oslo bosma_16-11-2012

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AlgaePARC: Exploring scale-up challenges in microalgae mass production, Rouke Bosma, AlgaePARC, Wagening University

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oslo bosma_16-11-2012

  1. 1. Algae Production And Research Center AlgaePARCExploring scale-up challenges in microalgae mass production Rouke Bosma Maria Barbosa Dorinde Kleinegris René Wijffels ALGAE WORKSHOP, 16-11-2012
  2. 2. Algae as a promising innovation High productivity ● Oil content: 20-60% ● 20,000-50,000 liter/ha/year oil ● Palm oil: 6,000 liter/ha/year No ‘competing claims’ ● Grow on seawater ● Use of residual nutrients (CO2, N, P) ● Co-products have value (e.g. lipids, proteins)
  3. 3. From a craft to an industrial process…• Current worldwide microalgal manufacturing infrastructure ~5000 tons of dry algal biomass• High value products such as carotenoids and ω-3 fatty acids used for food and feed ingredients.• Total market volume is €1.25 billion (average market price of €250/kg dry biomass)• World production of palm oil is nearly 40 million tons, with a market value of ~0.50 €/kg Wijffels R.H., Barbosa M.J. (2010) An outlook on microalgal biofuels. Science 329: 796-799
  4. 4. How can we decrease production costs? Horizontal tubes • At 1 ha scale today: 10 €/kg • At 100 ha scale today: 4 €/kg • What could be possible: 0.50 €/kg Still too expensive for biodiesel alone • Increasing photosynthetic efficiency Raceway ponds • Integrate processes (free nutrients) • Decreasing mixing • Developing cheaper and less energy consuming harvesting technologies • Choosing locations with higher irradiations Flat panelsNorsker et al. (2011) Microalgal production- a close look at economics,Biotechnology Advances 29: 24-27Bosma, R. et al. (2010). Towards increased microalgal productivity inphotobioreactors, International Sugar Journal 112: 74-85.
  5. 5. Biorefinery of microalgae: A need ! 400 kg lipids ● 100 kg as feedstock chemical industry (2 €/kg lipids) Biofuels Chemicals ● 300 kg as transport fuel (0.50 €/kg 150 € 200 € Oxygen 256 € lipids) N removal Food proteins 500 kg proteins 500 € 140 € Sugars ● 100 kg for food (5 €/kg protein) Feed proteins 100 € 300 € ● 400 kg for feed (0.75 €/kg protein) 100 kg polysaccharides ● 1 €/kg polysaccharides 70 kg of N removed Production costs: 0.50 €/kg biomass ● 2 €/kg nitrogen Value: 1.65 €/kg biomass 1,600 kg oxygen produced ● 0.16 €/kg oxygen Norsker et al. (2011) Biotechnology Advances 29: 24-27 Wijffels, Barbosa and Eppink. (2010). Biofuels, Bioproducts & Biorefining,4: 287-295.
  6. 6. Wageningen UR algae research Interaction between basic research and pilots Multidisciplinary approach Research topics Systems ● Efficient use of sunlight Design Biology ● Reduction of energy input Application Systems development Design Metabolic Modelling ● Use of residual nutrients ● Lipid accumulation Product Chains processing Fermentation Strain technology Development ● Strain improvement ● Scale-up Bioprocess Biorefinery Engineering ● Biorefinery Analytics Scale-up ● Design scenarios/LCA’s
  7. 7. Develop this process is a sustainable and economical way within the next 10 - 15 yearsWijffels & Barbosa (2010). Science 329(5993): 796-799 To make the production economically feasible, it is essential to develop cultivation systems in which algae convert the light with a high photosynthetic efficiencyBosma, R. et al. (2010). International Sugar Journal 112: 74-85.
  8. 8. MANY SCATTERED ACTIVITIES• Different locations• Different designs• Different measurements• How to compare systems?• How to learn from this process ?
  9. 9. Example, photosynthetic efficiencyTheoretical maximum photosynthetic efficiency 9%10% of light lost by transmission x 0.905% of biomass lost during the night x 0.9510% of energy used for maintenance x 0.90Maximum photosynthetic efficiency in photobioreactors: 7%• At lab scale a photosynthetic efficiency of 6% seems to be within reach• What about - Pilot scale 10 – 100 m2 - Extended time > 1 yr• How to design/operate even larger (1-100 ha plants)? Bosma, R. et al. (2010). International Sugar Journal 112: 74-85.
  10. 10. AlgaePARCAlgae Production And Research CenterBridge the gap between fundamental research and scalable applications in industry
  11. 11. AlgaePARC objectives International center of applied research Bridge between basic research and applications Development of competitive technology-economics, sustainability Acquire information for full scale plants Algal biomass for food, feed, chemicals and fuels
  12. 12. Official opening of AlgaePARC 17 June 2011
  13. 13. Production systems at AlgaePARC Raceway pond Horizontal tubular reactorAdvantage Advantage- Cheap to build and to operate - High controllability- Established technology - Closed system - High biomass concentrationsDisadvantages- Prone to contamination Disadvantages- Water evaporation - Photo inhibition- Controllability - Oxygen built up- Low biomass concentrations
  14. 14. Principal of light dilution– go vertical!Imax : 1800 µmol photons m-2 s-1 Imax : 400 µmol photons m-2 s-1 Direct sunlight Dilution effect Cuaresma, M et al. (2011). Bioresource Technology 102: 5129-5137.
  15. 15. Production systems at AlgaePARC Flat panels Vertical stacked tubular reactorAdvantage Advantage- Low material costs - High controllability- No need for external cooling - Closed system- High biomass concentrations - Light dilutionDisadvantages Disadvantages- Prone to damage - Oxygen built up- Energy costs of air sparging - Costs/energy to built
  16. 16. AlgaePARCMain FeaturesUniqueness - 4 different systems that can run in parallel under the same outdoor conditionsFundamental aspects for successful operation and scale up of photobioreactors to commercial plantsControl Units: accurate online measurements and control of a wide range of metabolic and environmental parameters
  17. 17. R&D activities AlgaePARC Comparison of large-scale photobioreactors, process analysis and optimisation Deliverables: performance of different systems; optimised process control; Improved system Screening, testing & optimising algal species on growth & product productivity using different nutrient feedstocks Deliverables: Species; Cheap nutrient feedstock; High product productivity Dynamic Process Control strategies Deliverables: Dynamic process control strategies Life Cycle Assessment Deliverables: Sustainability analysis Test business cases Deliverables: Proof of concept2011 2012 2013 2014 2015 2016
  18. 18. Comparison of large-scale photobioreactors, process analysis and optimisationCompare large systems on - Areal and volumetric biomass and lipid productivity - Energy balance - Nutrient requirements - Carbon dioxide consumption and oxygen production - Operational costs (including manpower) - Cleanability - Culture stability (assessment of infections and algae population) - Robustness of the system Information for improvement of operation strategies
  19. 19. Funding AlgaePARC 8M€Facility financed by ● Ministry EL&I ● Province Gelderland ● Wageningen URResearch program financed byResearch program financed by
  20. 20. Future plansTechnology platform ● Production : AlgaePARC ->partnerships, new locations, different climates and conditions Biofuels Chemicals 200 € Oxygen 150 € ● AlgaePARC Biorefinery: In development 256 € Food proteins N removal 500 € 140 € Sugars Feed proteins 100 € 300 €PPP Projects – Pre-competitive ResearchProduct platform• Production strategies for compounds ofspecific interest to individual companies• Demo Bilateral projects
  21. 21. AlgaePARCAlgae Production And Research Centerwww.algaeparc.com
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