Download Soybean Oil (SBO) - Alpha Team

Healthy Table Spread from Algae
Team Alpha
Travis Dallas
Eric Graves
Joaquin Martinez
Chris McNinch
Ramune Otterson Meskyte
Charu Saini
Crypthecodinium Cohnii
Design Project Deliverables
1.
2.
3.
4.
5.
6.
7.
8.
Design Basis
Block Flow Diagram
Process Flow Diagram
Material and Energy
Balances
Calculations
Annotated Equipment
List
Economic Evaluation
Factored from
Equipment Cost
Utilities
9. Conceptual Control
Scheme
10. Major Equipment Layout
11. Distribution and End
12. Constrains Review
13. Applicable Standards
14. Project Communication
File
15. Information Sources and
References
Sterilization
• Thermal Sterilization
will be conducted at
121°C for 1 hour
• Shell and tube heat
exchangers will be used
for continuous
sterilization with steam
• Medium components
will be mixed and
sterilized
Fermentor Mass Balance
Inlet Material Flow
• Basis: Batch Fermentor with
92,400 Liters of fermentation
broth
• Inocculum of 7,000 Liters of seed
batch with c cohnii concentration
of 20 g dwcells/L
• 93 hours required per batch
• Aerated to 20% Dissolved Oxygen
Saturation
Ton (US)
Liters
Glucose Used
per Batch
12.27
5058
Yeast Used per
Batch
1.67
690
Sea Salt Used
per Batch
4.45
30% Silicon
Anti-foam
1.86
Glucanex
0.10
Water
Initial Algae
Biomass
92.82
0.02
1540
85112
Fermentor Energy Balance
• Fermentation is exothermic and
cooling water is required to keep
the broth at 27°C.
• Fermentor is constructed out of
stainless steel with an area of
149.1 sq meters.
Metabolic Heat
Evolution (kJ)
Cooling Water Required
(L)
49,219,622
1,308,024
From Algae Oil to Table Spread
•
•
•
Though the table spread market is
shrinking, the health food market is
increasing at an incredible rate
AlphaAlgae Healthy Table Spread
will have zero trans-fats, zero
animal ingredients (vegan), and no
dairy components (kosher),
allowing for it to attract a very large
group of consumers
It will be assumed that AlphaAlgae
will take 1 % of the table spread
market the first year, and will
increase every year afterwards.
Table Spread Production
•
•
•
•
•
•
•
•
First, the oil phase and the water phase must be prepared.
The oil phase consists of refined, zero trans fat oil mixture, the DHA-rich algae oil,
and oil-soluble flavors, golden color, and lecithin.
The water phase consists of purified water and sea salt, used for both flavor and as
a preservative.
These two phases are mixed together in an emulsion tank with a temperature
around 100 °F.
A two-tank system is called a “flip flop” system. When one tank is emulsifying, the
other tank is undergoing preparations.
The emulsification then undergoes pasteurization to both kill microbes and to
ensure a consistent temperature throughout the spread
This is followed by cooling and crystallization, creating the final spread product
The spread is then stored, ready for transit.
Example of a Table Spread
Production Line:
Example Process Flow Diagram of
Table Spread Production Line
What is in Each Tub Of Table
Spread?
• 11.3 grams of algae oil (4.6 grams DHA)
• 329.3 grams zero-trans fat oil mixture (interesterfied
hardstock, palm, coconut, liquid oil)
• 75.7252 grams water
• 6.058 grams natural sea salt
• .852 grams natural soy lecithin
• 8452.52 μg beta-carotene (vitamin A and color)
• 2 ppm diacetyl (butter flavor)
• 2.13 grams mono and diglycerides
• 0.426 grams sorbic acid
• 35.2188 μg ergocalciferol (vitamin D)
Production Rates of AlphaAlgae
Table Spread:
• 10.4 million tubs of butter / year
• 4883.68 tons of table spread / year
• 0.822168 tons of table spread / hour
•
lbs / batch
•
tubs / batch
•
batch / day
Table Spread Marketing Analysis
• Table spreads enjoy a market size of around 5.2 billion dollars
/ year
• A spread with 1 % of the market would sell around 52 million
dollars / year
• Sales straight from the plant are around 35 % of the selling
price at the market
• For the first year, our total table spread sales will then be
around 18.2 million dollars
• Health food market is increasing very rapidly
• This increase will allow for the market share of AlphaAlgae
Healthy Spread to increase quickly
Market Financial Analysis
(Based on Whole Foods Market Analysis)
Growth Rate
Net Income (YTD vs last YTD)
3.7%
Sales (5-year Annual Avg)
15.75%
Profit Margins
Net Profit Margin (last year)
3.1%
5 Year Net Profit Margin (5 year Avg)
2.4%
Financial Conditions
Debt/Equity Ration
0.36
Investment Returns
Return on Equity (5 year Avg)
10.8%
Return on Assets (5 year Avg)
6.0%
Return on Capital (5year Avg)
7.6%
Soybean Oil (SBO)
•781.39 tons SBO Hardfat (Cargill)
•2993.72 tons crude SBO (Cargill) at
$867.40/ton
Refining Crude SBO
1. Degumming(removal of phospholipids)
•
•
Mix with water and H3PO4
Forms a gum, and then centrifuge out
2. Removal of free fatty acids
•
•
•
3.
4.
Use NaOH and NaCO3 to form soluble in water salts,
removed by centrifuge
Rinse with hot water to remove soapstock, centrifuge again
Soapstock – add H2SO4 make feedstock for chickens
Bleaching – Filtering with both a Fuller’s Earth
filter and activated carbon filter
Deodorization
•
•
Steam distillation under high vacuum and 250-260°F
Cooled under vacuum
Interesterification
Mixing hardfat with refined SBO
Using 99% pure Sodium methoxide at
0.4% wt under vacuum at 100°C
Stirring 500rpm for 20 minutes
Termination
• Add DI and citric acid
• Wash with DI to remove soap
• Dried at 110°C for 30 minutes