11 gabriel acien - 16.30 paneeli unlocking potential of algae
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Yksi European Bioeconomy Scene -konferenssin puheista. One of the speeches in European Bioeconomy conference. Konferenssin ohjelma/Conference programme: https://www.bioeconomy.fi/wp-content/uploads//2019/06/EUBioScene_programme.pdf
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11 gabriel acien - 16.30 paneeli unlocking potential of algae
- 1. This project has received funding from the European Union’s Horizon 2020 Research and Innovation program under the Grant Agreement No. 727874 F. Gabriel Acien Dpt. Chemical Engineering, University of Almeria, SPAIN Unlocking potential of algae Helsinki, July 9th, 2019
- 2. Microalgae potential markets Potential applications •Photosynthetic efficiencies up to 10% •Biomass production up to 100 tn/ha·year •Non arable land required •Brackish and seawater useful •Suitable for nutrients recovery from wastewaters •etc…
- 3. Diagnostic Despite the large potential of products derived from algae, implementation is still limited mainly due to unfavorable economics. At present, microalgae are being applied in a limited volume (< 10 000 tones dry weight/year) in various niche markets (including food supplements) and macroalgae mass production is facing several challenges including the lack of space to further expand. To reach broader economic viability, costs of algal biomass production need to be reduced and the scale of production needs to be increased significantly. Even when the price of biomass production is reduced, algal biomass needs to be refined into multiple products in order to increase its total value and achieve economic feasibility.
- 4. Market study CHALLENGES: MARKETABLE END PRODUCTS LARGE PRODUCTION CAPACITY LOW PRODUCTION COST
- 5. WATER Feed additives, aquafeed biostimulants, biopesticides Nitrogen Phosphorus Challenges • Large scale production: Develop robust and scalable microalgae production and processing processes, in continuous mode all the year around. Economic analysis limiting technologies. • Sustainable production: To integrate the treatment of wastes to increase the sustainability of the entire process. Life Cycle Analysis determines what is possible or not. • Markets/commercialization: Only products now requested by the markets and that legally accepted are considered. Business plan is the driver of the project.
- 6. Block diagram of the project
- 7. Description of the project Sustainable Algae Biorefinery for Agriculture aNd Aquaculture (SABANA) Call H2020-BG-2016-2017 Blue Growth - Demonstrating an ocean of opportunities Organism European Commission Topic/Type/Budget BG-01-2016, Innovation action, 10,5 M€ Duration (months) 48 (2017-2020)
- 8. After 24 months of activities…
- 9. Recent achievements Market analysis • Market of agriculture products is confirmed both for biostimulants and biopesticides, in addition to biofertilizers • Microalgae based products are scarce but highly appreciated, major problem being the low amount of biomass available and high cost Biomass production cost<10 €/kg Minimum capacity>20 tn/year
- 10. Market analysis Recent achievements • Market of aquaculture is confirmed both as feed additives and aquafeed • Major bottlenecks are the low amount of biomass available and high cost Material €/t Protein content, % Protein cost, €/kg Fish meal 60 1,400.00 € 60% 2.33 € Fish meal by-products 1,400.00 € 60% 2.33 € Fich meal 67 1,750.00 € 67% 2.61 € Shrimp-meal 1,100.00 € 51% 2.16 € Father meal 350.00 € 75% 0.47 € Sunflower meal 30 190.00 € 30% 0.63 € Sunflower meal 36 240.00 € 37% 0.65 € Soy meal 475.00 € 50% 0.95 € Poultry meal 650.00 € 65% 1.00 € Blood meal 950.00 € 95% 1.00 € Guar meal 50 460.00 € 43% 1.07 € Guar meal 60 560.00 € 52% 1.08 € Soy conc. Prot. 860.00 € 61% 1.41 € Corn Gluten 860.00 € 56% 1.54 € Weath Gluten 1,500.00 € 79% 1.90 € Biomass production cost<2 €/kg Minimum capacity>100 tn/year
