At a high-tech facility manufacturing products for the dietary supplement, nutraceutical, and pharmaceutical industries, our Supercritical Fluid Extraction (SFE) technology was implemented to recover high-value Omega-3 fatty acids (DHA/EPA) from microalgae.The primary objective of the project was to obtain high-value biochemical compounds that meet the stringent quality and purity requirements of the food and pharmaceutical industries, while eliminating or minimizing the use of conventional organic solvents and maintaining process conditions that preserve heat-sensitive components.
Technical Process and Supercritical CO₂ Extraction Engineering
Polyunsaturated fatty acids such as Omega-3 are particularly sensitive to high temperatures, oxygen, and oxidative conditions. Supercritical CO₂ extraction offers significant advantages in recovering these sensitive compounds, as it can operate at relatively low temperatures and allows CO₂ to be readily separated from the product at the end of the process.
Carbon dioxide (CO₂) is used as the primary extraction fluid. When brought above its critical temperature and pressure, CO₂ combines the high density and solvent power characteristic of liquids with the high diffusivity and low viscosity characteristic of gases. This enables it to penetrate the algal matrix effectively and extract the target oil components.
At the end of the process, reducing the pressure allows CO₂ to separate readily from the extract, enabling the production of high-quality products with a low risk of residual organic solvents.
The system operates at pressures of up to 350 bar, with precise control over pressure, temperature, and CO₂ flow rate. By optimizing process parameters, the objective is to selectively extract target oil components from microalgae and obtain fractions rich in Omega-3.
Extraction at relatively low temperatures limits the exposure of Omega-3 fatty acids to heat. This helps reduce the risk of thermal degradation and oxidation while preserving the functional properties of the final product.
Key Deliverables and Added Value
Low Solvent Residues and High Product Quality:
The easy separation of CO₂ from the product after extraction significantly reduces the risk of residues associated with conventional organic solvents. Following appropriate post-processing and quality control procedures, the resulting Omega-3-rich oil can be used in dietary supplements, nutraceuticals, and related pharmaceutical applications.
Environmentally Friendly and Sustainable Process:
By reducing the use of organic solvents and the associated waste generation, the process supports more sustainable production. An integrated closed-loop CO₂ recovery system enables the CO₂ to be recovered and reused at the end of the process, helping reduce raw material consumption and environmental impact.
High Selectivity and Process Efficiency:
Precise control of pressure, temperature, and CO₂ flow rate allows the solvent power and selectivity of the extraction process to be optimized according to process requirements. This helps increase the recovery of target oil components while limiting the co-extraction of unwanted compounds.
