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| report [2013/06/21 19:25] – [4.4. Eco – efficiency] team1 | report [2013/06/22 19:49] (current) – team1 | ||
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| We expect that the Solar Dryer will fulfill the clients needs which are drying algae with the use of solar power. We expect it to dry the algae to less then 10 % humidity in 24 hours. We also expect our algae-dryer to be one of the most energy efficient in the market. | We expect that the Solar Dryer will fulfill the clients needs which are drying algae with the use of solar power. We expect it to dry the algae to less then 10 % humidity in 24 hours. We also expect our algae-dryer to be one of the most energy efficient in the market. | ||
| - | ==== 1.6. Work plan ==== | + | ==== 1.6. Product planning |
| Regarding the work plan we divided our task into three modules. The general milestones together with a start and end date for every task are located in the Gantt chart shown in Figure 2. Furthermore, | Regarding the work plan we divided our task into three modules. The general milestones together with a start and end date for every task are located in the Gantt chart shown in Figure 2. Furthermore, | ||
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| === 4.4.5. Maximum use of renewable sources === | === 4.4.5. Maximum use of renewable sources === | ||
| - | As already mentioned the idea of our product implies usage of solar power. 15 W solar panel is installed to run the prototype. Considering the replicated product, we believe all the electrical appliances would require more power, hence the bigger solar panel should be used. Then the question arises, is it more sustainable to run the device on the solar power or simply connecting it to the casual electricity grid. In order to answer this question many aspects must be considered. Firstly, we would have to consider production of the solar panel itself. According to the survey run by Sherrell R. Greene, Vice President for Consulting Services at EnergX posted at his blog [37], we may notice that CO2 emission from solar electricity generation is not significantly lower than natural gas, coal or oil resources. The results of the survey are presented in the graph below (Figure | + | As already mentioned the idea of our product implies usage of solar power. 15 W solar panel is installed to run the prototype. Considering the replicated product, we believe all the electrical appliances would require more power, hence the bigger solar panel should be used. Then the question arises, is it more sustainable to run the device on the solar power or simply connecting it to the casual electricity grid. In order to answer this question many aspects must be considered. Firstly, we would have to consider production of the solar panel itself. According to the survey run by Sherrell R. Greene, Vice President for Consulting Services at EnergX posted at his blog [37], we may notice that CO2 emission from solar electricity generation is not significantly lower than natural gas, coal or oil resources. The results of the survey are presented in the graph below (Figure |
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| - | Figure | + | Figure |
| These results would force us to check what kind of electricity generation the potential customer uses. Taking into account the fact that the potential customer would be universities in Europe running tests on algae oil production, we may assume that it is possible that they would use renewable sources of energy to create electricity. If not, it is also possible that energy consumed by the device would not significantly affect the power consumption of a certain university lab. It is also wise to mention that any kind of electricity generation it is, the equipment installed would require so little energy that it would not be significant for university grid usage. What is more, 15 W solar panel would not support the devices fully. Thus, more powerful solar panel would be needed. As our projects aim was to use solar power, we decided to minimize the number or fans to one in order to reduce power consumption. | These results would force us to check what kind of electricity generation the potential customer uses. Taking into account the fact that the potential customer would be universities in Europe running tests on algae oil production, we may assume that it is possible that they would use renewable sources of energy to create electricity. If not, it is also possible that energy consumed by the device would not significantly affect the power consumption of a certain university lab. It is also wise to mention that any kind of electricity generation it is, the equipment installed would require so little energy that it would not be significant for university grid usage. What is more, 15 W solar panel would not support the devices fully. Thus, more powerful solar panel would be needed. As our projects aim was to use solar power, we decided to minimize the number or fans to one in order to reduce power consumption. | ||
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| ==== 4.5. Life – cycle analysis ==== | ==== 4.5. Life – cycle analysis ==== | ||
| - | Life – cycle analysis or assessment, presented in Figure | + | Life – cycle analysis or assessment, presented in Figure |
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| - | Figure | + | Figure |
