Methods of and systems for producing biofuels from algal oil

• US 8,313,648 B2
• Filed: 06/04/2012
• Issued: 11/20/2012
• 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, Zullo, Luca Costantino, Shinde, Sandip
• Primary Examiner(s): Drodge, Joseph
• Application Number:
  US13/487,752
• Publication Number:
  US 20120244585A1
• Time in Patent Office: 169 Days
• Field of Search: 435/134, 435/262, 435/267, 435/271, 435/272, 443/07, 443/08, 446/05, 47/14, 554/12, 554/14, 554/20, 208/15, 208/18, 208/19, 208/49, 208/64, 208/87, 208/133, 208/142, 203/28, 203/39, 203/91, 560/218, 562/600, 585/240, 585/310, 585/317, 585/320, 585326-329, 210/632, 210/633, 210/634, 210/638, 210/639, 210/749, 210/770, 210/774, 210/806
• US Class Current: 210/638
• CPC Class Codes: C10G 2300/1014 of vegetal origin
• CPC Class Codes: C10G 3/50 in the presence of hydrogen, hydrogen donors or hydrogen generating compounds
• CPC Class Codes: C10L 1/026 for compression ignition
• CPC Class Codes: C10L 1/04 essentially based on blends of hydrocarbons
• CPC Class Codes: C10L 2290/36 Applying radiation such as microwave, IR, UV
• CPC Class Codes: C10L 2290/544 Extraction for separating fractions, components or impurities during preparation or upgrading of a fuel
• CPC Class Codes: C11B 1/02 Pretreatment
• CPC Class Codes: C11B 1/10 by extracting
• CPC Class Codes: C11B 1/108 after-treatment, e.g. of miscellae
• CPC Class Codes: C11B 3/006 by extraction
• CPC Class Codes: C11B 3/16 by mechanical means
• CPC Class Codes: C11C 3/003 by esterification of fatty acids with alcohols C11C3/02 takes precedence
• CPC Class Codes: C12P 3/00 Preparation of elements or inorganic compounds except carbon dioxide recovery of carbon dioxides as by-products C12F3/02
• CPC Class Codes: C12P 7/6463 obtained from glyceride producing microorganisms, e.g. single cell oil
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

A method for producing biofuels is provided that includes dewatering intact algal cells to make an algal biomass, extracting neutral lipids from the algal biomass, and esterifying the neutral lipids with a catalyst in the presence of an alcohol. The method also includes separating a water soluble fraction comprising glycerin from a water insoluble fraction comprising fuel esters and distilling the fuel esters under vacuum to obtain 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 further includes hydrodeoxygenating 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. The method further includes supplying the hydrogenation and deoxygenation processes with hydrogen produced from reformed light hydrocarbons or an algae culture.

Claims

1. A method of making biofuels, comprising:

a. dewatering an algal cell culture comprising intact algal cells to generate a wet algal biomass;

b. adding a first ethanol fraction to the wet algal biomass in a ratio of about 1 part ethanol to about 1 part algal biomass by weight to generate first solid biomass fraction and a first liquid fraction comprising proteins;

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

d. combining the first solid biomass fraction with a second ethanol fraction in a ratio of about 1 part ethanol to about 1 part solid biomass by weight to generate a second solid biomass fraction from a second liquid fraction comprising polar lipids;

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

f. combining the second solid biomass fraction with a third ethanol solvent fraction in a ratio of about 1 part ethanol to about 1 part solid biomass by weight to generate a third solid biomass fraction from a third liquid fraction comprising neutral lipids, wherein the third solid biomass fraction comprises carbohydrates and the third solid biomass fraction comprises intact algal cells;

g. separating the third solid biomass fraction from a third liquid fraction comprising neutral lipids, 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;

h. simultaneously transesterifying and esterifying the neutral lipids with an enzyme catalyst in the presence of an alcohol to produce a water soluble fraction comprising glycerin and a water insoluble fraction comprising fuel esters;

i. separating the water soluble fraction comprising glycerin from the water insoluble fraction comprising fuel esters;

j. distilling the fuel esters under vacuum to obtain a C16 or shorter fuel esters fraction, a C16 or longer fuel ester fraction, and a residue comprising carotenoids and omega-3 fatty acids;

k. hydrodeoxygenating 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 heating the biomass during at least one of steps b, d, and f to a temperature below the boiling point of the extraction solvent set at the conditions present during said corresponding step.

