1. Microaglae to Biodiesel Group Delta: Valerie Delgatti Dan Detro Kevin Jackson Joshua Jones Xin Qin

2. Progress Since Last Meeting…  Design Basis  Material balance Algae extraction  Individual unit operations Centrifuge vs. fringe drain sand filter  Initial Process Flow Diagram Labeled streams and unit operations

3. Progress Since Last Meeting…  Made industry contacts Bruce Salisbury from Four Corners Power Plant  Information about microalgae to biodiesel with CO2 stream from power plant Jeff Christopherson from Crown Iron Works  Information regarding solvent extraction unit (Mark III)

4. Algae Strain  Chlorella sp. (green algae)  Widely known  Approximate composition  Typically, 28 – 32 percent oil content by weight

5. Design Basis Calculations  For 10,000 BPD equivalence of gasoline output basis  10,450 BPD of triglycerides output necessary  Approximately 6,500 tons of Chlorella sp. Processed per day

6. Initial PFD

7. Photo-Bioreactor vs. Raceway pound  Raceway ponds are used for large scale production of algae  Photo-bioreactors are used for laboratory scale studies or small scale algae production.  More research needs to be done on this

8. Centrifugation  Centrifuges are a reliable yet costly route to separating the water from the algae.  150 horsepower motor, 350 Gallon per Minute Capacity, and the cost is approximately 500,000 dollars per centrifuge.  With a product stream of 50% algae by weight, 7 whole centrifuges are needed, costing 3.5 million dollars. With a product stream of 1% algae by weight, 31 whole centrifuges are needed, costing 15 and a half million dollars.  Alternatives?

9. Fringe Drain Sand Filters  Suggested by industry contact  Sandbox design  Tractor removal  relatively cheap to install and works great for the job

10. Expeller Pressing vs. Solvent Extraction  Physically squeeze the oil out of a pre-dried algae feed  Recover 70 – 75 percent of the oil from the algae  Completely drying the algae before pressing Expeller Pressing  widely used in industry  Recover from 95 – 99 percent  The algae do not have to be fully dried to undergo this process Solvent Extraction

11. Introducing Stainless Steel Model III Extractor

12. Stainless Steel Model III Extractor UnitManufacturerSpecifications Stainless Steel Model III Extractor Crown Iron Works - Capable of processing ~8000 tons of material per day - Retention time is around 30 minutes - 10-11 pumps that run at ~25 Horsepower each - One pump may have to be a 50 horsepower pump - The extractor motor (conveyor belt motor) has to be ~75 horsepower - The installed costs for a carbon steel extraction unit such as this one is 1.2 million dollars

13. Triglyceride vs. Biodiesel Which is more profitable? Triglyceride  Human Consumption  Animal Feed  Industry Use Biodiesel  Limited Glycerol Market

14. Triglyceride vs. Biodiesel Our gain is 1,119,273 dollars per Day

15. Catalyst  Alkali (NaOH, KOH) -catalyzed transesterification Pros:  Relatively fast reaction times Cons:  Unwanted side products (soap from FFA’s)  Heterogeneous solid catalyst Pros:  No soap production  Elimination of waste streams and process steps Cons:  Cost

16. Axens Esterfip-H Catalysis Process

17. The Slaughterhouse Model  Water: Recycled into photobioreactors  Lipids: Material for biodiesel  Keratinoids: Sell to users or combusted for energy  Cellulose: Sold to ethanol processors or sold to papermills

18. Things to do for next three weeks  More complete material and energy balance  Capital and operating cost analysis  Add more detail to the process flow diagram  Choose centrifuge or fringe drain sand filter  Choose fixed catalyst or acid catalyst

19. Acknowledgements Group Delta would like to acknowledge two very helpful industry contacts. Bruce Salisbury, Engineering Supervisor of the Four Corners Power Plant in New Mexico and Jeff Christopherson, design manager of extraction at Crown Ironworks Group Delta would like to give a special thank-you to them for their time.

20. Reference 1.) Energy content of gasoline: http://en.wikipedia.org/wiki/Gasolinehttp://en.wikipedia.org/wiki/Gasoline 2.) Energy content of BioDiesel: http://www.biodiesel.org/pdf_files/fuelfactsheets/BTU_Content_Final_Oct2 005.pdf http://www.biodiesel.org/pdf_files/fuelfactsheets/BTU_Content_Final_Oct2 005.pdf 3.) http://www.biodiesel.org/pdf_files/fuelfactsheets/Weight&Formula.PDFhttp://www.biodiesel.org/pdf_files/fuelfactsheets/Weight&Formula.PDF 4.) Gerpen, J. Van, B. Shanks, R. Pruszko, D. Clements, and G. Knothe. Biodiesel Production Technology. Tech. Golden: NREL, 2004. 5.) Crown Iron Works Model III Extractor product brochure 6.) Christi, Yusuf. "Biodiesel from Microalgae." Biotechnology Advances 25 (2007): 294-306. 7.) Bruce Salisbury, Engineering Supervisor of the Four Corners Power Plant, New Mexico. 8.) Jeff Christopherson, design manager of extraction at Crown Ironworks, Minnesota. 9.) "Chlorella -." Wikipedia, the free encyclopedia. 16 Feb. 2009.

21. Website For more informations about our design progress and detailed calculations please visit groupdelta.wikispaces.com