| Such assesment consists of several steps. The first one is the analysis of the raw material extraction. Then, focus may be put on processing the materials. The next stage of life–cycle consideration is manufacturing of needed parts. Afterwards, we reach the assembling process. The two steps left are the product usage and its life end. Taking into account the device we are creating, our position is at the assembly process. We are buying already existing parts and elements to build solar algae dryer. Materials needed to produce our distiller are as following: Poly(methyl methacrylate) also known as plexiglass, mirror serving as reflector, devices: ultrasound water level controller, water proof temperature level sensor, fans, solar panel, 12 V lead acid battery, micro controller and step motor controlling blinds. The remainings are parts needed to assemble the whole structure like: glue, pipes, valves, etc. | Such assesment consists of several steps. The first one is the analysis of the raw material extraction. Then, focus may be put on processing the materials. The next stage of life–cycle consideration is manufacturing of needed parts. Afterwards, we reach the assembling process. The two steps left are the product usage and its life end. Taking into account the device we are creating, our position is at the assembly process. We are buying already existing parts and elements to build solar algae dryer. Materials needed to produce our distiller are as following: Poly(methyl methacrylate) also known as plexiglass, mirror serving as reflector, devices: ultrasound water level controller, water proof temperature level sensor, fans, solar panel, 12 V lead acid battery, micro controller and step motor controlling blinds. The remainings are parts needed to assemble the whole structure like: glue, pipes, valves, etc. | ||
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| As far as life – cycle analysis is concerned we would mainly focus on the stages starting from assembly process. Yet, we will show the previous steps for plexiglass. | As far as life – cycle analysis is concerned we would mainly focus on the stages starting from assembly process. Yet, we will show the previous steps for plexiglass. | ||
| - | PMMA, also known as plexiglass can be seen in the Figure | + | PMMA, also known as plexiglass can be seen in the Figure |
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| - | Figure | + | Figure |
| Raw material for plexiglass prodution is polymer of methyl methacrylate that can be developed in laboratory and does not need the presence of any endangered natural resources. Moreover, part of its production right now is created from recycled plexiglass. The processing of the material requires its heating up, but no harmful air emissions were noted during this process. Afterwards, the material can be either molded or extruded, which again does not cause pollution. Coming to assembly process, PMMA must be first cut. This proceeding is usually done by usage of laser. Unfortunately, | Raw material for plexiglass prodution is polymer of methyl methacrylate that can be developed in laboratory and does not need the presence of any endangered natural resources. Moreover, part of its production right now is created from recycled plexiglass. The processing of the material requires its heating up, but no harmful air emissions were noted during this process. Afterwards, the material can be either molded or extruded, which again does not cause pollution. Coming to assembly process, PMMA must be first cut. This proceeding is usually done by usage of laser. Unfortunately, | ||
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| ==== 52. Ethics and deontology in Engeneering === | ==== 52. Ethics and deontology in Engeneering === | ||
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| In the first week of EPS we received a list with all the possible topics. We sat together as a team and talked about all the different topics on the list, and about each other’s fields of study. We were all interested in solar energy, so we chose the solar refrigerator. The contrast between warmth, the solar power, and coldness, the refrigerator, | In the first week of EPS we received a list with all the possible topics. We sat together as a team and talked about all the different topics on the list, and about each other’s fields of study. We were all interested in solar energy, so we chose the solar refrigerator. The contrast between warmth, the solar power, and coldness, the refrigerator, | ||
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| During the first meeting with the supervisors, | During the first meeting with the supervisors, | ||
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| Then we started to discuss specifications. For example, the budget, the capacity it had to have, the conditions it should work in, functions it should have and other requirements. | Then we started to discuss specifications. For example, the budget, the capacity it had to have, the conditions it should work in, functions it should have and other requirements. | ||
