Microalgae Concentrate Processing for Low-Viscosity Drying
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Solution Overview
Problem
Existing methods for producing microalgal concentrates face challenges in achieving low viscosity and high solid content, leading to high energy and cost requirements in the drying process, limiting commercialization due to inefficient drying methods.
Innovation Solution
A method involving pH adjustment and heat-treatment of microalgal fermented solutions, followed by evaporation and concentration, to produce a microalgal concentrate with low viscosity and high solid content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If general drying methods are used for microalgal fermented solution, then the drying process can be performed with simple equipment, but the energy consumption and production cost become excessively high
Solution Approach 1:
The patent applies preliminary action by adjusting the pH of the microalgal fermented solution to 2-3 before drying, and performing heat treatment at 60-80°C for 10-30 minutes. This preliminary treatment modifies the physical and chemical properties of the solution, reducing viscosity and improving drying efficiency, thereby lowering energy consumption in the subsequent drying process
Solution Approach 2:
The patent changes key parameters of the fermented solution including pH (adjusted to 2-3), temperature (heated to 60-80°C), and viscosity (reduced through treatment). These parameter changes transform the solution into a more favorable state for drying, enabling the use of economical drying methods with lower energy consumption
2Productivity
If freeze-drying or spray drying methods are used for microalgal fermented solution, then the drying efficiency is improved, but the production cost and energy consumption increase significantly
Solution Approach 1:
The patent modifies the physical parameters of the fermented solution by adjusting pH to 2-3 and heating to 60-80°C, which reduces viscosity and improves flow properties. This enables the use of simple evaporation concentrators and drum driers instead of expensive freeze-drying or spray drying equipment, achieving good drying efficiency at lower production costs
Solution Approach 2:
The patent employs economical drying equipment such as evaporation concentrators and drum driers with shorter processing times rather than expensive freeze-drying or spray drying systems. The preliminary pH and heat treatment compensates for the simpler equipment design, maintaining acceptable drying efficiency while significantly reducing capital and operational costs
3Ease of manufacture
If economical drying methods like hot air drying or drum drier are used, then the production cost is reduced, but the steam efficiency remains below 1 and energy consumption is still high
Solution Approach 1:
The patent performs preliminary pH adjustment to 2-3 and heat treatment at 60-80°C before the drying process. This preliminary action reduces the viscosity and modifies the molecular structure of the fermented solution, making it more amenable to economical drying methods. As a result, drum driers and other simple drying equipment can achieve steam efficiency greater than 1, meaning the energy output exceeds the energy input, thereby reducing overall energy consumption and production costs
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
Reduces steam and investment costs in the drying process, enabling economic production and improved discharge and transport capabilities of the microalgal concentrate.
Implementation Method 1
adjusting pH of a microalgal fermented solution
Implementation Method 2
heat-treating the fermented solution
Implementation Method 3
evaporating and concentrating the heat-treated fermented solution
Data Source
AI summary
The present invention relates to a method for producing a microalgae concentrate with low viscosity, the method comprising a step of adjusting the pH of a microalgae fermentation broth and a heat treatment step, in which utility costs and investment costs can be reduced in a dehydration and drying step to secure price competitiveness for production and commercialization of dried microalgae products.