As the pressure recovers, the bubbles rapidly collapse, generating strong mechanical shear force and energy shock waves that can act on the Haematococcus pluvialis in the slurry, destroying its cell walls and releasing fat-soluble active substances such as astaxanthin.

[0051] In some embodiments, the processing equipment can perform a circulating cell-wall breaking treatment on the algal slurry. This circulating cell-wall breaking treatment includes: circulating the algal slurry through a cavitation unit for hydraulic cavitation and then cooling it through a cooler. In each cycle, the algal slurry is pumped into the cavitation unit by a mixing feed pump to form cavitation bubbles that break down the cell walls of Haematococcus pluvialis in the slurry. It is then cooled by a cooler to prevent thermal degradation of astaxanthin. The cooled algal slurry is then returned to the mixing tank, ready for the next cycle.

[0052] Step 230: After the duration and rate of the cyclic cell disruption reach the preset standards, stop the cyclic cell disruption and obtain the disrupted algal slurry.

[0053] In some embodiments, after the cyclic cell disruption process is completed, the processing equipment can stop the cyclic cell disruption process by switching the pipeline valve and transport the disrupted algae slurry to the disrupted algae slurry storage tank for subsequent mixing with the extractant in a static mixer.

[0054] The preset standards include a cell disruption time of 0.5 to 3 hours and a cell disruption rate of more than 90% for the sampled algae slurry.

[0055] In some embodiments, the duration of the cyclic cell disruption is less than four hours. To achieve sufficient cell disruption of the algal cells and ensure extraction efficiency and product stability, the duration of the cyclic cell disruption is preferably 0.5 to 3 hours. More preferably, the duration of the cyclic cell disruption is 2 to 3 hours.

[0056] Circulating water refers to water used as a cooling medium in a cooler. For example, such as... Figure 1 As shown, the circulating water can be condensate. The circulating water can indirectly exchange heat with the algae slurry to reduce the temperature rise of the algae slurry during the circulating cell wall breaking process. In some embodiments, the circulating water temperature (i.e., the condensate temperature) of the cooler is not higher than 20°C. To inhibit astaxanthin degradation caused by temperature rise 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 5–15°C. Preferably, the circulating water temperature of the cooler is in the range of 8–10°C.

[0057] In some embodiments of this specification, by controlling the circulating cell disruption 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), the cell walls of algae can be fully disrupted, releasing fat-soluble active substances such as astaxanthin while inhibiting astaxanthin degradation caused by temperature increases, thus ensuring extraction efficiency and product stability.

[0058] Step 240: The cell wall-broken algae slurry and the extractant are transported together to a static mixer for mixing to form a mixed algae slurry.

[0059] Extractants are oily materials used to extract fat-soluble active substances such as astaxanthin from broken-cell algae slurry. Extractants can be pre-stored in extractant storage tanks.

[0060] In some embodiments, the extractant is one of medium-chain triglycerides (MCT) or ethyl esterified vegetable oil.

[0061] In some embodiments of this specification, the use of medium-chain triglycerides (MCT) or ethylated vegetable oils as extractants can significantly improve the extraction efficiency and astaxanthin content in the oil phase. Compared with conventional natural vegetable oils (such as coconut oil), modified low-viscosity oils used as extractants (such as MCT, ethylated safflower oil, and ethylated sunflower oil) have lower viscosity, better fluidity, and are less prone to emulsification, which is beneficial for subsequent oil-water separation. This significantly improves the separation efficiency and product purity in the astaxanthin extraction process, while avoiding solvent residue problems, eliminating the need for solvent removal, and simplifying the process for greater reliability. Furthermore, both MCT and ethylated vegetable oils are food-grade oils with good stability and safety, suitable for applications in food, health products, and other fields, effectively avoiding the problems of incomplete emulsification or insufficient dissolving power caused by traditional organic solvents.

[0062] Mixed algal slurry refers to a liquid mixture formed by mixing cell-wall-broken algal slurry with an extractant. In some embodiments, the mixed algal slurry is a three-phase mixture system, including an oil phase, an aqueous phase, and a solid phase. The oil phase mainly consists of medium-chain fatty acid glycerides or ethyl esterified vegetable oils used as extractants to dissolve fat-soluble active substances such as astaxanthin in the cell-wall-broken algal slurry; the aqueous phase originates from the water in the cell-wall-broken algal slurry and contains some soluble impurities; the solid phase consists of algal cell fragments remaining after cell-wall breaking.