- 11. Microalgae production cost - 0.5 1.0 1.5 2.0 2.5 3.0 RW+fertilizers RW-sewage RW-centrate RW-manure Productioncost,€/kg Raceway 0.0 0.5 1.0 1.5 2.0 2.5 3.0 TL+fertilizers TL-sewage TL-centrate TL-manure Productioncost,€kg Thin-layer • Production cost below 2 €/kg is possible only when using nutrients from wastewaters • Production cost is lower when using Thin-Layer reactors due to the higher productivity on these systems Recent achievements
- 13. Business plan Recent achievements • Market of agriculture products is much more interesting that aquaculture, contribution of wastewater treatment being minor • Thin-Layer are much more interesting by its higher productivity - 20,000 40,000 60,000 80,000 Biostimulant+biofertilizer Biopesticides+biofertilizer Feed additive+aquafeed Incomes, k€/year Raceway Premium High Regular - 20,000 40,000 60,000 80,000 Biostimulant+biofertilizer Biopesticides+biofertilizer Feed additive+aquafeed Incomes, k€/year Thin-layer Premium High Regular 0 50 100 150 200 RW+sewage RW+centrate RW+manure TL+sewage TL+centrate TL+manure Incomes, €/year
- 14. DEMO R&D DEMO FACILITY (1 ha) Recent achievements DEMO PRODUCTION UNIVERSITY OF ALMERIA
- 15. DEMO R&D (0.5 ha) Recent achievements Raceway reactors Thin-layer cascade Tubular reactors Large scale reactors Auxiliary facilities • Air, flue gas • Culture medium • Harvesting • Spry-dryer • Biomass processing
- 16. DEMO PRODUCTION (1.5 ha) Recent achievements
- 17. Fully automatized production facility Control and data acquisition systems already completed, but continuously improved… Recent achievements
- 18. Optimal harvesting strategy Recent achievements • Pre-concentration step is mandatory • A final dewatering step is required to achieve final concentration of 100 g/L • Robust large scale processing is not easy… Cost aprox(€/kg) Energy (kWh/m3) 0.30 1.00 0.05 0.13 0.07 0.15 0.03 0.11 Culture 1 g/L Sludge 10 g/L Paste 100 g/L Option 1 Centrifugation Option 2 Sedimentation Centrifugation Option 3 Dissolved air flotation Centrifugation Option 4 Non-pressure membrane Centrifugation
- 19. WET BIOMASS CELL DISRUPTION ENZYMATIC HYDROLISIS LOW VALUE BIOFERTILIZER LIQUID EXTRACTION CELL DISRUPTION HIGH VALUE BIOSTIMULANTS HIGH VALUE BIOPESTICIDES WET BIOMASS CELL DISRUPTION STABILIZATION PROCESS LOW VALUE AQUAFEED LIQUID EXTRACTION CELL DISRUPTION BIOACTIVE CONCENTRATES AQUACULTURE PRODUCTS Processing strategies AGRICULTURE PRODUCTS Recent achievements
- 20. Microalgae strains: selection Agriculture uses… Collection Strains Biostimulants Biopesticides Aquaculture Selected SZE 21 freshwater green microalgae 24 freshwater cyanobacteria 10 5 5 5 5 0 3 2 BEA 10 seawater green microalgae 10 seawater cyanobacteria 5 3 2 3 8 2 3 2 Biostimulant effect on watercress seed germination Control Antagonistic effect against phytopatogens Control
- 21. 0 10 20 30 40 50 60 70 SABANA-1 SABANA-2 SABANA-3 SABANA-4 SABANA-5 SABANA-6 SABANA-7 SABANA-8 SABANA-9 SABANA-10 SABANA-11 SABANA-12 Xanthomonas campestris Clavibacter michiganensis Rhizoctonia solani Phytophthora capsici Fusarium oxysporum Pythium ultimun Biostimulant effect Biopesticide effect Microalgae strains: in vitro trials Agriculture uses… Strains
