DSM has patented a solventless oil extraction process that extracts omega-3 fatty acids, such as DHA and EPA from microalgae to be used in aquaculture but results in a low-value, high-volume waste stream. The extraction involves fermentation, algae breakdown utilizing enzymes, and thermochemical demulsification processing. The process has a waste stream volume of more than 100,000 MT annually, which includes water, oil, proteins, carbohydrates, and salts. We planned to design a new process that reduces the waste stream volume and increases profit by recovering a high-value component from the waste stream, such as squalene, beta-glucan, or peptides, and recycling the waste stream back into the initial fermentation process.

Goals

• Develop and simulate a process that can be easily implemented into DSM's plants to extract at least one high-value component from their waste stream and recycle part of the waste stream to increase profitability by May 2021.

Objectives

• Research DSM's patented solventless algal oil extraction process and Schizochytrium, the algae used in the extraction, by the end of October 2020.

• Research possible high-value compounds in the waste stream and how they can be extracted by the end of November 2020.

• Research possible waste stream recycling processes by the end of November 2020.

• Decide on the most important criteria our design should meet to create a decision matrix by mid-December 2020.

• Research each proposed solution focusing on the criteria determined in the decision matrix and rank these solutions using the decision matrix by mid-December 2020.

• Select 2 proposed solutions and simulate them using SuperPro Designer by February 2021.

• Complete a cost analysis of the different solutions by March 2021.