3. The method of claim 1, further comprising heating the biomass under a pressure greater than atmospheric pressure during at least one of steps b, d and f.

4. The method of claim 1, further comprising utilizing at least one of the first liquid fraction comprising proteins, the second liquid fraction comprising polar lipids, and the third solid biomass fraction comprising carbohydrates to produce at least one of an animal feed, a human food, and a nutraceutical product.

5. The method of claim 1, further comprising growing the algal cells under suitable conditions to promote the production of neutral lipids, wherein carbon dioxide is provided to the algal cells as a carbon source.

6. The method of claim 1, further comprising growing the algal cells suitable conditions to promote the production of neutral lipids, wherein wastewater is provided to the algal cells and the wastewater is bioremediated by the algal cells.

7. The method of claim 6, wherein the bioremediation is integrated into a wastewater treatment plant.

8. A method of making biofuels, comprising:

a. dewatering an algal cell culture comprising intact algal cells to generate a wet algal biomass;

b. adding a first ethanol fraction to the wet algal biomass in a ratio of about 1 part ethanol to about 1 part algal biomass by weight to generate a first solid biomass fraction from a first liquid fraction comprising proteins;

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

d. combining the first solid biomass fraction with a second ethanol fraction in a ratio of about 1 part ethanol to about 1 part solid biomass by weight to generate a second solid biomass fraction from a second liquid fraction comprising polar lipids;

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

f. combining the second solid biomass fraction with a third ethanol solvent fraction in a ratio of about 1 part ethanol to about 1 part solid biomass by weight to generate a third liquid fraction comprising neutral lipids, and a third solid biomass fraction comprising carbohydrates and intact algal cells;

g. separating the third solid biomass fraction from the third liquid fraction, 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;

h. esterifying the neutral lipids with a catalyst in the presence of an alcohol;

i. separating a water soluble fraction comprising glycerin from a water insoluble fraction comprising fuel esters;

j. distilling the fuel esters under vacuum to obtain a C16 or shorter fuel esters fraction, a C16 or longer fuel ester fraction, and a residue comprising carotenoids and omega-3 fatty acids;

k. hydrodeoxygenating 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, wherein light hydrocarbons are produced by the hydrodeoxygenating processes; and

l. reforming the light hydrocarbons to produce hydrogen.

9. The method of claim 8, wherein the hydrogen is recycled to for use in subsequent hydrodeoxygenating processes.

10. A method of making biofuels, comprising:

a. dewatering intact algal cells of a first algal strain to make an algal biomass;

b. adding a first ethanol fraction to the algal biomass in a ratio of about 1 part ethanol to about 1 part algal biomass by weight to generate a first solid biomass fraction from a first liquid fraction comprising proteins;

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

d. combining the first solid biomass fraction with a second ethanol fraction in a ratio of about 1 part ethanol to about 1 part solid biomass by weight to produce a second solid biomass fraction from a second liquid fraction comprising polar lipids;

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

f. combining the second solid biomass fraction with a third ethanol solvent fraction in a ratio of about 1 part ethanol to about 1 part solid biomass by weight to generate a third liquid fraction comprising neutral lipids and a third solid biomass fraction comprising carbohydrates and intact algal cells;

g. separating the third solid biomass fraction from the third liquid fraction comprising neutral lipids, 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;

h. esterifying the neutral lipids with a catalyst in the presence of an alcohol to produce a water soluble fraction comprising glycerin and a water insoluble fraction comprising fuel esters;

i. separating the water soluble fraction comprising glycerin from the water insoluble fraction comprising fuel esters;

j. distilling the fuel esters under vacuum to obtain a C16 or shorter fuel esters fraction, a C16 or longer fuel ester fraction, and a residue comprising carotenoids and omega-3 fatty acids;

k. culturing a second strain of algae in conditions sufficient to produce hydrogen;

l. capturing the produced hydrogen and supplying the hydrogen to hydrodeoxygenating processes; and

m. hydrodeoxygenating 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.

11. The method of claim 10, wherein the second strain of algae comprises Chlamydomonas reinhardtii or Scenedesmus.

12. The method of claim 10, wherein the conditions sufficient to produce hydrogen comprise at least one of deprivation of sulfur, anaerobic conditions, and dark conditions.