The manufacturing process used to extract sodium alginates from brown seaweed fall into two categories: 1) calcium alginate method where the brown seaweed is first treated with calcium chloride to form a calcium alginate intermediate before washing with hydrochloric acid, and, 2) alginic acid method where there is no calcium alginate intermediate and the brown seaweed is treated only with the hydrochloric acid to extract sodium alginate. The conventional process involves large amounts of reagents and solvents, as well as time-consuming steps. Pre-treatments mainly aim at either breaking the cell wall to help extract the alginate, or removing other compounds and contaminants from the algae. Drying is of the first kind, also helping to prevent bacterial growth; algae which is dried is also usually powdered to expose more surface area. Common treatments to remove contaminants include treatments with
ethanol and
formaldehyde, the latter of which is very common; ethanol solutions help remove compounds bonded to the alginate, and formaldehyde solutions help prevent enzymatic or microbial reactions. The algae is then treated with an acidic solution to help disrupt cell walls, which converts the alginate salts into insoluble alginic acid; a subsequently applied alkaline solution (pH 9-10), usually
sodium carbonate, converts it back into water-soluble sodium alginate, which is then precipitated. It is also possible to extract the alginate directly with an alkaline treatment, but this is less common. Alginic acid is usually precipitated, through different techniques, with either an alcohol (usually ethanol),
calcium chloride, or
hydrochloric acid. After the alginin is precipitated into a fine paste, it is dried, ground to the desired grain size, and finally purified through a variety of techniques. Commercial alginate for biomedical and pharmaceutical use is extracted and purified through more rigorous techniques, but these are trade secrets.
Derivatives Various alginate-based materials can be produced, including porous scaffold material, alginate hydrogel, nonwoven fabric, and alginate membranes. Techniques used to produce these include ion cross-linking, microfluidic spinning, freeze drying, wet spinning, and immersive centrifugal jet spinning. Calcium salts added to a sodium alginate solution to induce ionic cross-linking, which produces the hydrogel. Freeze-drying the hydrogel to eliminate water produces the porous scaffold material. Wet spinning consists of extruding an alginate solution from a spinneret into a calcium salt solution to induce ionic cross-linking (forming the gel), and then
drawing the fibers out of the bath with draft rollers. Microfluidic spinning, a simpler and more eco-friendly implementation of the process, involves introducing calcium salt flows flowing alongside and touching a central "core" flow of alginate. These flows form a "sheath". The fiber then emerges from the core flow. This technique can be used to produce shaped and grooved fibers. Alginate fiber, which is used in fabric, is usually produced through either microfluidic spinning, wet spinning, or
electrospinning to obtain thinner fibers. Those fibers are used to produce alginate nonwoven fabric by
carding and needle punching. The resulting felts are used in wound dressings, facial masks, and tissue scaffolds due to its hygroscopic and water retention ability. ==Uses==