Method for dewatering microalgae with a bubble column

• US 5,910,254 A
• Filed: 12/20/1996
• Issued: 06/08/1999
• Est. Priority Date: 12/20/1996
• Status: Expired due to Term

• Current Assignee: Cognis International GmbH (BASF SE)
• Original Assignee: Eastman Chemical Company
• Inventors: Guelcher, Scott Arthur, Kanel, Jeffrey Scott
• Primary Examiner(s): Therkorn, Ernest G.
• Application Number:
  US08/770,284
• Time in Patent Office: 900 Days
• Field of Search: 47/1.4, 209/164, 210/703, 210/634, 435/67, 435/946, 514/458, 514/725
• US Class Current: 210/703
• CPC Class Codes: C12M 47/10 Separation or concentration of fermentation products bioreactors combined with means for distillation or extraction of liquid fuel C12M43/02
• CPC Class Codes: C12N 1/02 Separating microorganisms from their culture media
• CPC Class Codes: C12P 23/00 Preparation of compounds containing a cyclohexene ring having an unsaturated side chain containing at least ten carbon atoms bound by conjugated double bonds, e.g. carotenes containing heterorings C12P17/00
• CPC Class Codes: Y02W 10/37 using solar energy
• CPC Class Codes: Y10S 435/946 using algae

Abstract

A process for dewatering an aqueous suspension of microalgae is disclosed in which the aqueous suspension of the algae is introduced into a bubble column or a modified bubble column for generating a froth of bubbles and adsorbed algal cells that can be separated from the aqueous suspension. In one advantageous embodiment, the bubble column is a multi-stage loop-flow flotation column that has three loop-flow zones, each of which is defined by a draft tube concentrically mounted in the column to divide each loop-flow zone into a riser and the downcomer. Fine bubbles of gas and brine are in cocurrent upward flow in the riser and in cocurrent downward flow the downcomer. A higher gas holdup is promoted in the riser than in the downcomer, thereby circulating the brine in loop-flow upwardly through the riser and downwardly through the downcomer. Liquid communication between adjacent loop-flow zones is substantially eliminated. A froth enriched in algae is generated that can be separated from the aqueous suspension. The process has application in the recovery of mixed carotenoids from Dunaliella salina.

Claims

1. A process for dewatering an aqueous suspension of microalgae comprising the steps of:

(a) obtaining an aqueous suspension of algae from a source thereof;

(b) rupturing the algal cells;

(c) introducing the aqueous suspension into a froth flotation column selected from the group consisting of a Jameson cell and a multi-stage loop flow froth floatation column for downward gravity flow therein;

(d) generating fine bubbles of a gas for establishing a net countercurrent flow through the aqueous suspension in intimate contact with the aqueous suspension;

(e) adsorbing algal cells onto the bubbles to form bubble and alga agglomerates; and

(f) forming a froth of bubble and alga agglomerates.

2. The process of claim 1 wherein the step (d) of generating fine bubbles of a gas comprises sparging gas into the column.

3. The process of claim 1 wherein the step (d) of generating fine bubbles of a gas is accomplished externally of the column and the bubbles are introduced into the column.

4. The process of claim 1 further comprising the step of circulating the aqueous suspension in loop-flow within the column to promote intimate contact of fine bubbles and algal cells.

5. The process of claim 1 wherein the column includes at least one loop-flow zone defined by a vertically oriented baffle that divides the column into a riser and a downcomer wherein the gas and liquid are in cocurrent upflow in the riser and cocurrent downflow in the downcomer to promote intimate contact.

6. The process of claim 5 wherein the column includes multiple loop-flow zones, each separated from the other by a baffle zone.

7. The process claim 6 further comprising in a baffle zone above the loop-flow zone the steps of 1) diverting gas flow upwardly, thereby minimizing gas bypass into the downcomer region, and 2) diverting liquid flow downwardly and into the downcomer region, whereby liquid communication between adjacent loop flow zones is substantially eliminated.

8. The process of claim 5 wherein the vertical baffle consists of a draft tube concentrically mounted in the column.

9. The process of claim 1 wherein the column includes at least one loop-flow zone defining a radially inward region and a radially outward annular region, the process further comprising the step of promoting a higher gas holdup in the radially inward region than in the annular region, whereby the algal suspension is circulated in a loop-flow upwardly through the radially inward region and downwardly through the annular region to promote intimate contact.

10. The process of claim 9 wherein the column includes multiple loop-flow zones, each separated from the other by a baffle zone.

11. The process claim 10 further comprising in a baffle zone above the loop-flow zone the steps of 1) diverting gas flow upwardly, thereby minimizing gas bypass into the downcomer region, and 2) diverting liquid flow downwardly and into the downcomer region, whereby liquid communication between adjacent loop flow zones is substantially eliminated.

12. The process of claim 9 wherein the vertical baffle consists of a draft tube concentrically mounted in the column.

13. The process of claim 1 wherein the column includes at least one loop-flow zone defining a radially inward region and a radially outward annular region, the process further comprising the step of promoting a higher gas holdup in the radially outward annular region than in the radially inward region, whereby the algal suspension is circulated in a loop-flow downwardly through the radially outward annular region and upwardly through the radially inward region to promote intimate contact.

14. The process of claim 13 wherein the column includes multiple loop-flow zones, each separated from the other by a baffle zone.

15. The process claim 14 further comprising in a baffle zone above the loop-flow zone the steps of 1) diverting gas flow upwardly, thereby minimizing gas bypass into the downcomer region, and 2) diverting liquid flow downwardly and into the downcomer region, whereby liquid communication between adjacent loop flow zones is substantially eliminated.

