Algae Oil Production Using Waste Sugar and Vacuum Filtration

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Solution Overview

Problem

The omega-3 polyunsaturated fatty acid (PUFA) market faces challenges in sourcing sustainable and cost-effective production methods, particularly for heterotrophic algae growth and extraction processes, which are currently capital-intensive.

Innovation Solution

A method involving the use of waste sugar as a carbon source for growing heterotrophic algae, combined with a low-cost dewatering process using vacuum drum filtration and an extraction method that omits hexane, allowing for efficient production and purification of PUFAs like omega-3.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional heterotrophic algae growth methods are used, then algae biomass can be produced, but production costs are high due to capital-intensive processes

Engineering Contradiction:

Improveproduction costVSAvoidalgae biomass production efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent converts waste sugar, which would otherwise be discarded or underutilized, into a valuable carbon source for heterotrophic algae growth. This transforms a waste product into a resource that drives biomass production, thereby reducing production costs while maintaining productivity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces an intermediary extraction process using alcohol and water to recover lipids from algae biomass. This intermediary step enables cost-effective separation of valuable omega-3 fatty acids from the biomass, making the overall production process more economical.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If hexane-based extraction methods are used, then lipid extraction efficiency is high, but safety and environmental concerns arise

Engineering Contradiction:

Improvelipid extraction efficiencyVSAvoidsafety and environmental impact

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces expensive and hazardous hexane with cheaper, food-grade alcohols like ethanol or isopropanol. These alternative solvents are less toxic, safer to handle, and can be more easily disposed of or recovered, thereby reducing safety and environmental risks while maintaining extraction efficiency.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the chemical parameters of the extraction system by substituting hexane with alcohol-based solvents. This parameter change modifies the extraction mechanism to be safer and more environmentally friendly while still achieving effective lipid recovery from algae biomass.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional dewatering processes are used, then algae biomass can be concentrated, but production costs increase

Engineering Contradiction:

Improveprocessing costVSAvoidbiomass concentration

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent employs vacuum filtration, a pneumatic-hydraulic process, to dewater algae biomass. This method uses pressure differential to separate water from biomass efficiently, achieving good concentration results at lower cost compared to thermal evaporation or centrifugation methods.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent changes the physical parameters of the dewatering process by using vacuum filtration instead of conventional thermal or mechanical methods. This parameter change reduces energy consumption and processing costs while achieving adequate biomass concentration for subsequent extraction steps.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces production costs and enhances the sustainability of omega-3 fatty acid production by leveraging waste sugar and efficient dewatering and extraction techniques, making the process more viable for meeting growing market demands.

Implementation Method 1

growing heterotrophic algae using waste sugar as a carbon source to produce polyunsaturated fatty acids

Methodology Applied

Scientific EffectFermentation: Fermentation

Implementation Method 2

dewatering process using vacuum drum filtration

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 3

extracting total lipids by reacting the dried biomass with a suitable alcohol

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 4

purifying polyunsaturated fatty acids from the total lipids

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS9023625B2Methods for production of algae derived oils

Publication Date: 2015.05.05 IO MEGA HLDG CORP

AI summary

The present invention comprises a method of producing algae derived oils comprising growing, stressing, and harvesting algae and then extracting total lipids from which specific oil fractions are purified.