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| When that was clear, we started to look for different kinds of drying methods. After brainstorming we came up with several kinds of methods and decided there were three worth looking into on a more profound level. They were the hydro cyclone, distilling and filtering. We analysed them thoroughly and discussed our findings with the supervisors in a meeting. There, we decided that distilling was the best method for the dryer, because the problem with filtering – the saturation of the membrane – was too hard to solve, and powering a hydro cyclone with a solar panel was also a big issue. | When that was clear, we started to look for different kinds of drying methods. After brainstorming we came up with several kinds of methods and decided there were three worth looking into on a more profound level. They were the hydro cyclone, distilling and filtering. We analysed them thoroughly and discussed our findings with the supervisors in a meeting. There, we decided that distilling was the best method for the dryer, because the problem with filtering – the saturation of the membrane – was too hard to solve, and powering a hydro cyclone with a solar panel was also a big issue. | ||
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| When the ordered materials arrived, we started assembling the Plexiglas, the sensors, the blinds, the stepper motor that controls the blinds and all the other parts. | When the ordered materials arrived, we started assembling the Plexiglas, the sensors, the blinds, the stepper motor that controls the blinds and all the other parts. | ||
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| In the end the dryer was finished and the electronic parts were programmed. | In the end the dryer was finished and the electronic parts were programmed. | ||
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| - | Figure | + | Figure |
| - | Figure | + | Figure 24 and 25 shows the dimension and shape of the tank. |
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| The tank is the ”main” part of our project. It is where we have our solution and it is where the process takes place. We developed our project starting with the tank. After the tank we thought about what parts we have to use for controlling the process, these are the level sensor and temperature sensor. These are connected to the control box (micro-controller), | The tank is the ”main” part of our project. It is where we have our solution and it is where the process takes place. We developed our project starting with the tank. After the tank we thought about what parts we have to use for controlling the process, these are the level sensor and temperature sensor. These are connected to the control box (micro-controller), | ||
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| The solar algae dryer is based on the plexiglass tank and it consists of different kinds of mechanical and electronic parts and modules. In this chapter we describe these different modules and how they work independently and as a part of the system. | The solar algae dryer is based on the plexiglass tank and it consists of different kinds of mechanical and electronic parts and modules. In this chapter we describe these different modules and how they work independently and as a part of the system. | ||
| - | Our system consists of three different modules. The drying process block, the controlling block and the power supply block. Figure | + | Our system consists of three different modules. The drying process block, the controlling block and the power supply block. Figure |
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| - | Figure | + | Figure |
| The drying process takes place in the plexiglass tank. This is where we put our solution, and the evaporation process takes place. We designed and assembled the tank by our own and it is made out of plexi because of the need to be transparent, | The drying process takes place in the plexiglass tank. This is where we put our solution, and the evaporation process takes place. We designed and assembled the tank by our own and it is made out of plexi because of the need to be transparent, | ||
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| During the process the evaporated water will rise to the roof of the tank and slide down to the water tank. This way we will recover all the water used in the process. The concentrated algae solution will remain in the major tank and be transported to an algae container when the process is ready. | During the process the evaporated water will rise to the roof of the tank and slide down to the water tank. This way we will recover all the water used in the process. The concentrated algae solution will remain in the major tank and be transported to an algae container when the process is ready. | ||
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| The second block is the controlling block, this module helps us control the process. Here we have the micro-controller as our major part of the controlling system. For the micro controller we are using an Arduino Uno ATmega328. All parts in the controlling block are connected to the micro-controller, | The second block is the controlling block, this module helps us control the process. Here we have the micro-controller as our major part of the controlling system. For the micro controller we are using an Arduino Uno ATmega328. All parts in the controlling block are connected to the micro-controller, | ||