[0063] In some embodiments, the cell-wall-broken algae slurry and the extractant can be separately fed to a static mixer via a cell-wall-broken algae slurry feed pump and an extractant feed pump, respectively, to form a mixed algae slurry. Specifically, the cell-wall-broken algae slurry can be fed from a cell-wall-broken algae slurry storage tank via a cell-wall-broken algae slurry feed pump, and the extractant can be fed from an extractant storage tank via an extractant feed pump. The cell-wall-broken algae slurry and the extractant can be fed to the static mixer via pipelines according to a feed rate ratio. The static mixer can achieve mixing by the fluid flow of the cell-wall-broken algae slurry and the extractant without mechanical power, thereby forming a mixed algae slurry. By setting the feed rate ratio, sufficient contact and mixing of the cell-wall-broken algae slurry and the oily extractant can be ensured, thereby promoting the efficient transfer of astaxanthin and optimizing the effect of subsequent three-phase centrifugal separation. The feed rate ratio can be preset by technicians according to different materials. For example, the feed rate ratio of cell-wall-broken algae slurry to extractant can be 2:1. For more information on the feed rate, please refer to Table 1 and its description.

[0064] In some embodiments, the amount of extractant added is 0.2 to 6 times the dry weight of Haematococcus pluvialis. To ensure sufficient extraction of astaxanthin while reducing the amount of extractant used, thus lessening the burden on subsequent oil phase concentration and separation, and improving overall extraction efficiency and cost control, preferably, the amount of extractant added is 0.3 to 5 times the dry weight of Haematococcus pluvialis.

[0065] In some embodiments, the cell-wall-broken algae slurry and the extractant can be continuously fed into a static mixer. The amount of extractant added can be set by the feed rate ratio of the cell-wall-broken algae slurry to the extractant. For example, when the feed rate ratio of the cell-wall-broken algae slurry to the extractant is 2:1, the amount of extractant added is twice the dry matter of Haematococcus pluvialis; or, for example, when the feed rate ratio is 11:5, the amount of extractant added is five times the dry matter of Haematococcus pluvialis.

[0066] Some embodiments in this specification, by controlling the amount of extractant added within a certain range (for example, the amount of extractant added is between 0.3 and 5 times the dry matter of Haematococcus pluvialis), can reduce the amount of extractant used 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.

[0067] Step 250: The mixed algal slurry is fed into a three-phase centrifuge for separation to obtain astaxanthin oil phase, aqueous phase and algal residue.

[0068] In some embodiments, the processing equipment can convey the mixed algal slurry to a three-phase centrifuge for separation to obtain astaxanthin oil phase, aqueous phase, and algal residue. Specifically, the three-phase centrifuge can generate a strong centrifugal force field under high-speed rotation and separate the mixed algal slurry into astaxanthin oil phase, aqueous phase, and algal residue based on the density differences between the oil phase, aqueous phase, and solid phase. The oil phase outlet, aqueous 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 aqueous phase and algal residue can flow into the wastewater receiving tank and the waste residue receiving tank, respectively. The astaxanthin oil phase can be filtered through the precision filter and then flow into the oleoresin receiving tank, thereby achieving independent collection and storage of the astaxanthin oil phase, aqueous phase, and algal residue.

[0069] In some embodiments, the rotational speed of the three-phase centrifuge is 2000 rpm to 7000 rpm. To ensure separation efficiency while avoiding excessive energy consumption and wear on the astaxanthin extraction device, reducing operating costs, and effectively preventing astaxanthin degradation due to temperature increases during separation, thereby improving astaxanthin extraction rate and oil phase purity, and extending the service life of the astaxanthin extraction device, preferably, the rotational speed of the three-phase centrifuge is 3000 rpm to 6000 rpm.

[0070] In some embodiments of this specification, by controlling the speed of the three-phase centrifuge within the range of 3000 rpm to 6000 rpm, separation efficiency can be ensured while avoiding excessive energy consumption and wear on the astaxanthin extraction device, reducing operating costs, and effectively preventing astaxanthin from degrading due to temperature rise during separation, thereby improving the astaxanthin extraction rate and oil phase purity, and extending the service life of the astaxanthin extraction device.

[0071] Step 260: Filter the astaxanthin oil phase through a precision filter to remove residual algal residue and obtain astaxanthin oleoresin.

