OPTIMIZING SYSTEMS TO MAXIMIZE THE YIELD OF ASTAXANTHIN FROM HAEMATOCOCCUS PLUVIALIS PRESENTED BY ALBERT VITALE ALGAE BIOMASS SUMMIT 2016

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1 OPTIMIZING SYSTEMS TO MAXIMIZE THE YIELD OF ASTAXANTHIN FROM HAEMATOCOCCUS PLUVIALIS PRESENTED BY ALBERT VITALE ALGAE BIOMASS SUMMIT 2016

2 For some business leaders, success is defined by monetary rewards, while others say success is having a positive impact on others. We believe that success must encompass both monetary rewards while having a positive impact on others.

3 Growing Haematococcus Pluvialis for the production of Astaxanthine has been a key and significant market for algae production for over a decade. During this time the pricing has varied dramatically and the resulting cycles have created challenges for both growers and downstream processors Spot Market Asta Pricing

4 The lack of stability in the market has created huge challenges in the market for both growers and processors. From 2013 thru early 2015 the vast majority of new start up grow projects were centered on the production of HP In 2015 with the introduction of large volumes of foreign produced product from the S. E. Asian markets the spot market price collapsed By the end of 2015 the market price reached its low at $2250 a kg for pure Asta (USD 225 a Kg for 10% Oleo resin) With quality and delivery issues becoming apparent at the end of 2015 and beginning of 2016 the market starter a consistent rebound in While the market is strengthening there is no reason to believe the trend is stable and will continue

5 ONLY THE GROWERS AND PROCESSORS WHO ARE EFFICIENT WILL SURVIVE The cost centers are in the downstream process As the market price dropped for H.P. in 2015 the supercritical operators increased their pricing The current differences in downstream processing solutions vary widely. The least effective systems can recover as little as 65-70% of the available astaxanthine The most effective systems can recover as much as 96-97% of the available astaxanthine Growers and downstream processors who optimize their systems and product will be able to sell at a premium price to the processors

6 TRADITIONAL METHODS AND PROCESSES 1. GROW THE ALGAE 2. DECANT AND DEWATER 3. USE A LARGE MILL TO LYSE CELLS 4. SPRAY, PULSE OR DRUM DRY THE PRODUCT 5. EXTRACT USING CO2, OR CHEMICAL AND CO2, OR CHEMICAL EXTRACTION

7 INTEGRATED SYSTEMS ARE THE KEY TO SUCCESS TO OPTIMIZE THE PROCESS AND OBTAIN THE MAXIMUM YIELD THE SYSTEMS MUST ALL FUNCTION TOGETHER TO LIMIT THE OXIDATION, CONTROL THE INTRODUCTION OF HEAT AND PROVIDE THE OPTIMAL FORM FOR EXTRACTION. IT IS IDEAL TO CRACK AND DRY IN ONE SINGLE TIME AND TEMPERATURE SENSITIVE PROCEDURE TO ENSURE THE PRODUCT VIABILITY/YIELD PRODUCT QUALITY WILL DETERMINE THE BEST CELL LYSING METHOD THE FORM OF THE MATERIAL AT EXTRACTION IS CRITICAL LOGISTICAL SUPPORT IS ESSENTIAL (PRODUCT MUST BE STORED AT FREEZING TEMPS DURING ALL LOGISTICAL MOVES)

8 WHERE DO WE START? DEWATERING THE ONLY EASY PART OF THE PROCESS. (HP SETTLES WATER IS DECANTED AND THEN PRODUCT IS DEWARTERED IN A CLARIFIER, CENTRIFUGE OR DYNAMIC SETTLER)

9 LYSING THE CELL WALLS (WHY BECAUSE IS WE DON T LYSE IT WE CAN T EXTRACT THE ASTA!) HOW WAS THE ALGAE GROWN? CLOSED SYSTEM (PBR) HOMOGENIZER OPEN SYSTEMS HIGH SILICA CONTENT (OVER 7%) -BEAD MILL OR INK PRESS LOW SILICA/ASH CONTENT -HOMOGENIZER

10 NOT ALL SYSTEMS ARE THE SAME! HOMOGENIZERS ARE DIFFERENT 1. TEMP CANNOT GO ABOVE 4-5C DURING THE PROCESS 2. PRESSURE IS CRITICAL BAR FOR COMPLETE DISRUPTION BEAD MILLS ARE DIFFERENT TOO 1. TEMP CANNOT GO ABOVE 4-5C DURING THE PROCESS 2. DIFFERENT SIZES AND MATERIALS FOR BEADS 3. LATENCY TIME IS CRITICAL 4. SIZE OF MILL AND LATENCY DETERMINE THE FLOW RATE

11 WHAT WE ARE LOOKING FOR AT THE END OF THE PROCESS

12 DRYING IS THE MOST IMPORTANT STEP HIGH TEMPERATURE DESTROYS HIGH VALUE MATERIALS FLAKE VS. POWDER

13 WHY DRYING MATTERS? FLAKE VS POWDER? FLAKE ALLOWS THE SUPER CRITICAL FLUID TO BETTER PERMEATE. POWDER CLUMPS IN THE REACTOR VESSEL AND LIMITS THE ABILITY TO PERMEATE. (YOU CAN REDUCE CAPACITY AND LIMIT FLOW TO INCREASE VIABILITY BUT THEN THE CAPEX AND OPEX COSTS INCREASE DRAMATICALLY ON THE REACTOR OR TOLLING SERVICES)

14 Integration Matters

15 THANK YOU FOR YOUR TIME! SPECIAL THANKS TO: SYNTHETIC GENOMICS FOR BIOMASS PRODUCED AND DRIED PRODUCTS MTAF EXTRACTIONS FOR HOMOGENIZER, GLEN MILLS FOR BEAD MILL G3 ENTERPRISES FOR REFRACTIVE WINDOW DRYING