- 22. Microalgae strains: field trials Agriculture uses… Regular High Premium Biostimulants €/L 5 10 20 Biopesticides €/L 10 15 25 Major improvements: • No large volumes requested, medium size facilities • Enhanced biomass containing target compounds • Demonstrate the bioactivity in real field conditions • Safety and sustainability of produced biomass
- 23. COM CT TISO NAN SCE p Initial body weight (g) 11.4±0.26 11.4±0.20 11.4±0.43 11.4±0.12 11.4±0.39 0.9984 Final body weight (g) 29.8±2.77a 47.9±3.62b 47.7±4.95b 45.2±0.28b 45.7±4.87b 0.0006 Daily gain (DG, mg day-1) 0.22±0.03a 0.43±0.04b 0.43±0.05b 0.40±0.01b 0.40±0.05b 0.0003 Specific growth rate, SGR (%) 1.12±0.09a 1.69±0.08b 1.68±0.08b 1.63±0.01b 1.63±0.08b <0.0001 Feed efficiency ratio (FER) 0.52±0.05a 0.81±0.06b 0.78±0.04b 0.77±0.01b 0.80±0.05b 0.0001 Feed conversion ratio (FCR) 1.92±0.18b 1.24±0.08a 1.28±0.06a 1.30±0.02a 1.26±0.08a <0.0001 Protein efficiency ratio (PER) 0.95±0.09a 1.47±0.10b 1.42±0.07b 1.40±0.02b 1.45±0.09b 0.0001 Survival (%) 96.8±2.75 88.9±5.50 90.5±0.01 92.1±5.50 95.2±0.01 0.1129 Values are mean ± SD of triplicate determination. Values in the same row with different lowercase letter indicate significant difference (p < 0.05) 1.- Senegalese sole juveniles 2.- Seabream juveniles 3.- Seabream larvae Microvilli length (μm) Microvilli diameter (μm) Number of microvilli μm2 Total absorption surface per microvilli (μm2) CT 1.38 ± 0.17 a 0.10 ± 0.01 61.93 ± 12.12 a 28.80 ± 3.25 a TISO 1.57 ± 0.16 b 0.10 ± 0.01 76.60 ± 10.17 b 39.14 ± 3.44 b NAN 1.99 ± 0.25 c 0.10 ± 0.01 70.57 ± 9.80 ab 45.93 ± 3.68 c SCE 1.35 ± 0.25 a 0.10 ± 0.01 66.78 ± 15.66 a 26.30 ± 10.41 a p <0.0001 0.0616 <0.0001 <0.0001 Aquaculture uses… In vivo feeding trials
- 24. Ultraestructural study Transmision electron microscopy (TEM) images CTCOM ISO NAN SCE None of the dietary treatments cause damage in the brush border integrity of intestinal mucosa ISO and NAN-fed fish showed significant increase in microvilii length and microvilli absorption surface compared to fish fed microalgae-free diets Aquaculture uses… In vivo feeding trials Microalgae biomass must not be considered to replace nutrients for aquafeed, but as feed additive to enhance the “health” of fishes and “safety” of production
- 25. Effect of fish flesh quality Aquaculture uses… In vivo feeding trials •Help to preserve Water Holding Capacity (WHC) in fillet, even during storage. •Texture Profile Analysis (TPA): Increase in firmess of fish fillet. •Lower level of lipid peroxidation in fillet, even during storage for eight days
- 26. Acknowledgements… EU Commission… Partners… Our team and collaborators…
- 27. SABANA Sustainable Algae Biorefinery for Agriculture aNd Aquaculture www.eu-sabana.eu | info@sabana.eu @sabana.eu sabana.eu sabana.eu
Editor's Notes
- Thanks for inviting me to talk about SABANA Project, focused into the sustainable production of end products for agriculture and aquaculture from microalgae
- The market for microalgae based products can be divided in four major categories, with largely different safety/regulatory issues: human, feeding, agriculture and bioenergy. When comparing the market size and value of the products in the different markets it is observed as no large differences exist between agriculture or aquaculture applications versus human applications. However, the safety requirements are largely different in this markets. Especially when considering the application of microalgae in agriculture as biostimulant and biopesticides the figures are including better for agriculture uses. Based on this figures we decide to focus in these fields.