[0072] In some embodiments, the astaxanthin oil phase obtained by three-phase centrifugation can be filtered through a precision filter to remove residual algae residue and obtain astaxanthin oleoresin. Specifically, the precision filter can employ a micron-sized filter element to separate residual algae residue from the oil phase through physical sieving and interception. The filtered astaxanthin oil phase can be stored as astaxanthin oleoresin in an oleoresin receiving tank, thereby obtaining astaxanthin oleoresin with high purity suitable for subsequent processing or direct use.

[0073] In some embodiments, the filtration precision of the precision filter is at least 3000 mesh. To effectively remove fine algal residue from the astaxanthin oil phase and avoid sedimentation, oxidation, or product quality degradation caused by impurities, thereby improving the purity and quality of the filtered astaxanthin oleoresin, preferably, the filtration precision of the precision filter is at least 2000 mesh.

[0074] Some embodiments in this specification demonstrate that by controlling the filtration precision of the precision filter within a certain range (e.g., above 2000 mesh), it is possible to effectively remove small algal residue particles from the astaxanthin oil phase, avoiding sedimentation, oxidation, or product quality degradation caused by impurity residues, thereby improving the purity and quality of the filtered astaxanthin oleoresin.

[0075] In some embodiments of this invention, algal slurry is transported to a cavitation unit, where hydraulic cavitation is used to circulate and break down the algal cell walls. A cooler is used in conjunction with this circulation process for real-time cooling. The mechanical energy generated by hydraulic cavitation effectively disrupts the algal cell wall structure, promoting the release of lipid-soluble active ingredients such as astaxanthin. The cooler inhibits the thermal degradation of astaxanthin caused by localized temperature rises during processing, thereby improving product activity and stability. Compared to traditional cell-wall breaking methods, this method offers advantages such as significantly reduced energy consumption, continuous flow operation, high production efficiency, and increased astaxanthin extraction rate. Furthermore, the equipment used, such as the three-phase centrifuge and static mixer, are common industrial equipment with low cost, facilitating large-scale industrial application. Further, the astaxanthin oil phase is separated by a three-phase centrifuge and then treated with a precision filter to remove fine impurities, resulting in pure and stable astaxanthin oleoresin suitable for subsequent processing or direct application.

[0076] It should be noted that the above description of process 200 is for illustrative purposes only and does not limit the scope of this specification. Those skilled in the art can make various modifications and changes to the process under the guidance of this specification. However, these modifications and changes remain within the scope of this specification.

[0077] In different embodiments, parameters such as raw material ratio, type and amount of phospholipase, cooling water temperature, cell wall breaking time, feed rate ratio of cell wall broken algal slurry to extractant, and centrifuge speed vary. The specific process parameters and astaxanthin extraction effects are listed in Table 1 below. For example, as shown in Example 1 in Table 1, the processing equipment can add Haematococcus pluvialis, water, and phospholipase B in a mixing tank at a mass ratio of 1:3, and add 2% of the dry weight of Haematococcus pluvialis phospholipase B to form a uniform algal slurry. The algal slurry is transported to the cavitation unit by a feed pump, and under the condition of a cooling water temperature of 8°C, hydraulic cavitation circulation cell wall breaking is carried out for 3 hours. After the cell wall breaking rate reaches more than 90%, the circulation cell wall breaking treatment is stopped to obtain cell wall broken algal slurry. Subsequently, the cell wall broken algal slurry and medium-chain triglycerides (MCT) are fed into a static mixer at a feed rate ratio of 2:1 to obtain mixed algal slurry. The mixed algal slurry is then transported to a three-phase centrifuge for separation at a centrifuge speed of 3000 rpm. After filtration 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 will not be described in detail here.

[0078] Table 1

[0079] To further verify the superiority of the astaxanthin extraction apparatus and method used in this specification, a control example was set up. The process parameters and astaxanthin extraction effects of the control example are listed in Table 2 below. The process of the control example is consistent with that of the embodiment. However, the control example differs from the embodiment of the present invention in some process parameters or processing conditions. For example, as shown in Control Example 1 in Table 2, compared with Example 1, this control example did not use phospholipase. Haematococcus pluvialis, water and phospholipase B were added to a mixing tank at a mass ratio of 1:5, the cooling water temperature was 10°C, and the cell wall breaking time was 3 hours to obtain cell wall broken algal slurry. The cell wall broken algal slurry and medium-chain triglycerides (MCT) were fed into a static mixer at a feed rate ratio of 6:1 to obtain mixed algal slurry. The mixed algal slurry was then transported to a three-phase centrifuge for separation at a centrifuge speed of 6000 rpm. After filtration through a precision filter, astaxanthin oleoresin was obtained, with an astaxanthin extraction rate of 61% and an astaxanthin content of 5.4%.