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| First we have a waterproof temperature sensor model DS18B20 for measuring the temperature of the water-algae solution. This is needed due to the fact that the water temperature can’t rise over 50°C because it would harm the algae. The temperature controller is connected to our micro-controller and gives a signal if the temperature rises over 50°C. | First we have a waterproof temperature sensor model DS18B20 for measuring the temperature of the water-algae solution. This is needed due to the fact that the water temperature can’t rise over 50°C because it would harm the algae. The temperature controller is connected to our micro-controller and gives a signal if the temperature rises over 50°C. | ||
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| === 6.4.2. Electrical chart === | === 6.4.2. Electrical chart === | ||
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| - | The scheme presented | + | Some of the mentioned electrical appliances require additional parts to be added. For instance, stepper motor can only be operated with the use of Darlington Array. There is also transistor connected to the fan and resistors joined with LEDs and temperature sensor. |
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| - | Figure | + | Figure |
| - | On the other hand, we managed to run the stepper motor and we conducted a test to check whether our idea of moving the blinds with it is suitable or not. The figure ... below shows the possible stepper motor localization for blinds operation. | + | On the other hand, we managed to run the stepper motor and we conducted a test to check whether our idea of moving the blinds with it is suitable or not. The Figure 30. below shows the possible stepper motor localization for blinds operation. |
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| - | The following | + | The following |
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| - | What we learned was that Y129 Astrosyn motor devoted to operate on 12 V is still moving on 5V only. Yet, this much was not powerful enough to move the blinds when motor was bonded with them. In order to connect stepper motor to 12 V, however, we needed additional power regulating circuit shown in the figure .... Operating on 12 V stepper motor was strong enough to turn the blinds. As already mentioned our project misses power supply and due to that we decided to omit stepper motor in our system as 5 V supply will not contribute to expected result. | + | What we learned was that Y129 Astrosyn motor devoted to operate on 12 V is still moving on 5V only. Yet, this much was not powerful enough to move the blinds when motor was bonded with them. In order to connect stepper motor to 12 V, however, we needed additional power regulating circuit shown in the Figure 32. Operating on 12 V stepper motor was strong enough to turn the blinds. As already mentioned our project misses power supply and due to that we decided to omit stepper motor in our system as 5 V supply will not contribute to expected result. |
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| - | Figure Power regulating system | + | Figure |
| === 6.4.3. Programming part === | === 6.4.3. Programming part === | ||
| - | The following figures (28,29) show exemplary parts of program written for Arduino Uno board taking care of running all the electrical appliances. The programs for separate devices were based on sample programs for these special kinds of equipment available online [43]. | + | The following figures (33,34) show exemplary parts of program written for Arduino Uno board taking care of running all the electrical appliances. The programs for separate devices were based on sample programs for these special kinds of equipment available online [43]. |
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| - | Figure | + | Figure |
| The sample program for level sensor used in our project is presented above. The program assigns some Arduino pins to device inputs or outputs. The presented code enables giving out signals by level sensor and calculates the distance from the pulse time value. Afterwards it returns the calculated value. | The sample program for level sensor used in our project is presented above. The program assigns some Arduino pins to device inputs or outputs. The presented code enables giving out signals by level sensor and calculates the distance from the pulse time value. Afterwards it returns the calculated value. | ||
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| This code requires special Arduino Library called OneWire. The mechanism of operation is based on MSB and LSB, so most significant and least significant byte. Temperature sensor is able to read current value of the temperature and returns it to the mother program. | This code requires special Arduino Library called OneWire. The mechanism of operation is based on MSB and LSB, so most significant and least significant byte. Temperature sensor is able to read current value of the temperature and returns it to the mother program. | ||
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| + | Figure 35. Stepper motor code | ||
| Similar approach is seen in CloseBlind function but in a reverse direction. In this case blind variable is set to 1, to show, that the blinds are closed. | Similar approach is seen in CloseBlind function but in a reverse direction. In this case blind variable is set to 1, to show, that the blinds are closed. | ||