- The market for microalgae based products can be divided in four major categories, with largely different safety/regulatory issues: human, feeding, agriculture and bioenergy. When comparing the market size and value of the products in the different markets it is observed as no large differences exist between agriculture or aquaculture applications versus human applications. However, the safety requirements are largely different in this markets. Especially when considering the application of microalgae in agriculture as biostimulant and biopesticides the figures are including better for agriculture uses. Based on this figures we decide to focus in these fields.
- The market for microalgae based products can be divided in four major categories, with largely different safety/regulatory issues: human, feeding, agriculture and bioenergy. When comparing the market size and value of the products in the different markets it is observed as no large differences exist between agriculture or aquaculture applications versus human applications. However, the safety requirements are largely different in this markets. Especially when considering the application of microalgae in agriculture as biostimulant and biopesticides the figures are including better for agriculture uses. Based on this figures we decide to focus in these fields.
- On this scenario the SABANA project is focused to develop a demonstration facility on which residuals as urban and animal wastewaters are recycled to produce microalgae biomass, suitable to be transformed into valuable products to enhance the sustainability of agriculture and aquaculture sectors. The major challenges are related with the large scale production of sustainable microalgae biomass and the production of marketable products according to actual regulation for agriculture and aquaculture
- The block diagram of the project is divided in two major tasks, the first one being related with the improvement of technology for large scale biomass production, and the second one being related with the development of methods for integral utilization of the biomass. On the first step only non usable water will be used, also wastes being used as nutrients source. On the second step, only technologies allowing a complete utilization of the biomass to obtain valuable products will be used. The project will start with a 1 ha facility, that in two years will be increased up to 5 ha, and finally a 20 ha facility will be designed and technically analyzed.
- This project is supported by the EU Commission on the Blue growth program, and it is an innovation action coordinated by the University of Almeria in collaboration with industrial partners as Aqualia, Biorizon, GEA Westfalia and Veronessi, in addition to academic partners as university of Milano, Szechenyo university, AlgaTech, KIT and University of Gran Canaria, in addition to CIB. This project was submitted to the call about blue growth. This program identify that microalgae have large potential for commercial development but still the production capacity and portfolio of products is too low. Major bottlenecks for this development are related with excessive production cost and low production capacity, in addition to the complete utilization of the biomass according to the biorefinery concept This project was submitted to the call about blue growth. This program identify that microalgae have large potential for commercial development but still the production capacity and portfolio of products is too low. Major bottlenecks for this development are related with excessive production cost and low production capacity, in addition to the complete utilization of the biomass according to the biorefinery concept
- The projects start eighteen months ago, and we can show some achievements…
- We complete a deliverable about market analysis for agriculture related applications confirming that this market is requiring microalgae based products as plant growth promoters and biopesticides, a large market existing for these types of products. On this market the biomass production cost must be below 10 €/kg and the required minimum microalgae production capacity is around 20 tn/year.
- In the case of aquaculture the microalgae biomass is also requested to replace fish meal and oil, all the previous studied confirming the adequacy of this raw material to be incorporated in aquafeed. This market requires biomass production cost below 2 €/kg and minimum microalgae biomass production capacities larger than 100 tn/year.
- This project is leaded by the University of Almeria, but high reputation industrial and academic partners from five different countries also participate. Major actors into the project are the companies Aqualia, Biorizon and GEA, which are responsible of the implementation of the demo facility.