16. The process of claim 13 wherein the vertical baffle consists of a draft tube concentrically mounted in the column.

17. The process of claim 1 further comprising the step of collapsing the froth and wherein steps (c) through (f) are repeated to further concentrate the aqueous suspension.

18. The process of claim 1 wherein the aqueous suspension is of the alga Dunaliella salina in brine.

19. A process for dewatering the algal Dunaliella salina in brine comprising the steps of:

(a) obtaining an aqueous suspension of algae from a source thereof;

(b) rupturing the algal cells;

(c) introducing the aqueous suspension into a froth flotation column selected from the group consisting of a Jameson cell and a multi-stage loop flow froth floatation column for downward gravity flow therein;

(d) generating fine bubbles of a gas for establishing a net countercurrent flow through the aqueous suspension in intimate contact with the aqueous suspension;

(e) circulating the suspension in a loop-flow within the column to promote intimate contact of fine bubbles and algal cells;

(f) adsorbing algal cells onto the bubbles to form bubble and alga agglomerates; and

(g) forming a froth of bubble and alga agglomerates.

20. The process of claim 19 wherein the column includes at least one loop-flow zone defined by a vertically oriented baffle that divides the column into a riser and a downcomer wherein the gas and liquid are in cocurrent upflow in the riser and cocurrent downflow in the downcomer to promote intimate contact.

21. The process of claim 20 wherein the column includes multiple loop-flow zones, each separated from the other by a baffle zone.

22. The process claim 21 further comprising in a baffle zone above the loop-flow zone the steps of 1) diverting gas flow upwardly, thereby minimizing gas bypass into the downcomer region, and 2) diverting liquid flow downwardly and into the downcomer region, whereby liquid communication between adjacent loop flow zones is substantially eliminated.

23. The process of claim 20 wherein the vertical baffle consists of a draft tube concentrically mounted in the column.

24. A process for separating the alga Dunaliella salina from brine for the subsequent recovery of mixed carotenoids from the alga, the process comprising the steps of:

a) obtaining a suspension of D. salina in brine from a source thereof;

b) rupturing the algal cells;

c) introducing the brine into a multi-stage loop-flow flotation column for net downward gravity flow therein, the column including at least two loop-flow zones defined by a vertical baffle to divide the column into a riser and a downcomer, wherein the gas and brine are in cocurrent upward flow in the riser and cocurrent downward flow in the downcomer;

d) dispersing the gas into fine bubbles by sparging the gas into the riser of the lowermost loop-flow zone for countercurrent flow through the brine;

e) promoting a higher gas holdup in the riser than in the downcomer, thereby circulating the brine in loop-flow upwardly through the riser and downwardly through the downcomer;

f) diverting gas flow from the riser upwardly, thereby minimizing gas bypass into the downcomer;

g) diverting liquid flow from the riser downwardly into downcomer, whereby liquid communication between adjacent loop flow zones is substantially eliminated, whereby the fine bubbles and algal cells are intimately contacted to adsorb the algae onto the surfaces of the bubbles; and

h) generating a froth enriched in algae, whereby the algae are separated from the brine.

25. The process of claim 24 further comprising the step of collapsing the froth to obtain an algal concentrate and wherein the steps (c) through (i) are repeated to provide an extractable concentration of mixed carotenoids.

26. The process of claim 24 further comprising the step of collapsing the froth to obtain an algal concentrate and wherein the steps (c) through (i) are repeated to provide a concentration of mixed carotenoids suitable for cross flow micro-filtration.

27. The process of claim 24 further comprising the steps of a) cross-flow micro-filtering the algal concentrate to provide a concentration of the mixed carotenoids in the retentate suitable for dense gas extraction, and b) extracting the mixed carotenoids from the retentate by dense gas extraction to provide a dry extract of mixed carotenoids.

28. The process of claim 27 further comprising the step of purifying the mixed carotenoids by chromatography.

29. The process of claim 24 wherein the superficial gas velocity, J_g, is from about 0.1 to 1.0 cm/s.

30. The process of claim 24 wherein the gas to feed ratio is from about 0.1 to 1.5.

31. The process of claim 24 wherein the liquid residence time is from about 2 to 20 minutes.

32. The process of claim 24 wherein the solids fraction in the froth on a gas free basis is from about 60 ppm to 17 percent by weight of the gas-free froth.

33. The process of claim 24 wherein the gas does not contain oxygen.

34. A process for extracting mixed carotenoids from the alga Dunaliella salina, the process comprising the steps of:

a) obtaining a suspension of D. salina in brine from a source thereof;

b) rupturing the algal cells;

c) introducing a feed of the algal suspension into a multi-stage loop-flow flotation column for net downward gravity flow therein, the column including at least two loop-flow zones, each defining a radially inward region and a radially outward annular region;

d) sparging a gas in the absence of oxygen into the radially inward region of the lowermost loop-flow zone for net countercurrent flow through the algal suspension at a superficial gas velocity, J_g, of from about 0.1 to 1.0 cm/s and at a gas to feed ratio of from about 0.1 to 1.5;

e) promoting a higher gas holdup in the radially inward region than in the annular region, thereby circulating the algal suspension in a loop-flow upwardly through the radially inward region and downwardly through the annular region;

f) diverting gas flow from the radially inward region upwardly and radially inwardly, thereby minimizing gas bypass into the annular region;

g) diverting liquid flow downwardly and radially outwardly into the annular region, whereby backmixing is substantially eliminated, and the fine bubbles and algal suspension are intimately contacted to adsorb the algae onto the surfaces of the bubbles;

h) generating a froth enriched in algae, whereby the algae are separated from the brine;

i) collapsing the froth to obtain an algal concentrate; and

j) repeating steps c) through i) to provide a concentration of mixed carotenoids having a solids fraction in the froth on a gas-free basis of from about 1 to 17 percent by weight of the gas-free froth.