[0080] Table 2

[0081] A comparison of Example 2 and Control Example 2 shows that, under the conditions of maintaining consistent ratios of Haematococcus pluvialis to water, phospholipase dosage, cooling water temperature, cell disruption time, extractant type, feed rate ratio, and centrifuge speed, only the type of phospholipase differs. Example 2 used phospholipase B, while Control Example 2 used alkaline protease. The results indicate that Example 2 achieved an astaxanthin extraction rate of 93% and an astaxanthin content of 7.3%, while Control Example 2 achieved an extraction rate of only 62% and an astaxanthin content of 5.7%. This difference demonstrates that phospholipase B can more effectively decompose phospholipids and glycolipid emulsifying components within Haematococcus pluvialis cells, significantly increasing astaxanthin release; while non-specific proteases (such as alkaline protease) have limited promoting effect on the astaxanthin extraction process. This verifies the significant technical advantage of using specific phospholipases (such as one or more combinations of phospholipase A1, phospholipase A2, and phospholipase B) in one or more examples of this specification for efficient astaxanthin extraction.

[0082] A comparison of Example 2 and Control Example 3 shows that, under the same conditions of Haematococcus pluvialis to water ratio, phospholipase type and dosage, cooling water temperature, cell disruption time, feed rate ratio, and centrifuge speed, only the type of extractant differs. Example 2 used medium-chain triglycerides (MCT) as the extractant, while Control Example 3 used coconut oil. The results showed that Example 2 achieved an astaxanthin extraction rate of 93% and an astaxanthin content of 7.3%; Control Example 3 achieved an extraction rate of 87% and 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 mixed algal 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 examples of this specification, MCT or ethyl esterified vegetable oil is used as the extractant to effectively improve the astaxanthin extraction effect and purity.

[0083] A comparison of Examples 1-5 in Table 1 and Comparative Examples 1-4 in Table 2 shows that the astaxanthin extraction apparatus and method used in this specification, employing medium-chain triglycerides (MCT) or ethyl esterified vegetable oil as diluents, can achieve efficient astaxanthin extraction under low energy consumption and temperature conditions. Compared to Comparative Examples 1-4, which did not use phospholipase, or used other enzymes, or employed different ratios of cell-wall-broken algae pulp to extractant, the astaxanthin extraction method used in this specification significantly improves both the extraction rate and content, demonstrating superior extraction effect and process stability.

[0084] The basic concepts have been described above. Obviously, for those skilled in the art, the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this specification. Such modifications, improvements, and corrections are suggested in this specification and therefore remain within the spirit and scope of the exemplary embodiments described herein.

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

[0086] Furthermore, unless expressly stated in the claims, the order of processing elements and sequences, the use of numbers and letters, or other names described in this specification are not intended to limit the order of the processes and methods described herein. Although various examples have been discussed in the foregoing disclosure of some embodiments of the invention that are currently considered useful, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments; rather, the claims are intended to cover all modifications and equivalent combinations that conform to the spirit and scope of the embodiments described herein. For example, while the system components described above can be implemented using hardware devices, they can also be implemented solely using software solutions, such as installing the described system on existing servers or mobile devices.

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

[0088] In some embodiments, numbers describing the quantity of components and attributes are used. It should be understood that such numbers used in the description of embodiments are modified in some examples with the terms "approximately," "approximately," or "generally." Unless otherwise stated, "approximately," "approximately," or "generally" indicates that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may be changed depending on the characteristics required by individual embodiments. In some embodiments, numerical parameters should take into account specified significant digits and employ a general method of digit reservation. Although the numerical ranges and parameters used to confirm their breadth of range in some embodiments of this specification are approximate values, in specific embodiments, such values ​​are set as precisely as feasible.

[0089] For each patent, patent application, patent application publication, and other material such as articles, books, specifications, publications, and documents referenced in this specification, the entire contents of which are incorporated herein by reference. This excludes historical application documents that are inconsistent with or conflict with the content of this specification, as well as documents that limit the broadest scope of the claims in this specification (currently or subsequently appended to this specification). It should be noted that in the event of any inconsistency or conflict between the descriptions, definitions, and / or terminology used in the supplementary materials to this specification and the content of this specification, the descriptions, definitions, and / or terminology used in this specification shall prevail.