- This project was submitted to the call about blue growth. This program identify that microalgae have large potential for commercial development but still the production capacity and portfolio of products is too low. Major bottlenecks for this development are related with excessive production cost and low production capacity, in addition to the complete utilization of the biomass according to the biorefinery concept
- Concerning business plan the results confirm that market of agriculture related products is much more interesting than market of aquaculture products, both of them being suitable from the economic point of view, whereas to focus in wastewater treatment is much less attractive from the economic point of view. In any case to use thin-layer reactors is advantageous versus raceways due to the higher productivity achieved on these reactors.
- On this first year we complete the installation of the demo facility located in Almeria, just at the university of Almeria, in the research center of IFAPA
- The demo facility has been concluded, finally it being equipped with 100 m2 pilot raceway reactors and thin-layer cascades to perform studies, and tubular reactors to produce inocula and clean biomass. Also it includes semi-industrial size raceway reactors and required auxiliary equipment as air supply and flue gases supply, culture medium preparation, harvesting and processing of the biomass.
- The demo facility has been concluded, finally it being equipped with 100 m2 pilot raceway reactors and thin-layer cascades to perform studies, and tubular reactors to produce inocula and clean biomass. Also it includes semi-industrial size raceway reactors and required auxiliary equipment as air supply and flue gases supply, culture medium preparation, harvesting and processing of the biomass.
- Concerning harvesting, it was concluded that at large scale a pre-concentration step is mandatory to reduce the biomass production cost, different strategies being evaluated on this sense. The target is to achieve a final sludge containing more than 100 g/L of biomass. The combination of flocculation with sedimentation or dissolved air flotation and final dewatering by centrifugation allows to reduce the harvesting cost and energy consumption, but it is slightly lower when using sedimentation in addition this operation being easier and more robust.
- Concerning processing we conclude that whatever the end product a cell disruption step is requested, otherwise the performance of next conversion processes being low. According to the final purpose different processing schemes has been defined all them being evaluated at laboratory and pilot scale.
- Concerning agriculture uses a large number of strains provided by the Szenischy university of Hungary and the Spanish Bank of algae has been evaluated, including freshwater and marine strains in addition to green algae and cyanobacteria. These strains were evaluated for both the stimulation of germination and growth in plants, and as biopesticide versus fungi and bacteria.
- For agriculture applications a wide number of strains demonstrated to be effective as plant growth promoter, enhancing the germination index up to 40% over the control. In the case of biopesticides some strains shows relevant activity, upper than 30%, as antifungal or antibacterial but not for all the pathogens evaluated, then the final selection of the strains being a function of market relevance of different diseases.
- At demo scale we are producing around 200 L per day of biostimulant, then we are able to perform field trials. Essays performed using ornamental plants as petunia, allows to demonstrate a positive response when providing Spirulina based products, but the performance of plants is including higher when using Scenedesmus based products. Most promising strains have been identified during the project that are being now evaluated.
- Concerning fish trials first we confirm that the microalgae biomass was not toxic by bioassays using fish cell lines, then experiments incorporating the microalgae biomass as replacement of 10% fish meal and fish oil were performed. Results shows that no variations on the growth or final weight of the fishes were measured, the major difference being observed in the microvilli of the digestive system of the fishes. Thus a relevant improvement of microvilli length, number and total absorption surface was determined.
- The improvement of microvilli is strain specific it being larger when using Isochrysis and Nannochloropsis, than using Scenedesmus. The increase of microvilli length and absorption surface in fishes feed with aquafeed containing marine microalgae, is related with an increase of the healthy of the fishes and a major tolerance to adverse growth conditions.
- The improvement of microvilli is strain specific it being larger when using Isochrysis and Nannochloropsis, than using Scenedesmus. The increase of microvilli length and absorption surface in fishes feed with aquafeed containing marine microalgae, is related with an increase of the healthy of the fishes and a major tolerance to adverse growth conditions.
- So finally, I want to thanks the support of the EU Commission, the hard work of the partners involved into the project, and specially to our team and collaborators for their involvement on the successful development of the project.
- If you are interested into the project you can find more information into the web page and social networks of the project. Thanks.