Liquid fractionation method for producing biofuels

• US 8,182,556 B2
• Filed: 10/07/2011
• Issued: 05/22/2012
• Est. Priority Date: 04/06/2010
• Status: Expired due to Fees

• Current Assignee: Heliae Development, LLC (PT Perusahaan Perkebunan London Sumatra Indonesia Tbk)
• Original Assignee: Heliae Development, LLC (PT Perusahaan Perkebunan London Sumatra Indonesia Tbk)
• Inventors: Kale, Aniket
• Primary Examiner(s): Kosar, Andrew D
• Assistant Examiner(s): CUTLIFF, YATE KAI RENE
• Application Number:
  US13/268,272
• Publication Number:
  US 20120045802A1
• Time in Patent Office: 228 Days
• Field of Search: None
• US Class Current: 44/385
• CPC Class Codes: A61P 7/00 Drugs for disorders of the blood or the extracellular fluid
• CPC Class Codes: B01D 11/04 of solutions which are liquid
• CPC Class Codes: C11B 1/10 by extracting
• CPC Class Codes: C11B 1/108 after-treatment, e.g. of miscellae
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

A method for producing biofuels is provided. A method of making biofuels includes dewatering substantially intact algal cells to make an algal biomass, sequentially adding solvent sets to the algal biomass, and sequentially separating solid biomass fractions from liquid fractions to arrive at a liquid fraction comprising neutral lipids. The method also includes esterifying the neutral lipids, separating a water miscible fraction comprising glycerin from a water immiscible fraction comprising fuel esters, carotenoids, and omega-3 fatty acids. The method also includes obtaining a C16 or shorter fuel esters fraction, a C16 or longer fuel ester fraction, and a residue comprising carotenoids and omega-3 fatty acids. The method includes hydrogenating and deoxygenating at least one of (i) the C16 or shorter fuel esters to obtain a jet fuel blend stock and (ii) the C16 or longer fuel esters to obtain a diesel blend stock.

Claims

1. A method of making biofuels, comprising:

a. dewatering intact algal cells to make an algal biomass;

b. adding a first solvent set fraction to the algal biomass in a ratio of about 1 part solvent set to about 1 part algal biomass by weight;

c. separating a first solid biomass fraction from a first liquid fraction comprising proteins;

d. combining the first solid biomass fraction with a second solvent set fraction in a ratio of about 1 part solvent set to about 1 part solid biomass by weight;

e. separating a second solid biomass fraction from a second liquid fraction comprising polar lipids;

f. combining the second solid biomass fraction with a third solvent set solvent fraction in a ratio of about 1 part solvent set to about 1 part solid biomass by weight;

g. separating a third solid biomass fraction from a third liquid fraction comprising neutral lipids, wherein the third solid biomass fraction comprises carbohydrates, wherein the first liquid fraction has a higher protein concentration than the second and third liquid fractions, the second liquid fraction has a higher polar lipids concentration than the first and third liquid fractions, and the third liquid fraction has a higher neutral lipids concentration than the first and second liquid fractions, and wherein the algal cells of the third solid biomass fraction are intact;

h. esterifying the neutral lipids wherein esterifying is catalyzed by an acid, a base or an enzyme to generate a water miscible fraction comprising glycerin from a water immiscible fraction comprising fuel esters, carotenoids, and omega-3 fatty acids;

i. separating a water miscible fraction comprising glycerin from a water immiscible fraction comprising fuel esters, carotenoids, and omega-3 fatty acids, wherein the fuel esters comprise C16 or shorter fuel esters and C16 or longer fuel esters;

j. obtaining a C16 or shorter fuel esters fraction, a C16 or longer fuel ester fraction and a residue comprising carotenoids and omega-3 fatty acids by at least one of vacuum distillation, adsorption, and liquid-liquid extraction; and

k. hydrogenating and deoxygenating at least one of (i) the C16 or shorter fuel esters to obtain a jet fuel blend stock and (ii) the C16 or longer fuel esters to obtain a diesel blend stock.

2. The method of claim 1, further comprising isolating at least one of carotenoids, omega-3 fatty acids, glycerin, carbohydrates, and polar lipids.

3. The method of claim 1, further comprising isolating polar lipids from impurities components that are not polar lipids.

4. The method of claim 1, further comprising processing the polar lipids into at least one of lubricants, detergents, and food additives.

5. The method of claim 1, further comprising isolating carotenoids from non-carotenoids components.

6. The method of claim 1, further comprising isolating lecithin found in the water immiscible fraction carotenoids and other non-lecithin components.

7. The method of claim 1, further comprising isolating omega-3 fatty acids from non-fatty acid components.

8. The method of claim 1, further comprising isolating eicosapentaenoic acid found in the third liquid fraction from non-fatty acid components.

9. The method of claim 1, further comprising isolating docosahexaenoic acid from non-fatty acid components.

10. The method of claim 1, further comprising isolating glycerin from non-glycerin components.

11. The method of claim 1, wherein at least one of the first, second, and third solvent sets comprises an alcohol.

12. The method of claim 1, wherein at least one of the first, second, and third solvent sets comprises at least one of methanol, ethanol, isopropanol, acetone, ethyl acetate, and acetonitrile.