Detailed Project Report on MICROALGAE (POWDER) (PRODUCTION RATE – 200 TPA)

Microalgae are prokaryotic or eukaryotic photosynthetic microorganisms that produce carbohydrates, proteins and lipids as a result of photosynthesis. They can grow rapidly and live in harsh conditions due to their unicellular or simple multicellular structure. Examples of prokaryotic microorganisms are Cyanobacteria (Cyanophyceae) and eukaryotic microalgae are for example green algae (Chlorophyta) and diatoms (Bacillariophyta). Microalgae are present in all existing earth ecosystems, not just aquatic but also terrestrial, representing a big variety of species living in a wide range of environmental conditions. It is estimated that more than 50,000 species exist, but only a limited number of around 30,000, have been studied and analyzed. Sunlight, water, nutrients and arable land are the major requirements for growing algae. Micro algae have the ability to fix CO2 using solar energy with efficiency 10 times greater than that of the terrestrial plants with numerous additional technological advantages. Algae are more efficient at utilizing sunlight than terrestrial plants, consume harmful pollutants, have minimal resource requirements and do not compete with food or agriculture for precious resources.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




MICROALGAE (POWDER) (PRODUCTION RATE – 200 TPA)
[EIRI/EDPR/4747] J.C.: 2967US$

Microalgae are prokaryotic or eukaryotic photosynthetic microorganisms that
produce carbohydrates, proteins and lipids as a result of photosynthesis. They
can grow rapidly and live in harsh conditions due to their unicellular or simple
multicellular structure. Examples of prokaryotic microorganisms are
Cyanobacteria (Cyanophyceae) and eukaryotic microalgae are for example green
algae (Chlorophyta) and diatoms (Bacillariophyta). Microalgae are present in all
existing earth ecosystems, not just aquatic but also terrestrial, representing a big
variety of species living in a wide range of environmental conditions. It is
estimated that more than 50,000 species exist, but only a limited number of
around 30,000, have been studied and analyzed. Sunlight, water, nutrients and
arable land are the major requirements for growing algae. Micro algae have the
ability to fix CO2 using solar energy with efficiency 10 times greater than that of
the terrestrial plants with numerous additional technological advantages. Algae
are more efficient at utilizing sunlight than terrestrial plants, consume harmful
pollutants, have minimal resource requirements and do not compete with food or
agriculture for precious resources.

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CONTENTS

INTRODUCTION

ANOTHER SIMPLER ORGANIZAT IONAL SYSTEM DIVIDES MICROALGAE INTO
FOUR CATEGORIES:

PHYLOGENETICAL AND BIOCHEMICAL DIVERSITY OF MICROALGAE

RECENT DEVELOPMENT

FUNCTIONS OF MICROALGAE

POTENTIAL ALTERNATIVE TO HEALTH SUPPLEMENTATION FOR HUMANS

USES/APPLICATIONS

CHARACTERISTICS/IMPORTANCE

PROPERTIES

LIPID CONTENT FROM MICROALGAE

LIPIDS CONTENT OF MICROALGAE IS SHOWN IN TABLE.

MARKET OVERVIEW

GROWTH DRIVERS

OPPORTUNITIES

INCREASE IN THE FUND FOR MICROALGAE PRODUCTION

RISE IN THE STRATEGIC INITIATIVES BY MARKET PLAYERS

RESTRAINTS/CHALLENGES

COMPLICATIONS ASSOCIATED WITH MICROALGAE PRODUCTION

PHOTOBIOREACTORS

BIOREACTOR CONCEPTS, TYPES & MODELING

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PHOTOBIOREACTOR DESIGN

PHOTO-BIOREACTOR DESIGN FOR MICROALGAE

GAS-LIQUID FLOW IN PBRS

LIGHT TRANSFER AND NUTRIENTS UTILIZATION STRATEGIES FOR PBRS

PROSPECTIVE

BENEFITS OF PHOTOBIOREACTORS

INCREASED PRODUCTIVITY

HIGHER QUALITY BIOMASS

REDUCED CONTAMINATION

REDUCED LAND AND WATER USE

VERSATILITY

SUSTAINABLE PRODUCTION

SCALABILITY

CONSISTENT QUALITY

REDUCED LABOUR COSTS

REDUCED CAPITAL COSTS

APPLICATIONS/CHALLENGES OF PHOTOBIOREACTORS

BIOTECHNOLOGY

BIOFUELS

WASTEWATER TREATMENT

FOOD PRODUCTION

CARBON CAPTURE

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CHALLENGES AND FUTURE DIRECTIONS

COST

SCALE-UP

EFFICIENCY

PRODUCTIVITY

PHOTOBIOREACTORS: ADVANTAGES & DISADVANTAGES

OPEN ALGAE CULTURE SYSTEMS

RACEWAY PONDS

FIBERGLASS TANKS

ARTIFICIAL PONDS

TUBULAR PHOTOBIOREACTORS

INTERNALLY LIT PHOTOBIOREACTORS

SPECIFICATION

RAW MATERIALS

CARBON DIOXIDE

SODIUM CHLORIDE (SALT)

MICRONUTRIENTS (TYPICAL)

RAW MATERIAL SUPPLIERS

BASIS - TECHNICAL

FORMULATION

MANUFACTURING PROCESS STEPS

OPERATION PARAMETERS

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OPERATING CONDITIONS

CONTROL AND MONITORING EQUIPMENT FOR THE PHOTOBIOREACTOR

PROCESS (BLOCK) FLOW

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

STP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE GENERATION & MANAGEMENT/GREEN BELT

PLANT & MACHINERY (BROADLY)

SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS

PHOTOBIREACTOR

CHEMICAL PROCESS EQUIPMENTS

FREEZE DRYING UNIT

MATERIAL HANDLING EQUIPMENTS

LABORATORY EQUIPMENTS

MIXER

STORAGE TANKS

INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

D.G. SETS

EOT CRANES

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POWER TRANSFORMERS

ETP PLANTS

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSOR

PLATEFORM WEIGHING MACHINE

ELECTRICAL MEASURING INSTRUMENTS

ENGINEERING CONSULTANTS

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

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TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

SAFETY & OCCUPATIONAL MEASURE

(STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

PROJECT IMPLEMENTATION MANAGEMENT

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

PROPOSED IMPLEMENTATION SCHEDULE

ENGINEERING PACKAGE/DOCUMENTS

BASIS – PROJECT ECONOMICS

PROJECT FINANCIALS

CONCLUSIONS

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 200 MT/Annum

Land & Building (9200 sq.mt.) US$ 13.12 Lac

Plant & Machinery US$ 4.79 Cr

Working Capital for 1 Month US$ 2.17 Lac

Total Capital Investment US$ 4.96 Cr

Rate of Return 33%

Break Even Point 50%