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| There is part of code in the loop shown below, to exhibit how the device will behave whether what the position of blinds is and what value the temperature achieves. | There is part of code in the loop shown below, to exhibit how the device will behave whether what the position of blinds is and what value the temperature achieves. | ||
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| + | Figure 36. Stepper motor dependance on temperature loop | ||
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| + | Since, we did not manage to run blinds with the usage of stepper motor, below in Figure 37., main running code is displayed. | ||
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| + | Figure 37. Main code | ||
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| + | Program always controls level, whenever the level exceeds 140 mm, the stopOperation function is called causing the green diode to turn on. If it is below 140 mm, the yellow diode is on. Any time the program checks the level value, it also checks temperature. Whenever it exceeds 50˚C, the red diode turns on. | ||
| ==== 6.5. Tests ==== | ==== 6.5. Tests ==== | ||
| Tests have to be implemented to ensure that the product can fulfill our clients’ needs. For our drying process we put a 5 l solution of algae and water in the tank, and at the end we want a 0,5 l concentrated solution. During this process we have to make sure that the temperature of the water doesn’t raise over 50°C. To ensure that it works correctly and the temperature doesn’t go over 50°C, it has to be tested and water put into the tank with a temperature over 50° degrees. In this case the thermometer should give a signal to the micro-controller that it should adjust the blinds and cool down the process. | Tests have to be implemented to ensure that the product can fulfill our clients’ needs. For our drying process we put a 5 l solution of algae and water in the tank, and at the end we want a 0,5 l concentrated solution. During this process we have to make sure that the temperature of the water doesn’t raise over 50°C. To ensure that it works correctly and the temperature doesn’t go over 50°C, it has to be tested and water put into the tank with a temperature over 50° degrees. In this case the thermometer should give a signal to the micro-controller that it should adjust the blinds and cool down the process. | ||
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| The other test that has to be performed is by the end of the drying process. When the algae are dry enough they should contain less than 10 % of water. This means that at the end of the process we would have a 0,5 l solution left of the 5,0 l. When the process is ready (the solution is 0,5 l) the ultra sound level controller should give a signal to the micro-controller to stop the process, and close the blinds. These are the two main tests that our product needs to fulfill. | The other test that has to be performed is by the end of the drying process. When the algae are dry enough they should contain less than 10 % of water. This means that at the end of the process we would have a 0,5 l solution left of the 5,0 l. When the process is ready (the solution is 0,5 l) the ultra sound level controller should give a signal to the micro-controller to stop the process, and close the blinds. These are the two main tests that our product needs to fulfill. | ||
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| === 6.5.1.3. Performing the experiment === | === 6.5.1.3. Performing the experiment === | ||
| - | We started with marking scale on the plastic tank. We decided to put the mark each 5mm. Then, we mounted as shown in Figure | + | We started with marking scale on the plastic tank. We decided to put the mark each 5mm. Then, we mounted as shown in Figure |
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| The distance between bottom and ultrasonic sensor, so the height of the containers wall was 12 cm. The Arduino environment was also installed and operating code has been compiled. | The distance between bottom and ultrasonic sensor, so the height of the containers wall was 12 cm. The Arduino environment was also installed and operating code has been compiled. | ||
| The measurement started with pouring water till obtaining 5mm on the scale and reading the value read by sensor. Microcontroller program returns the distance read from data given by sensor. | The measurement started with pouring water till obtaining 5mm on the scale and reading the value read by sensor. Microcontroller program returns the distance read from data given by sensor. | ||
| - | Afterwards, pouring the water was repeated every 5mm several times till reaching 30 mm. The pouring is presented in Figure | + | Afterwards, pouring the water was repeated every 5mm several times till reaching 30 mm. The pouring is presented in Figure |
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| - | We tried to conduct the test also with the floating body inside the tank, to check if the sensor reads the distance more accurately shown in Figure | + | We tried to conduct the test also with the floating body inside the tank, to check if the sensor reads the distance more accurately shown in Figure |
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| === 6.5.1.4. Results === | === 6.5.1.4. Results === | ||
