Methods of microbial oil extraction and separation

• US 9,896,642 B2
• Filed: 04/14/2010
• Issued: 02/20/2018
• Est. Priority Date: 10/14/2008
• Status: Active Grant

• Current Assignee: Corbion Biotech, Inc. (Corbion NV)
• Original Assignee: Corbion Biotech, Inc. (Corbion NV)
• Inventors: Wittenberg, Jon, Arana, Felipe
• Primary Examiner(s): Desai, Anand U
• Assistant Examiner(s): Liu, Samuel W
• Application Number:
  US13/264,379
• Publication Number:
  US 20120130099A1
• Time in Patent Office: 2,869 Days
• Field of Search: 435243
• CPC Class Codes: A23K 10/37 from waste material from hydrolysates of wood or straw A23K10/32; from molasses A23K10/33
• CPC Class Codes: A23K 50/10 for ruminants
• CPC Class Codes: A23K 50/30 for swines
• CPC Class Codes: A23K 50/75 for poultry
• CPC Class Codes: A23K 50/80 for aquatic animals, e.g. fish, crustaceans or molluscs
• CPC Class Codes: C11B 1/06 by pressing
• CPC Class Codes: C11B 1/10 by extracting
• CPC Class Codes: C11C 3/003 by esterification of fatty acids with alcohols C11C3/02 takes precedence
• CPC Class Codes: Y02A 40/818 Alternative feeds for fish, e.g. in aquacultures
• CPC Class Codes: Y02P 60/87 Re-use of by-products of food processing for fodder production

Abstract

Lipids can be extracted from a microbial biomass that constitutes at least 20% lipids by weight and has a moisture content of less than 4% by weight by applying pressure to the biomass so as to release lipids therefrom, thereby leaving a biomass of reduced lipid content; and collecting the lipids.

Claims

1. A method for extracting triglyceride oil from microalgal biomass, the method consisting of:

a. drying the microalgal biomass to produce dried microalgal biomass;

b. conditioning the dried microalgal biomass by heating the dried microalgal biomass to a temperature of from 70°

C. to 150°

C. to produce conditioned feedstock having a moisture content of from 0.5% to 2.5% by weight of the microalgal biomass wherein prior to said conditioning a bulking agent is added to the dried microalgal biomass; and

c. subjecting the conditioned feedstock having a moisture content of from 0.5% to 2.5% to pressure sufficient to separate at least 25% of the total triglyceride oil from the conditioned feedstock,

leaving spent microalgal biomass of reduced triglyceride oil content relative to the conditioned feedstock, wherein said method does not use organic solvent for the extraction.

2. The method of claim 1, wherein the triglyceride oil is extracted by an expeller press.

3. The method of claim 1, wherein more than 50% of the triglyceride oil is separated from the conditioned feedstock.

4. The method of claim 2, wherein the expeller press is a continuously rotating worm shaft within a cage having a feeder at one end and a choke at an end opposite thereof, and having openings within the cage,

wherein the cage has an internal length that is between at least ten times to at least 20 times its internal diameter and comprises a plurality of elongated bars with at least some of the elongated bars separated by one or more spacers, the bars resting on a frame, wherein the one or more spacers between the bars form the openings, and triglyceride oil is released through the openings to a collecting vessel fluidly coupled with the cage,

wherein the spacers between the elongated bars are of different thicknesses thereby allowing variation of the space between each elongated bar, wherein either the spacers or the gaps between the bars are from 0.005 to 0.030 inches thick,

wherein the biomass enters the cage through the feeder, and rotation of the worm shaft advances the biomass along the cage and applies pressure to the biomass disposed between the cage and the choke, the pressure lysing cells of the biomass and releasing triglyceride oil through the openings of the cage, and spent biomass of reduced triglyceride oil content is extruded from the choke end of the cage.

5. The method of claim 4, wherein the pressure increases by a factor of between 10 and 20 from the feeder end to the choke end of the cage and does not increase by more than 100% of the pressure at the feeder end of the cage per linear foot of the cage between the feeder and choke ends of the cage.

6. The method of claim 1, wherein the moisture content of the conditioned feedstock is between 0.7% and 1.2% by weight.

7. The method of claim 1, wherein the biomass is conditioned with heat for a period of time between 10 and 60 minutes.

8. The method of claim 7, wherein a bulking agent is switchgrass, soybean hulls, dried rosemary, corn stover, cellulose, sugar cane bagasse, or spent microbial biomass that comprises between 40% and 90% polysaccharide and less than 10% triglyceride oil, and is added to the microbial biomass prior to conditioning the dried microbial biomass.

9. The method of claim 1, wherein the microalgal biomass that was cultivated through a process selected from the group consisting of a heterotrophic process, a photoautotrophic process, and a mixotrophic process.

10. The method of claim 1, wherein the microalgal biomass has a fatty acid profile of at least 4% C8-C14.

11. The method of claim 1, wherein the extracted triglyceride oil has one or more properties selected from:

less than 0.01 milligram of chlorophyll per kilogram of triglyceride oil;

or

one or more of the following;

no more than 8 ppm chloride, no more than 2 ppm phosphorus, no more than 26 ppm potassium, no more than 12 ppm sodium, and no more than 5 ppm sulfur.

12. The method of claim 1, wherein the spent biomass comprises less than 40% triglyceride oil by weight.

13. The method of claim 12, wherein the spent biomass comprises less than 20% triglyceride oil by weight.

14. The method of claim 13, wherein the spent biomass comprises less than 10% triglyceride oil by weight.

15. The method of claim 14, wherein the spent biomass comprises less than 5% triglyceride oil by weight.

16. The method of claim 1, wherein the pressure is applied mechanically.

17. The method of claim 1, wherein the pressure that is applied mechanically is applied by an expeller press.

18. A method for extracting triglyceride oil from microalgal biomass, the method consisting of:

a. drying the microalgal biomass to produce dried microalgal biomass;

b. conditioning the dried microalgal biomass by heating to a temperature of from 70°

C. to 150°

C. to produce conditioned feedstock having a moisture content of from 0.5% to 2.5% by weight of the microalgal biomass wherein prior to said conditioning a bulking agent is added to the dried microalgal biomass; and

c. subjecting the conditioned feedstock having a moisture content of from 0.5% to 2.5% to pressure sufficient to separate at least 5% of the total triglyceride oil from the conditioned feedstock and leaving spent biomass of reduced triglyceride oil content relative to the conditioned feedstock, wherein said method does not use organic solvent for the extraction.

19. The method of claim 18, wherein the microalgal biomass is derived from microalgae of the genus Chlorella or the genus Prototheca.

20. The method of claim 19, wherein the moisture content is from 0.5% to 2.0% by weight.

21. The method of claim 20, wherein the moisture content is from 0.7% to 1.2% by weight.

22. The method of claim 18, wherein the pressure is applied mechanically.

23. The method of claim 22, wherein the pressure that is applied mechanically is applied by a expeller press.