[0090] Finally, it should be understood that the embodiments described in this specification are merely illustrative of the principles of the embodiments described herein. Other variations may also fall within the scope of this specification. Therefore, alternative configurations of the embodiments described herein are intended to be illustrative rather than limiting, and should be considered consistent with the teachings of this specification. Accordingly, the embodiments described herein are not limited to those explicitly introduced and described herein.

Claims

1. An astaxanthin extraction apparatus, characterized by, The device includes: a mixing tank, a cavitation unit, a static mixer, a three-phase centrifuge, a precision filter, a cooler, multiple power pumps, and multiple storage tanks, wherein: The mixing tank is configured to mix Haematococcus pluvialis, water, and phospholipase to form a homogeneous algal slurry; The cavitation device is configured to receive the algal slurry and use hydraulic cavitation to break the cell walls of the algal slurry to obtain broken algal slurry. The static mixer is configured to mix the cell-wall-broken algal slurry and the extractant to form a mixed algal slurry; The three-phase centrifuge is configured to receive the mixed algal slurry and perform three-phase separation on the mixed algal slurry to obtain astaxanthin oil phase, aqueous phase and algal residue; The precision filter is configured to filter the astaxanthin oil phase to remove residual algal residue and obtain astaxanthin oleoresin. The cooler is configured to receive the cell-wall-broken algae slurry from the cavitation unit, cool the cell-wall-broken algae slurry, and deliver the cooled cell-wall-broken algae slurry to the static mixer. The plurality of power pumps include: A mixing feed pump is configured to provide conveying power to the algal slurry to transport the algal slurry from the mixing tank to the cavitation unit; A cell wall-breaking algae slurry feed pump is configured to provide conveying power to the cell wall-breaking algae slurry to transport the cell wall-breaking algae slurry from the cavitation unit to the cooler; An extractant feed pump is configured to provide delivery power to the extractant in order to deliver the extractant to the static mixer; The plurality of storage tanks includes: A cell wall-broken algae slurry storage tank is configured to store the cell wall-broken algae slurry; An oleoresin receiving tank is configured to store the astaxanthin oleoresin; The wastewater receiving tank is configured to store the aqueous phase separated during the three-phase separation process; The waste receiving tank is configured to store the algal residue separated during the three-phase separation process.

2. A method for extracting astaxanthin, which is implemented based on the astaxanthin extraction apparatus according to claim 1, characterized by, The method includes: Haematococcus pluvialis, water, and phospholipase are added to a mixing tank and mixed to form a uniform algal slurry; The algae slurry is transported to the cavitation unit by a mixing feed pump, and the algae slurry is subjected to a circulating cell-breaking treatment. The circulating cell-breaking treatment includes: the algae slurry is sequentially passed through the cavitation unit for hydraulic cavitation treatment and then cooled by a cooler. Once the duration and cell disruption rate of the cyclic cell disruption reach a preset standard, the cyclic cell disruption is stopped, and cell-disrupted algae slurry is obtained. The cell wall-broken algal slurry and the extractant are fed together into a static mixer for mixing to form a mixed algal slurry; The mixed algal slurry is fed into a three-phase centrifuge for separation to obtain astaxanthin oil phase, aqueous phase and algal residue; The astaxanthin oil phase is filtered through a precision filter to remove residual algae residue and obtain astaxanthin oleoresin.

3. The method according to claim 2, characterized in that, The mass ratio of Haematococcus pluvialis to water is 1:3 to 1:10, and the amount of phospholipase added is 1% to 5% of the mass of Haematococcus pluvialis.

4. The method according to claim 2, characterized in that, The duration of the circulating cell disruption is 0.5 to 3 hours, and the circulating water temperature of the cooler is not higher than 20°C.

5. The method according to claim 2, characterized in that, The extractant is one of medium-chain triglycerides (MCT) or ethyl esterified vegetable oil.

6. The method according to claim 2, characterized in that, The amount of extractant added is 0.3 to 5 times the dry matter of the Haematococcus pluvialis.

7. The method according to claim 2, characterized in that, The three-phase centrifuge operates at a speed of 3000 rpm to 6000 rpm.

Images