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| After finding out that the algae were negatively charged we could make a charging test in the lab to see if we could attract them to one side of the tank. | After finding out that the algae were negatively charged we could make a charging test in the lab to see if we could attract them to one side of the tank. | ||
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| At first we tried with two titanium electrodes but it created a current and oxidized, so we had to find another method. Then we built a capacitor, which is two charged plates, one positive and one negative, and between the plates and the algae there is a capacitor, in this case a plastic box. We charged the plates with a 12 V input and measured the density of the algae every half an hour. For measuring the density we used a spectrometer that is an instrument used to measure properties of light over a specific portion of the electromagnetic spectrum [43]. | At first we tried with two titanium electrodes but it created a current and oxidized, so we had to find another method. Then we built a capacitor, which is two charged plates, one positive and one negative, and between the plates and the algae there is a capacitor, in this case a plastic box. We charged the plates with a 12 V input and measured the density of the algae every half an hour. For measuring the density we used a spectrometer that is an instrument used to measure properties of light over a specific portion of the electromagnetic spectrum [43]. | ||
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| === 6.5.2.1. Results === | === 6.5.2.1. Results === | ||
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| ==== 6.6. Overheating of algae solution ==== | ==== 6.6. Overheating of algae solution ==== | ||
| - | As already mentioned, one of our major concerns is making sure the algal solution will not exceed 50 ˚C. And why is that? Algal biomass obtained from the process of drying is rich in many various beneficial components, such as among many others: lipids, pigments (carotenoids) or omega 3 acids. Their possible degradation is the reason for not to overheat the microalgae solution. According to Arief Widjaja in “Lipid production from microalgae as a promising candidate for biodiesel production” drying algae in high temperatures has deteriorating effect on lipid content [45]. The research made suggests that the decrease in lipid content may already be seen while drying in 60 ˚C. Even larger drop in lipid content may be noticed while drying in temperatures exceeding 60 ˚C. The gathered data is shown in Figure | + | As already mentioned, one of our major concerns is making sure the algal solution will not exceed 50 ˚C. And why is that? Algal biomass obtained from the process of drying is rich in many various beneficial components, such as among many others: lipids, pigments (carotenoids) or omega 3 acids. Their possible degradation is the reason for not to overheat the microalgae solution. According to Arief Widjaja in “Lipid production from microalgae as a promising candidate for biodiesel production” drying algae in high temperatures has deteriorating effect on lipid content [45]. The research made suggests that the decrease in lipid content may already be seen while drying in 60 ˚C. Even larger drop in lipid content may be noticed while drying in temperatures exceeding 60 ˚C. The gathered data is shown in Figure |
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| As far as omega 3 fatty acids are concerned, they are easily oxidized when subjected to light, air or high temperatures. All the plants containing this kind of acids (for instance flax seeds) are treated at the temperatures not exceeding 40 ˚C in order not to destroy the natural structure or beneficial properties [44]. | As far as omega 3 fatty acids are concerned, they are easily oxidized when subjected to light, air or high temperatures. All the plants containing this kind of acids (for instance flax seeds) are treated at the temperatures not exceeding 40 ˚C in order not to destroy the natural structure or beneficial properties [44]. | ||
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| === 6.7.2. Porto climate === | === 6.7.2. Porto climate === | ||
| - | In order to check the possible operation efficiency of our device, we gathered | + | In order to check the possible operation efficiency of the device, we gathered data concerning predicted weather and atmospheric conditions for the on-going year and the next. The following figures (45 and 46) present average heat index (in degrees Celsius) and solar radiation |
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| The presented diagrams and graph make it possible to expect the best distiller performance from April till October. High solar radiation, followed by extensive heat index and significantly higher average temperatures are noted in the mentioned months. Those factors speed up evaporation process. What is more, relative humidity is also at its lowest ratings, which does not contribute to slowing down the whole process. | The presented diagrams and graph make it possible to expect the best distiller performance from April till October. High solar radiation, followed by extensive heat index and significantly higher average temperatures are noted in the mentioned months. Those factors speed up evaporation process. What is more, relative humidity is also at its lowest ratings, which does not contribute to slowing down the whole process. | ||