Astaxanthin Extraction Using Non-Reactive Attrition Milling
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Solution Overview
Problem
Current processes for producing astaxanthin from Haematococcus pluvialis algae result in low yields due to cell destruction and contamination, with existing extraction methods being cumbersome and prone to oxidation, leading to inefficient and degraded product.
Innovation Solution
A method involving controlled growth and stress phases in bioreactors with optimized light and nutrient supply, followed by filtration to separate nutrients and use of an attrition mill with non-reactive surfaces to extract and mill astaxanthin, minimizing oxidation and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If algae cells are subjected to stress phase with nutritional withdrawal to promote astaxanthin production, then astaxanthin concentration increases, but cell destruction and death increase resulting in low yields
Solution Approach 1:
The patent applies parameter changes by transitioning the algae from growth conditions (with nutrients) to stress conditions (without nutrients) while controlling other parameters like light intensity and temperature. This controlled parameter change triggers astaxanthin production while minimizing cell death, resolving the contradiction between high astaxanthin concentration and cell survival rate.
2Productivity
If acids are used to break algae cells and liberate astaxanthin, then extraction efficiency improves, but astaxanthin degradation increases
Solution Approach 1:
The patent replaces the chemical extraction method (using acids) with a mechanical extraction method (using an attrition mill with non-reactive surfaces). This substitution eliminates the harmful chemical reactions that cause astaxanthin degradation while maintaining effective cell breakdown and astaxanthin liberation, thus resolving the contradiction between extraction efficiency and astaxanthin degradation.
3Ease of manufacture
If conventional milling methods are used to break algae cells, then cell disruption is achieved, but oxidation of astaxanthin occurs
Solution Approach 1:
The patent uses an attrition mill with non-reactive surfaces that create an inert environment during milling, preventing oxidation of the astaxanthin while still achieving effective cell disruption. The non-reactive surfaces of the mill prevent harmful chemical interactions, resolving the contradiction between cell disruption capability and astaxanthin oxidation.
4Quantity of substance
If outdoor ponds with recirculating raceways are used for algae growth, then large scale production is possible, but gas/water intermix and turbulence are insufficient
Solution Approach 1:
The patent employs a photobioreactor system that uses pneumatic and hydraulic mechanisms to achieve efficient gas/water intermix and turbulence, improving mass transfer and algae growth rates compared to conventional outdoor ponds, while still enabling large-scale production.
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 enhances astaxanthin yield to over 1.5% of dry weight, achieving a high-quality, non-oxidized product with reduced contamination and thermochemical stress.
Implementation Method 1
During a growth phase of the algae, carbon dioxide may be supplied to the feedstock, and light from a light source may be supplied to the feedstock, thereby amplifying the algae
Implementation Method 2
During a stress phase, carbon dioxide may be supplied to the amplified algae and light from a light source may be supplied to the amplified algae, thereby promoting production of astaxanthin by the amplified algae
Data Source
AI summary
A method for producing astaxanthin incorporates a method for producing astaxanthin-rich algae cells and a method for extracting astaxanthin therefrom. An initial feedstock comprises healthy algae, water, and nutrients. During a growth phase, carbon dioxide and light from a light source are supplied to the feedstock, thereby amplifying the algae. At least a portion of the nutrients remaining after amplification of the algae are separated from the amplified algae. During a stress phase, carbon dioxide and light are supplied to the amplified algae, thereby promoting production of astaxanthin by the amplified algae. The amplified algae and a cover are placed within an interior of an attrition mill having interior surfaces and media which are substantially non-reactive to astaxanthin and milled to release the astaxanthin from the algae. The cover limits oxidation of the released astaxanthin.